Abstract: The present disclosure relates to sensors including pressure sensors, humidity sensors, flow sensors, etc. In some illustrative cases, a sensor assembly may include a pressure port connected to a sensor unit, an electrical connector connected to the sensor unit and an outer housing encompassing at least portions of the pressure port, sensor unit and electrical connector. In one example, the sensor unit may include a carrier carrying a sense element, where the carrier may extend into a recess of the pressure port and may be secured to the pressure port at an internal side thereof through the use of an adhesive layer.

Abstract: The present disclosure relates to sensors including pressure sensors, humidity sensors, flow sensors, etc. In some cases, a cable harness assembly for connection with a sensor assembly may include a cable cover having a first end and a second end, a cable extending through an opening in the first end of the of the cable cover, and a crimp ring configured to engage the cable at a position within the cable cover, such that the attached crimp ring may not fit through the opening. The second end of the cable cover may be configured to connect to a housing of an electrical connector. Further, the cable may have wires that may be configured to electrically connect to electrical terminals of the electrical connector. In some instances, the electrical connector may be electrically connected to a sensor.

Abstract: The present disclosure relates to sensors including pressure sensors, humidity sensors, flow sensors, etc. In some cases, a cover for use with a sensor assembly may include an electrically insulating body having perimeter features extending a majority of the way around perimeters of upper and lower printed circuit boards that the cover may vertically separate. In one example, the body of the cover may include support features that extend from a lower side of the cover and those support features may contact the lower printed circuit board in at least two locations. The support features of the cover may be separated by a gap and a sensor connected to the lower printed circuit board may be situated within the gap.

Abstract: A gas sensor apparatus and method of forming the same generally includes a gas sensor element comprising a heater and a plurality of electrodes. A ceramic substrate can be provided for supporting the electrodes on one side of the ceramic substrate and the heater on the opposite side of the ceramic substrate. The gas sensor element is preferably embedded in the ceramic substrate. The ceramic substrate also possesses a substantially circular shape in order to prevent a breakage of the gas sensor element, avoid thermal loss, and permit the gas sensor apparatus to withstand mechanical shock and high vibrations while occupying a minimal package space.

Abstract: A system for measuring in-cylinder parameters utilizing an image charge measured in an engine cylinder by an in-cylinder pressure sensor due to chemi and or thermal ionization in Engine. The in-cylinder pressure sensor includes a sensing element, which is a metal sensor probe with a selective coating (e.g., metal, oxides of metal, native oxides, semiconductor, oxides of semiconductors, ceramics, glass, dielectric, etc., in the form of a coating on the metallic probe, tube, etc) in order to function in harsh, corrosive and/or elevated temperature environments. The output of the sensor can be connected to a signal-conditioning unit, which includes a low noise differential charge amplifier with an auto offset correction circuit to measure fast varying signals. The signal out from the conditioning unit can be acquired utilizing a high-speed microcontroller-based data acquisition system with suitable software to analyze and estimate parameters such as, for example, in cylinder pressure and knocking.

Abstract: A method for joining dissimilar materials of sensor button for measuring torque is illustrated. The dissimilar materials can be welded together by laser welding. The parts can be cleaned and held together firmly by a fixture and welded with established machine parameters. The method of micro-crack free weld joint can give a robust joint for the life time of the automotive which mandate for the function of torque sensor to facilitate the positive strain transfer from the parent material.

Abstract: Exemplary embodiments of the present invention relate methods and devices for measuring flow rate of particulate matter within an exhaust gas stream. In one particular exemplary embodiment, a sensor for detecting and monitoring particulate matter within an exhaust flow path of an engine is provided. The sensor includes a housing having an attachment for mounting the sensor. The sensor also includes a sensing rod supported by an insulating base. The sensing rod is attached to the housing and includes a probe adapted to be placed within the exhaust flow path. The probe includes a section having an increased surface area per unit length as compared to at least one other section of the probe. The sensing rod is configured to detect particulate matter flowing through the exhaust component and generates a signal based thereupon. The sensor further includes an electrical connector in communication with the sensing rod.

Abstract: A single cell oxygen sensor apparatus and method are disclosed. An yttrium-based stabilized layer having electrical terminals connected to the yttrium-based stabilized layer can be provided on a substrate, wherein the yttrium-based stabilized layer is excitable by a constant current applied to the electrical terminals. A plurality of electrodes are located on a side of the yttrium-based stabilized layer and a plurality of heater elements located on said substrate opposite said yttrium-based stabilized layer. The heater elements can maintain the yttrium-based stabilized layer at a particular temperature. A cavity is formed and located between the yttrium-based stabilized layer and the heater elements. The partial pressure of oxygen can be measured by comparing the partial pressure of oxygen within the cavity with respect to the partial pressure of oxygen in the atmosphere external to the single cell oxygen sensor apparatus.

Abstract: A gas sensor apparatus and method of forming the same generally includes a gas sensor element comprising a heater and a plurality of electrodes. A ceramic substrate can be provided for supporting the electrodes on one side of the ceramic substrate and the heater on the opposite side of the ceramic substrate. The gas sensor element is preferably embedded in the ceramic substrate. The ceramic substrate also possesses a substantially circular shape in order to prevent a breakage of the gas sensor element, avoid thermal loss, and permit the gas sensor apparatus to withstand mechanical shock and high vibrations while occupying a minimal package space.

