Abstract: A system configured to detect defects in a first oxygen sensor is disclosed. The system is configured to detect defects in a first oxygen sensor. The system includes an X-ray imaging device configured to capture a production X-ray image of the first oxygen sensor and an electronic processor configured to use a trained oxygen sensor defect detection model to identify a defect of the first oxygen sensor by producing a pseudo X-ray image by simulating a projection of a fan beam through CT data of a second oxygen sensor.

Abstract: A gas sensor includes a gas sensing element positioned at least partially within a body and being exposed at a first end to measure a gas in contact with the first end. A sleeve is fixed to the body and extends from the body in a direction opposite the first end of the gas sensing element. The sleeve includes it remote end portion having an engagement feature. A connector housing is overmolded onto the end portion of the sleeve to lock onto the sleeve via the engagement feature. The connector housing includes a plug connector portion partially enclosing a plurality of electrical terminals electrically connected to the gas sensing element.

Abstract: A gas sensor includes a sensor housing and a sensing element located within the sensor housing. The sensing element has a distal end and defines an axis. The gas sensor also includes a sensor protection device coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection device includes a first member coupled to the housing, the first member having a generally rectangular cross-sectional shape in a plane perpendicular to the axis. The first member includes a gas inlet and a gas outlet. The sensor protection device also includes a second member coupled to the housing.

Abstract: A gas sensor includes a sensor housing and a sensing element located within the sensor housing. The sensing element defines an axis. The sensing element has a distal end extending from the sensor housing. The gas sensor further includes a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection element includes a tube having a conical portion, and a gas inlet located on the tube, the gas inlet spaced from the axis. The gas inlet is shaped to direct gas into the tube to induce a vortex gas flow within the conical portion of the tube.

Abstract: A gas sensor includes a sensor housing, and a sensing element located within the sensor housing, the sensing element defining an axis and having a distal end extending from the sensor housing. The gas sensor further includes a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection element includes a tube, the distal end of the sensing element located within the tube, the tube including a window located along a side of the tube adjacent the distal end of the sensing element. The sensor protection element further includes a fabric layer positioned adjacent the window, the fabric layer spaced from the sensing element and extending generally parallel to the axis.

Abstract: A gas sensor includes a sensor housing and a sensing element located within the sensor housing. The sensing element has a distal end and defines an axis. The gas sensor also includes a sensor protection device coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection device includes a first member coupled to the housing, the first member having a generally rectangular cross-sectional shape in a plane perpendicular to the axis. The first member includes a gas inlet and a gas outlet. The sensor protection device also includes a second member coupled to the housing.

Abstract: A gas sensor includes a gas sensing element positioned at least partially within a body and exposed at a first end to measure a gas in contact with the first end. The gas sensing element defines an axial direction. A flange extends from the body in a direction transverse to the axial direction. The flange has a first side facing toward the first end and a second side facing toward a remote end of the gas sensor. An O-ring is configured to sealingly position the gas sensor within a bore. An insertion portion of the gas sensor is defined by a wall and configured to hold the O-ring. The wall of the insertion portion is spaced a distance from the body at an axial position of the O-ring to provide a gap therebetween.

Abstract: A gas sensor includes a sensor housing and a sensing element located within the sensor housing. The sensing element defines an axis. The sensing element has a distal end extending from the sensor housing. The gas sensor further includes a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection element includes a tube having a conical portion, and a gas inlet located on the tube, the gas inlet spaced from the axis. The gas inlet is shaped to direct gas into the tube to induce a vortex gas flow within the conical portion of the tube.

Abstract: A gas sensor includes a sensor housing, and a sensing element located within the sensor housing, the sensing element defining an axis and having a distal end extending from the sensor housing. The gas sensor further includes a sensor protection element coupled to the sensor housing and at least partially surrounding the distal end of the sensing element. The sensor protection element includes a tube, the distal end of the sensing element located within the tube, the tube including a window located along a side of the tube adjacent the distal end of the sensing element. The sensor protection element further includes a fabric layer positioned adjacent the window, the fabric layer spaced from the sensing element and extending generally parallel to the axis.

