Erich Zabler

Mechatronic sensors in integrated vehicle architecture

Abstract At present, electronic controls and systems are in the process of becoming essential and integral parts of our vehicles whereas they were previously replacements for corresponding mechanical systems predominantly separately acting or fulfilling add-on functions. From this viewpoint, the electronic systems in the vehicle will be interconnected with each other to a much greater degree than was previously the case; for this reason, they must also be reclassified and subdivided. Accordingly, electronic signal-processing components, for example, which were previously located in central control units, will be moved to the periphery where they are mechanically and electrically integrated with the sensor or actuator directly at the point at which they are actually required (mechatronics). The varied advantages of such sensors which are also capable of digital communication by means of new connection systems (bus systems) can be seen in the concrete example of an ‘intelligent’ short-circuit-ring displacement sensor. The accuracy of this sensor can be increased considerably by simultaneously simplifying its design; the highly accurate measured signal can be transmitted in a digital form.

Computer tomography for nondestructive testing in the automotive industry

The application of computer tomography (CT) for non-destructive testing is of continuing interest to research and industry alike, as economic pressure is ever increasing on production processes. Three concurring goals drive the development of CT, namely: It has to be fast, cheap and precise. With a fast CT-system, the technique can not only be used for error analysis and precision measurements, but also for the application as a standard tool in the production line for the complete quality control of parts. At the Robert Bosch corporate research centre in Stuttgart, Germany, we have set up a CT-system, that allows us to conduct experiments towards these goals and to test and develop the latest software for the reconstruction of x-ray images. One of our main challenges is to use CT for reverse engineering processes and to create computer assisted design (CAD) models from measured data. For this application often a coordinate measurement machine (CMM) is used that gathers a cloud of data points by optical inspection. However, for many parts the inside of the object is relevant. Here CT has the unique advantage of delivering volumetric data. Once the process of the generation of a cloud of data points can be achieved with high precision, standard reverse engineering CAD software can be used to determine the dimensions of the interior structure of an object. This paper describes the use of CT for non-destructive testing at Robert Bosch GmbH, the accuracy limits for the measurement of volumetric data and the classification and analysis of material defects. Furthermore, it highlights the ongoing research to make CT fast, exact and cheap, and to enable its utilisation for 100% testing of parts at the end of a production line.

Sensoren im Kraftfahrzeug

Der Begriff Sensor fuhrte sich ein, als in den zuruckliegenden 20…40 Jahren Messfuhler auch in Konsumanwendungen (z. B. Kraftfahrzeug und Hausgeratetechnik) einzogen. Sensoren – begrifflich identisch mit (Mess-)Fuhlern und (Messwert-)Aufnehmern – setzen eine physikalische oder chemische (meist nichtelektrische) Grose Φ in eine elektrische Grose E um; dies geschieht oft auch uber weitere, nichtelektrische Zwischenstufen.

Sensor measuring principles

There is a great number of sensors at work in motor vehicles. They act as the sensory organs of the vehicle and convert input variables into electrical signals. These signals are used in control and regulation functions by the control units in the engine-management, safety and comfort and convenience systems. Various measuring concepts are applied, depending on the task.