Abstract: An apparatus and method for packaging and operating a gas sensor for use in high temperature gas environments. A gas sensor can be configured, which includes a sensor element and a housing in which the sensor element is located. A parallel gas path can be configured form said housing, wherein said parallel gas path is based on the natural differential pressure with respect to the velocity of said gas. The parallel gas path is preferably vertical to provide a sufficient friction to soot particles compared to the gas, such that when a partial quantity of said gas reaches said sensor element, said soot particles are avoided by said sensor element.

Abstract: Exemplary embodiments of the present invention relate methods and devices for measuring flow rate of particulate matter within an exhaust gas stream. In one particular exemplary embodiment, a sensor for detecting and monitoring particulate matter within an exhaust flow path of an engine is provided. The sensor includes a housing having an attachment for mounting the sensor. The sensor also includes a sensing rod supported by an insulating base. The sensing rod is attached to the housing and includes a probe adapted to be placed within the exhaust flow path. The probe includes a section having an increased surface area per unit length as compared to at least one other section of the probe. The sensing rod is configured to detect particulate matter flowing through the exhaust component and generates a signal based thereupon. The sensor further includes an electrical connector in communication with the sensing rod.

Abstract: A system for measuring in-cylinder parameters utilizing an image charge measured in an engine cylinder by an in-cylinder pressure sensor due to chemi and or thermal ionization in Engine. The in-cylinder pressure sensor includes a sensing element, which is a metal sensor probe with a selective coating (e.g., metal, oxides of metal, native oxides, semiconductor, oxides of semiconductors, ceramics, glass, dielectric, etc., in the form of a coating on the metallic probe, tube, etc) in order to function in harsh, corrosive and/or elevated temperature environments. The output of the sensor can be connected to a signal-conditioning unit, which includes a low noise differential charge amplifier with an auto offset correction circuit to measure fast varying signals. The signal out from the conditioning unit can be acquired utilizing a high-speed microcontroller-based data acquisition system with suitable software to analyze and estimate parameters such as, for example, in cylinder pressure and knocking.

Abstract: A method for joining dissimilar materials of sensor button for measuring torque is illustrated. The dissimilar materials can be welded together by laser welding. The parts can be cleaned and held together firmly by a fixture and welded with established machine parameters. The method of micro-crack free weld joint can give a robust joint for the life time of the automotive which mandate for the function of torque sensor to facilitate the positive strain transfer from the parent material.

Abstract: An apparatus and method for packaging and operating a gas sensor for use in high temperature gas environments. A gas sensor can be configured, which includes a sensor element and a housing in which the sensor element is located. A parallel gas path can be configured form said housing, wherein said parallel gas path is based on the natural differential pressure with respect to the velocity of said gas. The parallel gas path is preferably vertical to provide a sufficient friction to soot particles compared to the gas, such that when a partial quantity of said gas reaches said sensor element, said soot particles are avoided by said sensor element.

Abstract: A gas sensor apparatus and method of forming the same generally includes a gas sensor element comprising a heater and a plurality of electrodes. A ceramic substrate can be provided for supporting the electrodes on one side of the ceramic substrate and the heater on the opposite side of the ceramic substrate. The gas sensor element is preferably embedded in the ceramic substrate. The ceramic substrate also possesses a substantially circular shape in order to prevent a breakage of the gas sensor element, avoid thermal loss, and permit the gas sensor apparatus to withstand mechanical shock and high vibrations while occupying a minimal package space.

Abstract: A single cell oxygen sensor apparatus and method are disclosed. An yttrium-based stabilized layer having electrical terminals connected to the yttrium-based stabilized layer can be provided on a substrate, wherein the yttrium-based stabilized layer is excitable by a constant current applied to the electrical terminals. A plurality of electrodes are located on a side of the yttrium-based stabilized layer and a plurality of heater elements located on said substrate opposite said yttrium-based stabilized layer. The heater elements can maintain the yttrium-based stabilized layer at a particular temperature. A cavity is formed and located between the yttrium-based stabilized layer and the heater elements. The partial pressure of oxygen can be measured by comparing the partial pressure of oxygen within the cavity with respect to the partial pressure of oxygen in the atmosphere external to the single cell oxygen sensor apparatus.

Abstract: An apparatus is provided to reduce strain transferred from a body, such as a shaft, to a strain sensor, such as a SAW device. The strain sensor is capable of measuring a maximum amount of strain. A strain absorber has the strain sensor mounted thereon and is arranged to mount the strain sensor to the body. The strain absorber is arranged to transfer a reduced amount of strain from the body to the strain sensor so that the strain on the strain sensor is no greater that the maximum amount of strain.

Abstract: A sensor assembly for measuring a gas parameter includes a sensing element cover. A bottom wall and the sidewall of the cover have openings configured such that, when the cover is attached to the the sensor so as to surround the sensing element and gas is flowing into the cover interior via the sidewall opening, the gas flow in the cover interior is drawn in a downward motion and concentrated in the vicinity of the sensing element. The openings can be configured to promote rotary or swirling movement of the gas flow in the cover interior. Also, the cover can have an outer cover surrounding an inner cover and the outer cover can have openings only on the cover upstream side to concentrate flow into the inner cover. The sensor assembly can be orientated in an operating position using an orientation pin located on the sensor assembly.