Portfolio Archiv - Systec Automotive

PEMS Case Story: KBA

Susanne Koerber-Wilhelm — Wed, 21 Feb 2024 08:47:19 +0000

PEMS for KBA: Mobile emission measurement under official supervision

systec Automotive supported the German Federal Motor Transport Authority (KBA) with a portable exhaust measurement solution (PEMS).

Project Overview: Why this PEMS?

Since 2016, the German Federal Motor Transport Authority (KBA) has been using portable emission measurement systems (PEMS) for real-world emissions testing of vehicles. These systems are highly effective. However, the KBA was looking for a solution that was lighter, easier to use and less expensive. A Venturi flowmeter from systec Automotive made this possible.

The challenge: an easy and lightweight PEMS

Conventional PEMS, also called portable emission monitoring systems, are typically expensive and difficult to maneuver. They often weigh up to 100 kg and are therefore difficult to handle.

KBA needed a new emission measurement system. It had to be easy to install, affordable, and able to quickly measure emissions from both gasoline and diesel vehicles.

Development of the screening tool

A student at the Technical University of Hamburg-Harburg, under the supervision of Prof. Dr.-Ing. Thorsten A. Kern and in collaboration with KBA engineers, developed a prototype for a portable and cost-effective screening tool. The goal was to create a “mini-PEMS” that would test vehicles under different environmental conditions and provide accurate initial information about the vehicle’s emission control strategy.

PEMS for KBA: Technical Details

The High-Temperature Multivariable Gas Mass Flow Sensor

The TFI4B-2P series from systec Automotive was convincing for several reasons: Thanks to its high sampling rate of 2000 Hz, it detects pulsations and measures more accurately. It operates at temperatures up to 900°C and has an integrated PT1000 for temperature measurement. It also operates efficiently with low pressure loss and is well suited for high and medium gas flow rates.

As accurate as conventional PEMS

With regard to qualitative and quantitative measurement precision, the newly developed screening tool held its own against conventional PEMS: the results showed that the mini-PEMS equipped with the gas mass sensor from systec Automotive measures with adequate accuracy for qualitative evaluation.

Faster, lighter, cheaper

The developed mini PEMS screening tool enables a fast and cost-effective analysis of vehicle emissions. With the integrated gas mass sensor from systec Automotive, it offers the possibility to significantly reduce the number of expensive tests with conventional PEMS. Comparative measurements have proven the high measurement accuracy of the mini PEMS.

And it meets the requirements of the KBA: it is significantly lighter, more convenient, faster and also cheaper to measure than existing solutions.

Good to know! PEMS for KBA … and more

In the field of measuring emissions on vehicles, we work with many international customers. That includes not only manufacturers, but also authorities, similar to the German KBA, in several countries and regions. Examples are the EPA in the US and the EPA in Hongkong.

For more details, please contact us directly.

Or get a first overview of our PEMS solutions and competencies here.

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Multivariable Sensors for OEMs

ohbetz — Mon, 12 Dec 2022 09:38:55 +0000

The multivariable sensor from systec Automotive
Heart of many industrial applications

The DFC multivariable sensor platform from systec Automotive measures pressure, temperature, and differential pressure ultra-fast and very accurately and calculates the compensated mass flow. This advanced platform, based on a powerful microcontroller, provides a cost-effective core technology for a wide range of applications – it is the heart of many industrial flow meters, including those requiring gas massflow miniatur solutions.

Industrial Flowmeters with Multivariable Sensor

Various manufacturers use the multivariable DFC sensors from systec Automotive for their flow meters, especially for dp-based measurements such as pitot tubes, orifices, or venturis, which are used for compressed air, natural gas, or refrigerants. These industrial flow sensors are widely used in all industries, especially in machine control, compressed air billing, and fuel-air control.

Special designs are used, for example, in wire harness quality control to detect kinked or leaking hoses. Other multivariable transmitters are used in LFE’s (Laminar Flow Elements) as minimum gas volume sensors. The DFC is therefore an extremely economical and accurate industrial flow sensor for a wide range of applications.

Multivariable Transmitters and …

…Robotics

The multivariable DFC sensor platform provides flow and pressure signals in painting robots. This ensures controlled painting quality with sampling times of just a few milliseconds. Again, the DFC is a reliable air sensor that delivers accurate results in demanding environments.

… 3D Printing and Medical

Multivariable DFC transmitters are used in 3D printers (SLS) for reliable inert-gas supply and fume extraction, ensuring optimum printing results. In Laminar Flow Element (LFE) flowmeters, DFC sensors help to accurately mix and dose medical gases. Miniaturised for specific applications, these gas mass sensors provide accurate measurements.

Use as a gas massflow miniatur sensor demonstrates the versatility and precision of the DFC in a variety of applications.

Do you already have the right sensors and want to recalibrate them?
Find out more about our calibration laboratory and the services we offer, including ISO 9001 calibration and preparation for DAkkS certification.

