oxygen sensors

RATINGEN TECHNICAL CENTRE

3 engine dynamometers 2 vehicle dynamometers 1 cold chamber (-30C) Exhaust emissions analysis Sensor application 15 employees

OEM customers worldwide

Alfa Romeo AMG/Mercedes Aston Martin Audi Bentley BMW Citroen Daewoo Daihatsu Daimler Chrysler Ferrari Fiat Ford General Motors Honda Hyundai Isuzu Jaguar Kia Lancia Lotus Maserati Mazda Mitsubishi Nissan Opel Peugeot Renault Rolls Royce Rover Saab Seat Skoda Subaru Suzuki Toyota Volkswagen Volvo

Spark plugs Oxygen sensors

Oxygen sensors
The closed-loop 3-way catalytic converter is the best emission control method currently known. The oxygen sensor is an indispensable tool in measuring and regulating the exhaust gas composition. Objective: To meet statutory emission limits to keep the air clean Task: Fitting: To measure the residual oxygen level in the exhaust emissions of spark-ignition engines In the exhaust train upstream or downstream of the catalytic converter

Air/fuel control circuit

Injection Control unit

Engine
Oxygen sensor Catalytic converter Oxygen sensor

OBD 1
(ON BOARD DIAGNOSTICS)

EOBD
(EUROPEAN ON-BOARD DIAGNOSTICS)

Exhaust

Mixture ratio

1 kg fuel The fuel/air mixture ratio of 14.7:1 is termed the stoichiometric mixture.

14.7 kg air

The above mixture ratio must be available to ensure the optimum combustion of the fuel and air.

Air ratio
Rich mixture (oxygen deficient) 0.9 Stoichiometric mixture 1.0 Lean mixture (oxygen rich) 1.1

range
Nowadays almost all spark-ignition engines are operated at the stoichiometric air ratio of lambda = 1.0 This is done in order to achieve the best possible untreated emissions from the engine via the 3-way catalytic converter and thus comply with legislated emission control specifications.

Lambda window
Conversion rate of catalytic converter 100 % Sensor voltage

HC

50 % NOx

1,0

CO

V 0,2
0% Rich Stoichiometric Lean

- Value

FSI engine exhaust aftertreatment

Broadband oxygen sensor Engine controller

Cat NOx sensor

NOx cat =Co =NOx =HC

Oxygen sensor output signal

2000 rev/min

Zirconia sensors (OZA...)

- provide a voltage signal - require a defined reference air volume

Design of zirconia sensor

Heater connection (white lead) Sensor earth (grey lead)

Hexagonal metal body Heater Protective tube

Protective sleeve Sensor signal (black lead) Ceramic bracket

Zirconia element Sealing ring

Zirconia element

Sensor element platinum electrode

Air Exhaust

Zirconia sensor principle

Reference air

O2 O2 O2

O2 O2 O2-

O2 O2

O2 O2

e-

Platinum electrode

Zirconia element

2-

O2e-

U
Platinum electrode

Porous ceramic layer Exhaust

O2 O2 O2

O2 O2 O2

The voltage (U) is proportional to the oxygen level.

Reference air Exhaust

Titania sensors (OTA...)

- change their resistance as a function of residual oxygen level - are more compact than zirconia sensors - faster response time

Titania sensor design

Protective sleeve Substrate Ceramic bracket Signal lead

Outer metal body Sealing ring Titania element Glass seal Seal

Hexagonal metal body

Titania sensor principle

R

O2Platinum electrode

Ti 4+

O2-

Platinum electrode

O2Exhaust

The resistance (R) is reduced with a rich mixture.

Sensor resistance
10000000 1000000 100000

R ()

10000 1000 100

0.9 Rich

1.0 Stoichiometric

1.1 Lean

Change intervals

There are no recommended change intervals for oxygen sensors since the measurement principle is theoretically wear-free.

Causes of faults:
- vibrations - mechanical damage - moisture and dirt - fuel deposits - lead deposits - contact corrosion

Effects:
- poor engine running - emission test failure - high fuel consumption

Example

Fault diagnosis
Carbon fouling

Lead Contamination

Oil Contamination

A new sensor must be fitted!

Fault diagnosis
Connector plug melted Sensor deformed

A new sensor must be fitted!

Fault diagnosis
Moisture (very rare)

Cable damage

A new sensor must be fitted!

Fault diagnosis

Seal damaged

A new sensor must be fitted!

Connecting system

All NTK oxygen sensors are OEM quality and should only be replaced by a sensor of the same type. All connecting plugs are designed to be vehicle-specific and should not be replaced by other connector systems under any circumstances.

Wiring Function

Unheated

Heated

1 lead Signal Earth via housing

2 leads Signal Earth insulated

3 leads => signal + heater (2x) Earth via housing

4 leads => signal + heater (2x) Earth insulated

EGO: Exhaust Gas Oxygen

HEGO: Heated Exhaust Gas Oxygen

Symbols used
Identifying a sensor by its design features

1: No. of leads

2: Plug no. 3: Lead length incl. plug in mm

Summary 248 NTK sensors = approx. 90% market cover All sensors incl. connection in OE quality

TV certificate Approved by Federal Motor Vehicle Registration Agency Many years of product experience

Thank you for your attention