Telemetry measurement systems for highest requirements

Engine applications

The requirements placed on engines in the automotive industry are constantly increasing. In order to use fuels as efficiently as possible and thus keep consumption as low as possible, MANNER offers multifaceted measurement applications from sensor telemetry.

When it comes to optimizing performance, efficiency and durability, we support you in a wide variety of areas in order to obtain highly precise measurement values for engine components.

We always find a measuring solution with non-contact data transmission at the highest temperatures and speeds as well as in the most confined spaces.

The following measuring tasks in the engine are successfully realized by us with the exact sensor telemetry systems:

Piston temperature

Online recording of piston temperature

Piston telemetry from MANNER is one of the most important tools for developing pistons, verifying their operational stability and optimizing the lubrication process. The systems record online multi-channel temperatures at important points in the piston. Temperature distributions can be obtained for various load scenarios. From this, important conclusions can be drawn regarding the optimal design of the pistons.

The systems work with robust thermoelements that can easily withstand the increasing vibration levels and are easy to install and calibrate. The temperature-resistant electronics scan the measuring points at each piston stroke. The measured values are transferred to a stationary evaluation unit without contact or battery.

Con rod loading

Online recording of the dynamic con rod load

The gas forces acting on the piston as well as the oscillating mass forces of the engine exert a high accelerated-delayed tensile-pressure alternating load on the connecting rod and therefore place high demands on its design.  Mass, dimensions, stiffness, connecting rod screw connection, steel hardening/alloy and dimensioning of individual connecting rod points are of decisive importance.

MANNER has been providing customers with professional support for many years in measuring forces at all connecting rod points.  Continuous further development of con rod telemetry means that measurements of the most varied partial loads are continually optimized.  One of the most important partial aspects here is:

  • Gas force capacity
  • Compressive/tensile stress in the shaft
  • Compression/tensile stress in the transition to the large eye
  • Safety of the connecting rod shaft against buckling
  • The oval deformation of the conrod head and conrod eye
  • Gaps in the dividing joints of the connecting rod head
  • Transverse forces in the split joint
  • Bending stress
Con rod bearing temperature

Temperature at con rod bearing

At both ends of the conrod, the connecting rod eyes, the connection to the piston and crankshaft is made by means of plain bearings. With continuously increasing combustion pressures, these are exposed to increased loads.

The friction caused by rotating crankpins and piston pins must be reduced by the connecting rod bearings. The increase in combustion pressures leads to increased demands on the bearings, especially on the main conrod bearing, which leads the honking pin to the crankshaft.

With the extremely high forces which occur at the connecting rod eye, temperature measurements in the bearing are useful from several points of view and are often indispensable. MANNER Sensortelemetrie GmbH offers you solutions with non-contact measurement data transfer to optimally support you in the following tasks:

  • Temperature monitoring with different load scenarios
  • Evaluation of thermal load limits
  • Optimization of materials
  • Optimization of coating materials and processes
  • Optimization of lubricants and lubrication processes
Crankshaft load

Measurement of the dynamic crankshaft load

The vibrations at the crankshaft are stimulated by the gas and mass forces that occur.  The various parts of the crankshaft are subjected to high loads. MANNER Sensortelemetrie GmbH offers customer-specific measurement applications for the most varied load scenarios on the crankshaft.  Among the most important are:

  • Measurement of occurring forces (connecting rod contact force, bending moment)
  • Material expansion of the crankshaft in load operation
  • Torsion and torsional vibration

In addition to forces and torque, further measurements in the crankshaft area are possible, such as:

  • Crankshaft bearing temperature
  • Oil film dimensions / detection of the distance between bearing and bearing shell
  • Measurement of the oil pressure in the expanding system
  • Detection of the dynamic displacement of the connecting rod bearings on the crankshaft
Camshaft load

Detection of the dynamic camshaft load

The main load on the camshaft is determined by the valve train kinematics and their geometric structure. Furthermore, it is the excited valve train masses, the valve spring and the exhaust back pressure (possibly an engine brake) that additionally load the camshaft. In addition, it is the drive torque for auxiliary and secondary units that stress this essential engine component.