What is Your Application for our Multivariable Sensor?

Is your application not listed? If you need to measure or control your gas flow, pressure, or temperature, please contact us.

The DFC multivariable sensor platform is available in a variety of designs and with a wide range of interfaces: I2C, CAN, MODbus, 4-20mA, 0-10VDC. Our design team will be happy to assist you in finding the optimum design for your volume application, whether it is a compressed air sensor or an OEM flow solution. DFC also offers custom solutions for OEM flow applications, making it ideal for high volume production.

Discover the versatility of systec Automotive’s multivariable sensor and optimize your applications with our advanced technology.

Data sheet deltaflowC2

Data sheet deltaflowC-CSI

Data sheet BRP Sensor Board

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Sensors for H2 Fuel Stacks

ohbetz — Thu, 08 Dec 2022 09:27:31 +0000

Hydrogen Flow Meter

Accurate Hydrogen (H2) Flow Metering

Hydrogen Flow Meter by systec Automotive: systec Automotive provides comprehensive solutions for precise flow measurement of hydrogen (H2), utilizing cutting-edge hydrogen flow meters (Flowmeter H2). Our extensive experience in developing and equipping fuel cells (fuel stacks) and H2 flow measurement positions us as leaders in this field. We support fuel cell manufacturers and users in the development and production of both mobile and stationary hydrogen applications, emphasizing on fuel cell flow dynamics.

Fuel Cell Test Bed Measurements? – Cathode Monitoring of Fuel Cells and More

Our fuel cell test bed measurement solutions include high-precision systems that accurately measure the flow, pressure, and temperature to fuel cell cathodes (air), hydrogen (anode) and exhaust gases. These systems, equipped with hydrogen flow meters (Flowmeter H2), can be DAkkS-calibrated upon request and include all necessary certifications such as PED or ATEX. Our hydrogen flow meter sensors cover all relevant flow, pressure, and temperature ranges and are suitable for any fuel cell application, from small stacks to high-temperature systems.

deltaflowB: Industrial Hydrogen Flow Meter for Precise Results

The deltaflowB measurement systems, developed in collaboration with systec Controls, have extensively proved their functionality in the industry and have excelled under the toughest conditions. They are perfect used as a hydrogen flow meter for H2 flow measurement (Flowmeter H2) in various industrial applications, as well as for air or any other gas measurement. With their high accuracy and durability, they are in particular designed to fulfill highest demands in terms of accuracy and reliability. They are used on many test beds and laboratories.

Series Production of Hydrogen-Powered Vehicles

For hydrogen-powered vehicles, we offer robust systems for fuel cell cathode (air) measurement and exhaust gas monitoring. These systems, designed to withstand pressures up to and above 4 bar and resistant to water vapor and condensation, employ our TFI4G differential pressure method to measure flow, pressure, and temperature accurately and with long-term stability. For the anode side, in fuel cell flow measurement, we provide series-ready combination sensors, including hydrogen flow meters (Flowmeter H2), for pressure and temperature.

Fuel Cells and Flow – We Have the Right Measurement System!

Benefit from our extensive expertise in H2 flow measurement and fuel cell test bed applications, whether on the test bench, in mobile, or industrial settings. We offer high-precision references for test benches, as well as cost-effective sensors and hydrogen flow meters for mass production.

Partnering with systec Automotive ensures competence and reliability in your fuel cell projects.

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CAN Temperature Sensor

ohbetz — Thu, 09 Jun 2022 06:08:04 +0000

Digital Temperature Measurement with CAN Protocol

Using a CAN Temperature Sensor: In various applications such as engine systems, PEMS, fuel cells, and test benches, accurate temperature readings are essential and can be conveniently obtained through the CAN bus.

The T4BPT1000 is a reliable solution that converts PT1000 temperature measurements into a CAN signal, covering a wide temperature range of -50°C to 700°C. With its impressive accuracy of less than 3K throughout the wide range, it enables precise digital temperature measurements for all types of fluid flows in engine applications. It is suitable for measuring gases such as air, exhaust, hydrogen, blow-by, as well as liquids like cooling water, fuel, and oil, provided they are compatible with the stainless-steel temperature element. Optional high corrosion-resistant temperature sleeves are available upon request to meet specific requirements.

The PT1000 CAN Temperature sensor is designed with a screw-in immersion sleeve of G1/4″ size, featuring a 3mm diameter and 50mm immersion depth. Customized designs can be provided upon request to meet specific application requirements. The electronic unit is equipped with a robust TYCO HDSCS IP69 connection and complies with automotive specifications, ensuring reliable operation within a wide temperature range of -40°C to 125°C.

Material	Plastic, stainless steel
Temperature	-50..700°C (medium)
Temperature	-40..125°C (environment)
Media	Air / EGR / EGR / exhaust / blowby / all gas and fluids compatible with stainless steel 1.4404 (others a.A.).
Signal	CAN-Bus 5-30VDC
Accuracy	+/- 3K

Looking for information on pitot tubes for air flow metering? Click here and read about our solution.