Abstract: A gas sensor includes a gas sensing element positioned at least partially within a body and being exposed at a first end to measure a gas in contact with the first end. A sleeve is fixed to the body and extends from the body in a direction opposite the first end of the gas sensing element. The sleeve includes it remote end portion having an engagement feature. A connector housing is overmolded onto the end portion of the sleeve to lock onto the sleeve via the engagement feature. The connector housing includes a plug connector portion partially enclosing a plurality of electrical terminals electrically connected to the gas sensing element.

Abstract: A gas sensor, whose purpose is to determine a physical property of a measuring gas, e.g., to determine the concentration of a gas component or the temperature of an exhaust gas. The gas sensor includes a sensor element arranged in a metal housing which is sealed by at least one sealing element arranged in a metal receptacle. The metal receptacle is affixed to the housing. The sealing element surrounds the sensor element in a centered position along its longitudinal extension L or on its half facing the measuring gas.

Abstract: An insulation bushing assembly for use with an exhaust gas sensor. The insulation bushing assembly includes an insulation bushing having a passageway defining a surface, and a contact plate assembly having a contact plate coupled with the insulation bushing. A resilient member extends from the contact plate and into the passageway. The resilient member is engageable with the surface of the passageway such that the member is deflected by the surface from an undeflected position with respect to the contact plate to a deflected position with respect to the contact plate to retain the contact plate assembly in engagement with the bushing.

Abstract: A gas sensor, whose purpose is to determine a physical property of a measuring gas, e.g., to determine the concentration of a gas component or the temperature of an exhaust gas. The gas sensor includes a sensor element arranged in a metal housing which is sealed by at least one sealing element arranged in a metal receptacle. The metal receptacle is affixed to the housing. The sealing element surrounds the sensor element in a centered position along its longitudinal extension L or on its half facing the measuring gas.

Abstract: An insulation bushing assembly for use with an exhaust gas sensor. The insulation bushing assembly includes an insulation bushing having a passageway defining a surface, and a contact plate assembly having a contact plate coupled with the insulation bushing. A resilient member extends from the contact plate and into the passageway. The resilient member is engageable with the surface of the passageway such that the member is deflected by the surface from an undeflected position with respect to the contact plate to a deflected position with respect to the contact plate to retain the contact plate assembly in engagement with the bushing.

Abstract: A replacement kit for replacing an electrical device coupled to a vehicle via a plurality of vehicle lead wires. The replacement kit includes a replacement electrical device, a plurality of lead wires extending from the replacement electrical device, and a housing assembly for protecting a spliced connection formed with the lead wires to create an electrical connection between the electrical device and the vehicle. The housing assembly includes a base having a plurality of individually isolated bores extending therethrough. Each bore is capable of housing a spliced connection of a respective vehicle lead wire and a respective replacement electrical device lead wire, and each bore has therein a plurality of seal rings to form a substantially water-tight seal around the associated portion of the spliced connection. The housing assembly also includes a cap secured to the base. Preferably, the electrical device and the replacement electrical device are oxygen sensors.

Abstract: A replacement kit for replacing an electrical device coupled to a vehicle via a plurality of vehicle lead wires. The replacement kit includes a replacement electrical device, a plurality of lead wires extending from the replacement electrical device, and a housing assembly for protecting a spliced connection formed with the lead wires to create an electrical connection between the electrical device and the vehicle. The housing assembly includes a base having a plurality of individually isolated bores extending therethrough. Each bore is capable of housing a spliced connection of a respective vehicle lead wire and a respective replacement electrical device lead wire, and each bore has therein a plurality of seal rings to form a substantially water-tight seal around the associated portion of the spliced connection. The housing assembly also includes a cap secured to the base. Preferably, the electrical device and the replacement electrical device are oxygen sensors.