The various measuring applications of MANNER Sensortelemetrie GmbH are recommended for recording the torsional and bending moments at the camshaft. The exact measurement data is digitized in a space-saving and non-contact way and transferred to a corresponding output device.

Gain a decisive advantage with a precise MANNER sensor telemetry system on camshaft, cams or cam followers such as rocker arms or cam followers, cup tappets, flat tappets or roller tappets, or other components in the contact area.

Chain force

Dynamic force detection on the chain

The control chain as drive element of the camshaft is responsible for the exact adherence to the timing. Slide rails and chain tensioners compensate for the extension of the chain that occurs during operation.

Of great importance is the tensile force which must be applied to overcome the resistance of the camshaft. The load after the camshaft drive is also of decisive importance, since here a poor chain tension leads to fluttering, in extreme cases to a chain break.

This is already precisely measured and recorded in many applications with the help of MANNER sensor telemetry. With the help of our chain telemetry, exact voltage measured values of individual chain links can be transmitted without contact via an inductive coupling. Even excessively high or one-sided tensile and centrifugal forces can be determined precisely and preventively in this way.

Optimize your motor control and meet the decisive requirements of the control chain with regard to low noise, control precision and longevity. MANNER Sensortelemetrie GmbH will be pleased to develop the optimum application for your measuring task.

Valve temperature

Temperature recording on the valves

High valve temperatures mean high loads in terms of lower tensile strength of the material and lower wear resistance of the valves and valve seats.

However, the question of optimum heat dissipation and its effect on the combustion chamber filling still arises. The influences of design, materials, valve clearance and other factors must be determined in order to successfully reduce valve temperatures.

MANNER offers you optimum measuring applications based on non-contact and maintenance-free sensor telemetry for the online recording of valve temperatures on the fired passenger car or large engine.

The temperature-resistant electronics integrated in the valve disk scan the temperature measuring points. The pick-up antenna, which can be mounted at a generous distance, picks up the measured values contactlessly and transmits them via cable to the stationary evaluation unit. The service life of the system is almost unlimited and the feedback effect on the valve operation is negligible due to the low weight of 2 grams. A continuous signal contact is not required.

Valve stem force

Online recording of the dynamic valve stem force

The valve passes from the disc into the valve stem in a parabolic shape in order to offer as little resistance as possible to the gases flowing past.  The greatest load on the stem occurs when the valve closes.  When the disc hits the valve seat, the stem is subjected to considerable tensile forces from the valve spring. During the closing process, the stem may also bend (e.g. due to cylinder head distortion or coaxiality errors).

To determine these tensile and bending force loads, MANNER supports customers worldwide with our reliable load telemetry on the valve.  The temperature-resistant electronics integrated in the valve disc scan the force measuring points on the stem.  The pick-up antenna, which can be mounted at a generous distance, picks up the measured values without contact and transmits them via cable to the stationary evaluation unit.

The system’s service life is almost unlimited and no continuous signal contact is required.  The feedback effect on the valve operation is also negligible due to the low weight of 2 grams.

Applications on auxiliary aggregates

The auxiliary aggregates of a vehicle are also subject to technological change in the automotive industry. They are constantly subjected to optimization processes and require adequate measurement technology that takes into account the increasing requirements with regard to dynamic torque, speed, pressure and temperature loads as well as space-saving space conditions within the body.

In order to be able to evaluate uncomplicated, reliable and exact measurement data of these auxiliary machines, numerous sensor telemetry applications are already being used on or in the following auxiliary units:

  • Lighting machine
  • Servo pump for steering aid
  • Lubricant pump, oil pump and coolant pump
  • Vacuum pump e.g. for the brake
  • Air conditioning compressor and fan
  • Secondary air pump for exhaust gas aftertreatment
  • Starter
  • Hydraulic pump (e.g. for power steering)
  • Cooling water pump
  • Fuel pump / Injection pump
  • Dosing pump
  • Ventilator for the cooler
  • Compressor of air brake or turbocharger
  • Brake booster