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Commissioning / Advice

Christine Volpert — Thu, 08 Jul 2021 15:45:32 +0000

Commissioning, service, and advice on Gas Mass Flow for Automotive

We Know Flow, Perfectly!

Service and Advice on Gas Mass Flow for Automotive: systec Automotive has a team of highly skilled experts who excel not only in developing top-notch instruments but also in providing exceptional support, service and advice on gas mass flow meters for Automotive to our customers throughout the commissioning and field service stages of their projects.

With over 25 years of experience, our experts have accumulated a wealth of knowledge across diverse industries and applications. We are dedicated to sharing this expertise with our customers, allowing them to leverage our support and benefit from our in-depth understanding of their specific needs.

Whether you require assistance in implementing our instruments or troubleshooting any issues that may arise, our knowledgeable team is here to guide you every step of the way. Rely on our extensive experience and take advantage of our dedicated support services.

Development

Our comprehensive support for engine developers spans across every phase of the project. Starting from the early stages of thermodynamic engine conception, we offer expert advice on crucial considerations such as air mass measurement, EGR measurement, and engine filling models. We delve into understanding your specific objectives, whether it’s optimizing EGR control or reducing NOx emissions. Our team guides you in making informed decisions, exploring the merits of sensor utilization versus leveraging filling models. Additionally, we help identify the most suitable measurement points within the engine system, considering factors like placement before or after the turbocharger, after the CAC, or before/after the EGR cooler. By discussing your test bench or engine concept with us, you’ll gain valuable insights and recommendations to determine the most effective approach for your application.

Construction

Air mass sensors and EGR measurements pose significant challenges when applied to engines, as well as when instrumenting a test bench. Factors such as packaging, straight inlet requirements, pressure loss, and other parameters must be carefully considered. Manufacturers’ specifications often call for long inlets, which may be impractical or disrupt the mechanical engine design. Our expertise lies in guiding you towards achieving the highest measurement accuracy while avoiding costly design mistakes from the outset. Our advice extends beyond optimizing measurements; we also prioritize economically viable solutions that are robust, reliable, and tolerant to potential faults in the long run.

Engine Map Optimization

Our expertise, combined with our intelligent sensors, allows you to achieve precise measurement results on commercial vehicle engines in record time. Our patented filter strategies enable highly dynamic measurements with impeccably filtered sensor values, solving the seemingly impossible. Whether on-site or remote, our consulting engineers provide rapid support to optimize sensor parameters for your specific test bench application.

Globally recognized, our team of engineers and technicians are renowned for their exceptional skills. Get in touch with us to experience our unparalleled support first-hand.

Benefit from our service and advice on gas mass flow for Automotive.

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Calibration Laboratory

Christine Volpert — Thu, 08 Jul 2021 15:43:25 +0000

Calibration Laboratory and Environmental Tests

Flow meter calibration and more, ISO 9001 certified

systec Automotive is equipped with a comprehensive calibration laboratory featuring traceable standards for flow, pressure, temperature, current, and voltage. Our team of experts utilizes these standards not only for flow meter calibration for internal development tasks but we also provide our customers with cost-effective and reliable flow meter calibration services. All our measuring devices are in compliance with national standards and in accordance with ISO 9001 guidelines.

We specialize in calibrating air flow ranging from 0.5 to 3800 kg/h with an impressive uncertainty of only 0.25 – 0.36%. Additionally, we offer water flow calibration in the range of 0.3 – 110 t/h with an uncertainty of merely 0.05%.

Calibration laboratory: Equipment

Our calibration laboratory is equipped with highly accurate analogue pressure primary standards, including a Betz micro manometer with a range of 0–30 cmWS and a floating ball manometer. These standards exhibit an impressive uncertainty of only 0.2 Pa (0.002 mbar) or 0.02 % in the range of 0 – 2500 mbar. Notably, these standards are drift-free, ensuring consistent and reliable measurements. With such precision, our flow meter calibration capabilities are particularly well-suited for checking and recalibrating differential pressure transmitters to perfection.

This enables us to deliver precise flow meter calibration for a wide array of industrial flow meters at systec Automotive:

Differential pressure flow meters such as orifices, venturis, dynamic pressure probes, V-cones, etc.
Vortex or swirl flow meter or vortex.
Magnetic inductive flowmeters (MID’s).
Ultrasonic flow meters with clamp-on or wetted sensors
Turbines, quantometers,…

Environmental Test Lab complementing Calibration Laboratory

In addition to our expertise in flow meter calibration and pressure measurements, we offer comprehensive environmental testing services in our calibration laboratory. This includes conducting crucial tests such as temperature, humidity, vibration, and salt spray tests.

