新一代6635A1大型发动机缸压传感器,突破测量极限


The innovative 6635A1 cylinder pressure sensor from Kistler marks a decisive step forward in improving the efficiency and life expectancy of large engines. This exceptionally rugged and accurate piezoelectric sensor with an integrated charge amplifier is the key to optimized engine operation with closed loop control.

Closed Loop Combustion Control (CLCC) is firmly established as a suitable method for increasing the efficiency and life expectancy of large engines such as those used to power ships. The sensors required for continuous measurements of cylinder pressure are exposed not only to high pressures and temperatures but also to severe mechanical shocks. In view of the trend towards higher mean effective pressures (MEP) in engines, the ruggedness of pressure sensors is becoming a critical factor. But there is a drawback here: making the sensor more rugged almost inevitably means that it will also be less accurate.

Developed in close collaboration with engine manufacturers, the new cylinder pressure sensor 6635A1 was designed for use in engines running at medium speeds. The new sensor from Kistler optimally combines maximized operational lifetime with the greatest possible accuracy thanks to a host of innovative features:

  • PiezoStar crystal: Kistler grows its own piezoelectric crystals – up to five times more sensitive than quartz, they deliver excellent measurement stability and have minimal temperature dependance.
  • Optimized diaphragm design: the new, patented shape of the sensor diaphragm minimizes the thermal shock error, ensuring very good measurement characteristics.
  • Robust signal transmission: instead of a plug-in connector, a welded connection ensures reliable wear-free signal transmission – even in case of severe stresses induced by shocks or vibrations.
The PiezoStar crystal from Kistler is up to five times more sensitive than quartz: it delivers excellent measurement stability and is virtually independent of temperature.
The piezoelectric crystal grown by Kistler is up to five times more sensitive than quartz: it delivers excellent measurement stability and has minimal temperature dependance.

奇石乐创新产品6635A1缸压传感器,在提高大型发动机效率和预期寿命方面起着决定性的作用。该压电式传感器集成电荷放大器,结构坚固、测量结果精确,在闭环控制发动机的运行优化中扮演着关键角色。

业界普遍认为,闭环燃烧控制(CLCC)是提高大型发动机(如船用发动机)效率和预期寿命的适当方式。在大型发动机中,用于持续测量气缸压力的传感器不仅长期暴露在高压、高温的环境中,还会遭受严重的机械冲击。随着发动机平均有效压力(MEP)不断上升,压力传感器的坚固性显得愈发重要。但是,提高传感器坚固性会带来一个严重问题:坚固性的提高往往意味着测量准确性的降低。

奇石乐与发动机制造商紧密合作,开发出新型 6635A1 缸压传感器,该传感器专为中速运转的发动机设计。凭借一系列创新功能,奇石乐巧妙实现了6635A1运行周期和测量准确性的最大化,这些功能包括:

  • PiezoStar晶体: 奇石乐独立培育的压电晶体PiezoStar,敏感度高达石英晶体的五倍。该等晶体能够提供出色的测量稳定性,且几乎不受环境温度影响。
  • 优化膜片设计:6635A1缸压传感器搭载新型膜片,该膜片形状已取得专利认证。该膜片可最小化热冲击误差,确保优异的测量特性。
  • 可靠信号传输:6635A1缸压传感器采用焊接连接取代插入式连接器,即使在冲击或振动引起的严重应力环境下,也能保证可靠的无损信号传输。

模拟、验证和强化性能测试

复合有限元分析法(Complex FEM)模拟在新型传感器的研发过程中起着关键作用。奇石乐使用初次模拟原型与跨越多个模拟周期的模型进行对比,确保研发结果的可重现性。

传感器成品均须经过全面的负载和寿命测试,而该等测试面临重重挑战:研发人员不仅需要模拟内燃发动机恶劣的内部环境,还需要进行数千个运行小时的测试。奇石乐采用自行开发的液压测试台,同时模拟了传感器测试所需的不同压力、温度,以及高重复率的机械应力冲击环境。

奇石乐与发动机制造商紧密合作

新型传感器研发的成功,离不开另一项至关重要的因素:奇石乐与发动机制造商的直接合作。例如,要确定气缸盖内传感器的最佳位置时,我们几乎不可能对发动机内部边界条件进行准确的预测或模拟,但掌握特定发动机的准确知识,有助于我们为传感器模拟最合适的测试环境。

奇石乐新型6635A1缸压传感器用于中速四冲程发动机,具有可靠的爆震检测、气缸平衡和MEP计算等功能。6635A1可测压力范围高达350 bar,其信号传输与电力供应相互电隔离,且已通过欧盟认可组织互认(MR)、ATEX和IECEx认证。