1 CST employees 5,500EUR 750 millionA Combined Pressure and Temperature Sensor without external temperature probe
2 Content (1) Key P/T Sensor Specifications (2) Patented Thin Film Technology(3) Sensor Design for CO2 / R744 MACS(4) Finite Element Modeling / Simulation(5) Qualification Testing(6) Other Thin Film Applications and Sensor products
3 (1) Key P/T Sensor Specifications Pressure: Measurement Range 0 to 170 Bar Accuracy < ± 1,0% (F.Sp.) Response time ~4 ms (t63)Temperature: Media °C to +180°C Accuracy ~ ± 3 K Response time < 10 sec (t63) Ambient Temperature up to 135°CElectrical Interface: 3-pin LIN2.0, 3-pin PWM, pin P/T analog
4 (2) Patented Thin Film Technology Thin Film Element on SSTSputtered Metal Strain GaugeTiON Strain Gauge with high K-Factor/ Gauge Factor: K: TiON ~ 5 (CrNi ~ 1,1..2) K-Factor: dR/R= K * dl/lHigh Temperature Resistance (330°C)Pressure Range: 10 to Bar6 mm
5 (3) Sensor Design for CO2 / R744 MACS Digital output: LIN2.0 or PWM (Temperature output embedded in signal)Integrated Temp. feature: Less part complexity, higher reliability, less flow restriction and reduced leakage risk.Long term stability, Rugged Design.Smallest possible thread interface: M10x1mm
7 Kavlico DV ChipDual Frequency-Output ASIC for Thin-Film and PRT Resistive type sensors:Ratiometric multiplexed frequency (digital) output for Sensor (Pressure-) and Temperature-data.Coarse gain and offset calibration via serial-interface, allowing wide range of sensors.Fine calibration by µP ; calibration coefficients to be stored in memory of µP.Extreme temperature range ( -50ºC to +200ºC ).Low-Power (sleep mode and 3mA operational current)Self-diagnostics and failure analysis.
8 DV Chip placement on Thin Film Flexure Accurate Temperature measurement independent from ambient temperature.Digital, non-susceptible output (temperature output embeded in signal).Bridge padsBumps on DV ChipUnderfill AdhesiveElectrical Contact
9 Schematic p T Sensing (Sensor assy) Conditioning (PC Board) DV chip FlexwireInter-connectionMicro ControllerThin FilmStrainGaugeLIN2.0TransceiverOut
11 Effect of Chip on Diaphragm Stress and Deflection The influence of DV chip on the stress distribution and deflection of diaphragm is smallCondition: 180ºC temperature, 150 bar pressureRr
12 Thermal Analysis Impact to electrical Components (PCB) Ambient Conditions:25ºC still air150ºC still air 150ºC air flow / m/s135ºC still air200 kg/h and 180ºC or 165ºC
13 Temperature Distributions after 5 Min. (25ºC Ambient Temperature) 25°C, Voo = 0m/sPrinted Circuit Board112~140ºCInitial Fluid Temperature: 25ºC; Transient to 180ºC
14 b) Temperature Distributions after 5 Min. (150ºC Ambient Temperature) 150°C, Voo = 0m/s150°C, Voo = 4.4m/s167~173ºC166~172ºCPrinted Circuit BoardInitial Fluid Temperature: 25ºC; Transient to 180ºC
15 Replace PCBULTEM 2310 Polyetherimide Plastic ConnectorCircuit BoardStainless Steel 304LMount the circuit board to components with low thermal conductivity (plastics) away from the metal housing.
16 c) Design at 135ºC Ambient Temperature CO2 TemperaturePrinted Circuit Board TemperatureºC5 min of 180ºC5 min of 165ºCºCInitial Fluid Temperature: 135ºC; Transient to 180ºC and 165ºC
17 ConclusionsDV chip has negligible influence on the performance of sensor diaphragm / pressure sensor functionality.By connecting the circuit board to plastics and away from the metal housing, the circuit board temperature can be reduced to around~ 140ºC under 135ºC ambient Temperature
18 (5) Qualification Testing Leackage test Requirement <1,0 gram per year The test is carried out at an external test lab, specialized on these kind of tests.Design validation test on sensor level Start after sample build in July Duration appr. 6 month.
19 (6) Other Thin Film Application and Sensor Products: Direct Fuel Injection / Common RailIn-Cylinder PressureTransmission / Break PressureCompressed Natural Gas (CNG)Traction Control(Mobile) Hydraulic Pressure / ControlsHVAC / Hydraulic Machinery
20 Contact: Mr. Markus Butenop Director of Sales KAVLICO GmbH Potsdamer Str Minden Germany Phone: +49 (0) – 171 Fax.: +49 (0) – Web: /