With our eight climatic chambers, we can subject your devices to extreme temperature conditions ranging from -70°C to 200°C while maintaining defined humidity levels. Our climatic shock chamber enables rapid cycling between a minimum of -70°C and a maximum of +200°C within just 2 seconds, allowing for repetitive testing according to your specified parameters.

For smaller devices and circuit boards, we have a high-frequency shaker capable of accelerating them up to 2 kHz and up to 20 g, facilitating vibration and shock tests as required.

Flow Meter Calibration for accurate measurement

In our spray fog chamber, we can perform tests to assess the impermeability of your device against salt mist exposure. We are equipped in our calibration laboratory to conduct various tests involving current or pressure overlay, which are essential for evaluating equipment intended for use in demanding environments. This includes sensors in the automotive industry or devices designed for outdoor applications.

To ensure accurate and reliable testing, our climatic chambers undergo regular maintenance by the manufacturer, and the physical conditions within them are measured traceably.

Calibration laboratory: Good to know

We provide prompt, professional, and cost-effective services in environmental testing and calibration, fully compliant with ISO 9001 calibration standards.

For a comprehensive overview of our calibration laboratory equipment, please refer to the download file provided below. To inquire about your specific testing needs, we invite you to use our convenient online form.

For information on our portfolio of services, click here.

Frequently Asked Questions on the Calibration Laboratory

1. Why use the systec Automotive calibration laboratory for flow meter calibration?

The systec Automotive Calibration Laboratory offers calibration standards for air in the diameter range from 2 mm to approx. DN300 and for water between DN10 and DN100. For air, calibration can be performed with atmospheric air (Dn20..DN300) or with compressed air. This is ideal for calibrating vortex, ultrasonic, thermal or differential pressure based flow meters such as orifice plates, venturis or dynamic pressure probes. Transferability to other media is often possible but depends on the measuring principle. We will be happy to advise you.
For smaller flow rates and diameters, we are able to calibrate with atmospheric air or pressurised gases up to a pressure of 8 bar. We calibrate with water on our liquid test bench.
As well as flow meter calibration, our calibration services also include the calibration of absolute pressure, gauge pressure and differential pressure transmitters.

2. What steps do I need to take to use the calibration lab?

It is very easy for you to use the systec Automotive Calibration Laboratory: You write to us or give us a call with a description of the tests and/or calibrations you would like to have done and the time frame. We will check when the next suitable dates are available and send you an offer. You accept the offer and make an appointment. You send us the equipment to be tested and we carry out the tests on our own or with you on the agreed date.

If you’d like to enquire directly, please email us here or use the contact form below.

3. To do a flow meter calibration the calibration laboratory, do I need to have already purchased products from systec Automotive?

Regardless of whether you already use or have bought products from us, you can use the systec Automotive calibration laboratory. We carry out calibrations independent of the manufacturer.

We also offer environmental testing and the (re-)calibration of flow meters, pressure transmitters and other devices.

4. Which services does systec Automotive offer in the calibration laboratory?

We offer various types of flow meter calibration and other tests in our calibration laboratory for testing your flow meters and other instruments. Whether gas, vapour or liquid, clamp-on or media contact, ultrasonic or differential pressure, we have the right equipment for many calibration tasks.

You can also use ou calibration laboratory for environmental testing: In our climatic chambers, we can subject your instruments to controlled temperature changes, humidity, vibration and salt spray tests according to your requirements.

5. What kind of equipment is available in the calibration laboratory?

Flow meter calibration of gas, vapour and liquid flow meters, with and without clamp-on, is possible in our calibration laboratory. Our instruments are all traceable to national standards, thus making us able to do ISO 9001 calibration.

We are also well equipped to test and recalibrate differential pressure transmitters with our ‘analogue’ primary pressure standards, consisting of a 40 cm W.S. Betzmanometer and a floating ball manometer. These operate with an uncertainty of 0.02 mbar or 0.01% over the range 0.2500 mbar – and are drift free.

For environmental testing, we use climatic chambers, climatic shock chambers and shakers. This enables us to perform the most important environmental tests: Temperature, humidity, vibration, salt spray. Energised and pressurised tests are also possible.

For an overview of all the equipment available in the calibration laboratory, click here.

Or contact us directly to find out more about the equipment in our calibration laboratory and what tests are available.

6. Which certifications does the systec Automotive calibration laboratory hold?

All our calibrations are carried out in accordance with EN ISO 17025, with full traceability of instruments to national standards in accordance with ISO 9001. Our climatic chambers are regularly serviced by the manufacturer and the physical conditions are closely monitored. DAkkS accreditation of our calibration laboratory is in progress.

7. Are ISO 9001 flow meter calibrations available in the calibration laboratory?

systec Automotive is regularly audited and has been certified to ISO 9001 for many years. This also applies to the services provided in our calibration laboratory. Each of our flow meter calibrations is performed in accordance with EN ISO 17025, with full traceability of instruments to national standards in accordance with ISO 9001.

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Exhaust Gas Flow Metering

Christine Volpert — Thu, 08 Jul 2021 15:40:00 +0000

Exhaust Gas Flow Metering on the Engine Test Bed

deltaflowB - our exhaust gas flow meter

Precise reference flow measurement by a precise exhaust gas flow meter is one of the most important variables for exhaust gas and efficiency optimisation in modern engines. It plays a central role in exhaust gas flow and volume measurement on the engine test bed. Modern environmental regulations such as Euro 6, Euro 7, Tier II, Tier III, CN4 and CN5 need complex engine optimizations to be fulfilled.

The requirements for gas flow measurement on the engine dynamometer beds are particularly high. As a calibration standard, the measurement must not only be accurate, but also have a high dynamic response (measurement rate) and, depending on the application, withstand massive pulsation, contamination, soot and fowling and temperature. Their importance in modern test environments is immense. Gas mass flow measurement of fresh air, blow-by and exhaust gas is one of the most demanding measurement tasks, as it has to meet a large number of specific requirements:

Fast measurement dynamics
Large measurement ranges
Pressure and flow pulsations resistance
Lowest possible pressure drop
High accuracy
CAN bus integration

deltaflowB, our exhaust gas flow meter, is based on the principle of differential pressure measurement, which offers significant advantages over other measurement methods:

Insensitive to fouling and contamination, easy cleaning if necessary
Wide temperature and pressure range
High accuracy
Low long term drift
Easy to recalibrate

We have developed the deltaflowB as an exhaust gas flow meter specifically for various gas volume flow measurement on the engine test bed and as a master for the flow meter test bed, where it has become an integral part of the engine test bed equipment. It offers many advantages over standard differential pressure measurement:

Primary element:

The deltaflowB does not use classical primary elements (such as orifice, venturi, nozzle), but a newly developed combination of a low pressure loss venturi and an airfoil probe. This combination reduces the permanent pressure drop to well below 10% of the measured differential pressure, which means that even at maximum flow rates the pressure drop remains <20 mbar.

Sensorics:

Commercially available pressure, differential pressure and temperature sensors are too slow for the dynamic requirements of exhaust gas volume measurement on the engine dynamometer and flow measurement on the test bench. One of the main problems, in addition to the slow transmission of measured values to the test bench, is that engine pulsations cannot be detected by standard sensors. This leads to measurement errors that depend on the strength and frequency of the pulsation (square root error).

The CAN-based sensors from systec Automotive measure up to 2kHz and use sophisticated filter strategies to separate pressure and flow pulsations and calculate precise air mass flows.

Redundant digital analysing electronics:

The exhaust gas flow meter deltaflowB is equipped with triple sensor recording, which gives you several advantages:

Plausibility check of the 3 x 3 readings (p, dp, T)
Automatic maintenance and recalibration recommendations
High accuracy thanks to averaging

As the sensor readings are taken at different points in the venturi, the user also receives information about the flow conditions at the meter. For example, highly disturbed inlet conditions will result in deviations between the three sensors.

Measurement calculator:

The sensors are analysed and displayed on the PC measuring computer via CAN. The user-friendly software displays both: Individual measured values and filtered averages. The measurement PC and operator terminal are designed as a 19″ rack version. Connection to the test bench is via the PC’s second CAN interface as standard, with additional analogue outputs available via optional I/O cards.exhaust

Our Exhaust Gas Flow Meter on the Engine Test Bed:

Benefits at a Glance

Thanks to its Venturi design, the deltaflowB has low inlet requirements. It is supplied with an inlet section of approximately 10D, which can be connected upstream as required.

Its high measurement dynamics enable accurate readings even with pulsations, without the need for dampers, known as volumes, between the engine and the measurement. It is therefore an advanced solution for both exhaust gas volume measurement on the engine dynamometer and flow measurement on the test bench, and offers a robust, efficient alternative to thermal flow meters.

Finally, thermal flowmeters need to be recalibrated up to four times a year, depending on accuracy requirements. This is not necessary with deltaflowB. The intelligent evaluation of the deltaflowB compares the redundant sensors and automatically recommends recalibration, usually every two years.

Fluids	Air, Exhaust, Blow-By
Process	0..4,5bar abs -40..200°C
Dimensions	Starts from DN25 (0..160kg/h) up to DN200 (0..12.800kg/h) (others on request)
FlowSpan	Up to 1:28 (qmin/qmax)
Accuracy	Standard: 1% Pro: 0,5%
Flow Computer	CAN-based, Mess-PC 19″, 3HE Display/Keypad: 19″, Slider,1HE

Rather interested in a portable emission measurement system (PEMS)? See the case story about our mini PEMS used by the KBA.

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PEMS

Christine Volpert — Thu, 08 Jul 2021 15:25:58 +0000

PEMS

Mobile Exhaust Gas Flow Sensors and Measurement for Passenger Cars and Commercial Vehicles (PEMS)

Since the diesel scandal, the demand for reliable gas mass measurement for portable emission monitoring systems (PEMS) is high. Having exact data on real drive emissions has become even more essential for manufacturers of both passenger and commercial vehicles than before.

We support you in developing and using PEMS with customized versions of our TFI4B platform. The TFI4B is a sensor system consisting of differential pressure, absolute pressure and temperature sensors. A CAN bus provides the necessary connection to an engine control unit (ECU) or a mobile data logger system. The core electronics have a powerful microprocessor that processes, filters and calculates the signals. This means that we deliver the measurement directly to you and you do not need to use any other resources – our TFI4B platform works as an RDE (real drive emission) meter.

Learn more about our “Mini PEMS”, which we developed in cooperation with the German Federal Motor Transport Authority (KBA). Click here.

Real-Time Signal Analysis – Mobile Emission Testing Made Easy

To measure a vehicle’s emissions on the road, you first need small, lightweight measurement components to be used as an RDE meter. The lighter the real drive emission measurement solution, the more accurate the results and the more convenient the handling.
PEMS need to withstand high exhaust temperatures above 500°C . They must also be able to cope with pulsations in flow and pressure.

Our systec PEMS (portable emission monitoring system) meets all these requirements perfectly. The ultra fast electronics are sampling differential pressure, absolute pressure and temperature with up to 2 kHz. They are based on the TFI4B, which is used by many combustion engine manufacturers in series. In the PEMS version, these electronics are supported by an external high temperature thermometer – a CAN based PT-1000. The pressure sensors with the electronics are located in a stainless steel housing, protected against temperature and environmental influences, and separated from the hot venturi by hoses or steel pipes for thermal decoupling.

systec’s PEMS, like its TFI4B series counterparts, handles pulsations perfectly due to its ultra high sampling rate. This provides highest accuracy in highly dynamic drive. The mass flow signal is calculated with 2 kHz and then filtered to a stable value which is digitally transmitted via CAN-Bus, together with pressure, temperature and a complete OBD. The primary elements – usually venturis or dynamic pressure probes – can be easily dismounted and cleaned if necessary.

Exhaust gas flow sensors for passenger cars and commercial vehicles: systec PEMS has clear advantages!

The measurement of flow and pressure close to the engine is subject to pulsations, condensates and NHC, especially in mobile exhaust gas measurement on commercial vehicles. There is a complex pressure-flow characteristic in the exhaust gas, which depends on the engine map, aging, ambient conditions (air pressure, air temperature) and other variables. Since pressure and flow are connected by energy conservation, both variables must always be considered for accurate volume measurement in the case of pulsations.

Conventional PEMS measurement systems can only deal with these challenges to a limited extent: the low sampling rates and slow sensors lead to large calculation errors. The results are often unsatisfactory.

The systec PEMS measures pressure, temperature and differential pressure up to 2000 times per second and analyzes the condition of the fluid in the pipe in real time for perfect flow calculation. Complex evaluation and filtering technologies are used to calculate a precise and dynamic flow rate. The result is maximum accuracy in all operating conditions without engine maps.

A systec PEMS (portable emission monitoring system) is always fully optimized and calibrated to customer requirements. This ensures that the PEMS works with low pressure loss and with the required accuracy on the vehicle, both for exhaust gas flow sensors on passenger cars and on commercial vehicles. These advantages have also been confirmed by the KBA in extensive comparative tests (see download article below).

High accuracy under highly dynamic and pulsating conditions

Compact measurement of flow at high temperature resistance

Fast and simple adaptability to new applications

Perfectly calibrated sensors

No drift by contaminants such as oil or condensate film

Lifetime up to 1 million miles

Ambient conditions	-40..125°C
Fluid-Temperature	-40..900°C
Fluid-Pressure	0,5-4,5bar abs(other o.r.)
Differential Pressure	-50..250mbar (other o.r.)
Fluid	Air, Exhaust gas, EGR
Accuracy (new)	T +/- 1K, p +/- 0,3% d.MBE, dp +/- 0,3% d.MBE
Accuracy (life time)	T +/- 2K, p +/- 1,8% d.MBE, dp +/- 1,5% d.MBE
Accuracy flow	<1:10MBE: 0,35%d.MBE; >1:10MBE: +/-2% v.MW*
Connector	TYCO heavy duty, HDSCS-6pin (other o.r.)
Communikation	CAN-Bus (other o.r. (PWM, LIN, 0..5VDC)
Power Supply	5VDC stabilized, 35mA
	MBE= of span MW= of measured value

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Air Mass Flow Meter for Diesel Engines

Karthik Pushparaj — Thu, 08 Jul 2021 15:19:12 +0000

Air Mass Flow Meter for Diesel Engines – also for EGR monitoring

Measuring gas flows close to the engine is one of the most important and challenging tasks on commercial vehicle engines. A suitable air mass flow meter for commercial diesel engines has to fulfil more than just one task.

Current and future environmental standards can be achieved most efficiently by NOx reduction at the engine. For this, the application engineer needs to have a perfect EGR (Exhaust Gas Rate) to fill the cylinder.

Trying to meet the standards without EGR control by aftertreatment alone is significantly more expensive, less efficient, increases the vehicle weight and reduces the engine and vehicle efficiency by additional backpressure. The basis for a perfect engine NOx reduction is a reliable measurement of the ratio between fresh air and exhaust gas fed into the cylinder, also known as EGR monitoring.

Are air and EGR (exhaust gas recirculation) in the right ratio? The air mass flow sensor (MAF) for diesel motors and commercial vehicles, TFI, from systec Automotive delivers exactly the measured values you need for your EGR monitoring.

More robust than Thermal Mass Flow Meters

Conventional Thermal Mass Flow Meters (HFM) reach their limits with diesel engines due to

temperature,
pressure
pulsation
condensates/NHC/blow-by
corrosive components or
short inlet sections.

The solution: TruckFlow Integrated (TFI), air mass flow meter for diesel engines

TFI is the reliable air mass flow meter for the special requirements of commercial vehicle diesel and also H2 combustion engines. TFI4 is specially designed to deliver accurate results even under the most difficult conditions such as pulsation, pressure, temperature and condensates. This makes it ideal for diesel and other combustion engines.

In an environment where thermal flow meters fail within minutes, the TFI works reliably for the entire life of an engine, which is 1.6 million km or 8,000 hours. The TFI4, our reliable MAF for commercial engines, is also well suited for measuring moist air for the fuel cell cathode.

Air Mass Flow Meter (MAF): EGR Monitoring and Air Flow Measurement

As the pioneer in multivariable flow measurement technology, systec Automotive have developed the patented TFI sensor platform, as an air mass flow meter for diesel engines. It combines differential pressure, pressure and temperature measurements at the engine.

The result is a differential pressure-based flow measurement that is both highly dynamic and accurate. Using the CAN protocol, you receive precise, perfectly filtered engine data on your air masses as well as boost pressure and temperature of the air or EGR in real time. All this is completely independent of the ECU you are using and straightforward for the customer – this is how EGR monitoring works!

The TFI mass airflow sensor for diesel engines is much more than a conventional HFM sensor. Its advantages include

Can be used in diesel applications for air and exhaust gas (EGR) from 0 to 4.5 bar and with -50 to 800°C.
dp, pabs and T sensors in a single component
Suitable for corrosive and condensing gases
Compatible with various primary elements such as venturi, pitot tube, etc.
Minimal pressure drop, keeping motor efficiency
Highly dynamic real-time measurement with T90 < 10mS
Efficient patented pulsation filter
CAN messages with gas mass, pressure and temperature data, including OBD messages
Integrated engine mapping for best accuracy even in low-flow (IDLE) operation
Automatic zero point detection

The TFI meets all the requirements as a mass airflow sensor for diesel engines and has proven its functionality worldwide on many engine positions:

Before turbocharger
After turbocharger
After intercooler
Hot EGR/ cold EGR
Low-Pressure-Exhaust

Short straight inlet distance? No problem for our air mass flow meter!

Our engineers have extensive experience with short and variable inlet sections. With our accredited calibration facilities and CFD, we can provide effective advice on where and how best to place the TFI4 measurement on the engine, for both diesel and other applications.

This is how the perfect air or EGR mass measurement is applied to the engine: precise, cost-effective and durable.

Want a quick application on the engine? You found it!

No other flow measurement is faster and easier to apply to the engine than TFI4B. Thanks to the patented filtering methods, the optional low-flow mapping and the auto-zero function, you have very few tasks to solve in the ECU. You receive precise values in real time via CAN, which you can process directly for your engine control – highly dynamic and perfectly filtered. Our engineers will advise you efficiently on the optimal position for your application and support you with the optimal packaging on the engine.

With TFI4, you have a solution that is extremely cost effective, reduces ECU load, and can be used regardless of the manufacturer.

Power Supply	5VDC (stabilized from ECU)
Temperature Ambient	-40..125°C
Temperature Fluid	-40..150°C
Pressure Fluid	0,4-4,5 (7) bar abs
Material Housing	PBT GF 30 / Messing
Connector	Tyco HD 6pin HDSCS-connector
Sensor length	40mm (insertion depth could be altered on request)
Accuracy	Better 2% of flow

Also interested in exhaust gas flow metering on the engine test bed? Click and get an overview of our solution.

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The post Air Mass Flow Meter for Diesel Engines appeared first on Systec Automotive .

Pitot Tube for air flow measurements

Christine Volpert — Thu, 08 Jul 2021 14:26:11 +0000

Pitot Tube by systec Automotive:
High-Tech, Made in Germany

Pitot tube for Automotive: For over 15 years, systec Automotive has been dedicated to the development, manufacturing, and global distribution of pitot tubes for gas and liquid measurement. As a leading manufacturer in the industry, systec Automotive has earned a reputation for excellence worldwide.

Pitot tubes offer distinct advantages in engine applications due to their resistance to contamination and low pressure drop. They exhibit exceptional dynamics, enabling ultra-fast measurements. The TruckFlow pitot tube, in particular, is highly recommended for measuring air volumes before and after compressors, as well as for determining recirculated exhaust gas (EGR).

systec Automotive pitot tubes are designed to measure polluted and aggressive gases, liquids, and vapors. In our pursuit of product optimization, we collaborate with esteemed external partners such as the Technical University of Munich, the University of Erlangen, the Fraunhofer Institute, and TÜV Süd.

The Truckflow pitot tube features a superior, patented measurement profile characterized by high linearity, insensitivity to contaminants, and a response similar to a crankshaft breather, allowing for extremely rapid measurements. Unlike thermal flow measurements, the TruckFlow pitot tube does not exhibit deviations in measured values due to deposits. It effectively measures gases throughout the engine’s operating time, spanning up to 1,000,000 miles, even at elevated temperatures without the need for cooling.

Materials	plastics, aluminum, stainless steel, coated steel
Temperature	-40 to 400 ° C (depending on material)
Pressure	400 mbar to 6 bar abs-
Fluids	air before and after compressor, before and after intercooler, Exhaust Gas Recirculated (EGR)
Evaluation	External sensors (0..5 VDC, CAN-Bus, PWM, LIN-bus), calculation in the engine control unit
Accuracy	<2% (application dependent)

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The post Pitot Tube for air flow measurements appeared first on Systec Automotive .

Portfolio Archiv - Systec Automotive

PEMS Case Story: KBA

PEMS for KBA: Mobile emission measurement under official supervision

Project Overview: Why this PEMS?

The challenge: an easy and lightweight PEMS

Development of the screening tool

PEMS for KBA: Technical Details

The High-Temperature Multivariable Gas Mass Flow Sensor

As accurate as conventional PEMS

Faster, lighter, cheaper

Good to know! PEMS for KBA … and more

Multivariable Sensors for OEMs

The multivariable sensor from systec Automotive Heart of many industrial applications

Industrial Flowmeters with Multivariable Sensor

Multivariable Transmitters and …

…Robotics

… 3D Printing and Medical

What is Your Application for our Multivariable Sensor?

Sensors for H2 Fuel Stacks

Hydrogen Flow Meter

Accurate Hydrogen (H2) Flow Metering

Fuel Cell Test Bed Measurements? – Cathode Monitoring of Fuel Cells and More

deltaflowB: Industrial Hydrogen Flow Meter for Precise Results

Series Production of Hydrogen-Powered Vehicles

Fuel Cells and Flow – We Have the Right Measurement System!

CAN Temperature Sensor

Digital Temperature Measurement with CAN Protocol

Commissioning / Advice

Commissioning, service, and advice on Gas Mass Flow for Automotive

We Know Flow, Perfectly!

Development

Construction

Engine Map Optimization

Calibration Laboratory

Calibration Laboratory and Environmental Tests

Flow meter calibration and more, ISO 9001 certified

Calibration laboratory: Equipment

Environmental Test Lab complementing Calibration Laboratory

Flow Meter Calibration for accurate measurement

Calibration laboratory: Good to know

Frequently Asked Questions on the Calibration Laboratory

Exhaust Gas Flow Metering

Exhaust Gas Flow Metering on the Engine Test Bed

deltaflowB - our exhaust gas flow meter

Redundant digital analysing electronics:

Measurement calculator:

Our Exhaust Gas Flow Meter on the Engine Test Bed:

Benefits at a Glance

PEMS

PEMS

Mobile Exhaust Gas Flow Sensors and Measurement for Passenger Cars and Commercial Vehicles (PEMS)

Real-Time Signal Analysis – Mobile Emission Testing Made Easy

Exhaust gas flow sensors for passenger cars and commercial vehicles: systec PEMS has clear advantages!

High accuracy under highly dynamic and pulsating conditions

Compact measurement of flow at high temperature resistance

Fast and simple adaptability to new applications

Perfectly calibrated sensors

No drift by contaminants such as oil or condensate film

Lifetime up to 1 million miles

Air Mass Flow Meter for Diesel Engines

Air Mass Flow Meter for Diesel Engines – also for EGR monitoring

More robust than Thermal Mass Flow Meters

The solution: TruckFlow Integrated (TFI), air mass flow meter for diesel engines

Air Mass Flow Meter (MAF): EGR Monitoring and Air Flow Measurement

Short straight inlet distance? No problem for our air mass flow meter!

Want a quick application on the engine? You found it!

Pitot Tube for air flow measurements

Pitot Tube by systec Automotive: High-Tech, Made in Germany

The multivariable sensor from systec Automotive
Heart of many industrial applications

Pitot Tube by systec Automotive:
High-Tech, Made in Germany