GMI German-Malaysian Institute
DIPLOMA PROGRAMME
GROUP ASSIGNMENT
Academic Period : July 2024
Program : AUTOTRONICS ENGINEERING TECHNOLOGY (AET)
Course : AUTOMOTIVE SENSOR AND ACTUATOR
Code : AHS 1853
GENERAL INSTRUCTIONS:
1. Write down clearly (with capital letters) your name, trade, group and the
date of the assignment at the bottom of this page.
2. Please submit a comprehensive report and upload into google classroom.
3. Please check and do correction before submit the report.
Student’s Name/ ID No. : 1.MUHAMMAD AKIFFULLAH BIN MOHAMMAD AZMI
2.MUHAMMAD RAFIQ IMAN BIN SAIDI
3.MUHAMMAD RAFEIQ FURQAN BIN MOHD
REDZHUAN
4.MUHAMMAD DANISH DARWISH BIN KHAIRUL
ANUAR
Semester/Trade/Gro
: DAET 2
up
Date : 17/10/2024
AHS 1843 AUTOMOTIVE CONTROL SYSTEM
TABLE OF CONTENTS
NO. TOPICS PAGES
1. INTRODUCTION 3
MEASURING PRINCIPLES : POTENTIOMETER,
2. 4-10
MAGNETIC-INDUCTIVE, MAGNETOSTATIC TYPE.
3. FUNCTION OF 2 POSITION SENSOR IN TPS 11-13
4. CONCLUSION 14
5. REFFERENCES 15
Page 2 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
1. INTRODUCTION
Position Sensors measure a physical parameter known as position in an application
and provide feedback to a control system or operator.
Position sensors are used `to monitor the position of components such as throttle
valves, accelerator pedals, and steering wheels, among others. These sensors help
control systems to ensure the proper operation of various mechanical parts by
providing real-time feedback on their position.
Position sensors are available in both contacting & non contacting types including
Potentiometer, Magnetic inductive and Magnetostatic in various sensor packages.
Different types of technology ensure the most accurate measurements in different
applications. This report will discuss about 3 of these type measuring principles and
the functions or needs of 2 position sensor in Throttle Position Sensor (TPS) and
Acceleration Pedal Sensor (APS).
Throttle Position Sensor Accelerator Pedal Sensor
Page 3 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2. MEASURING PRINCIPLES
2.1 POTENTIOMETER
The most used of all the “Position Sensors”, is the potentiometer because it is an
inexpensive and easy to use position sensor. It uses a wiper contact linked to a
mechanical shaft that can be either angular (rotational) or linear (slider type) in its
movement along a track.
This movement causes the resistance value between the wiper/slider and the two end
connections to change giving an electrical signal output that has a proportional
relationship between the actual wiper position on the resistive track and its resistance
value. In other words, resistance is proportional to physical position.
Potentiometers come in a wide range of designs and sizes such as the commonly
available round rotational type or the longer and flat linear slider types. When used as
a position sensor the moveable object is connected directly to the rotational shaft or
slider of the potentiometer.
A DC reference voltage is applied across the two outer fixed connections forming the
resistive element. The output voltage signal is taken from the wiper terminal of the
sliding contact as shown below.
This configuration produces a potential or voltage divider type circuit output which is
proportional to the shaft position. Then for example, if you apply a voltage of say 10v
across the resistive element of the potentiometer the maximum output voltage would
be equal to the supply voltage at 10 volts, with the minimum output voltage equal to
0 volts. Then the potentiometer wiper will vary the output signal from 0 to 10 volts,
with 5 volts indicating that the wiper or slider is at its half-way or centre position.
Page 4 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2.2 MAGNETIC-INDUCTIVE
Magnetic-inductive sensor is a sensor that emits a high-frequency magnetic alternating
field. The sensors detect metal objects located in their measurement field. They use
the interaction of the metal object as an electrical conductor with the emitted magnetic
alternating field of the sensor to do so. There are 2 types of magnetic-inductive sensor
which is Eddy-current sensor and short-circuiting sensor.
Typical automotive applications include monitoring the position of components like
throttle valves, tracking the position of gear shifts, and detecting the position of
crankshaft and camshaft position. The flexibility of this sensing technology allows for
many different sensor designs match to specific vehicle systems and operating
conditions.
Crankshaft Position Sensor
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2.2.1 EDDY-CURRENT SENSOR
Eddy current sensors are primarily used for displacement and position measurement
of electrically conductive targets. They are generally used for measuring ferromagnetic
and non-ferromagnetic materials. They are suitable for applications in harsh industrial
environments due to their superior tolerance for oil, dirt, dust, moisture and magnetic
interference fields
The sensors are also capable of measuring at high speed up to 100 kilo Samples per
second. The sensors are generally miniature in size and therefore, are suitable for
measuring in an area where access is restricted. These sensors are also low-cost and
can be used in high-volume OEM applications.
In an eddy current probe, an alternating current flows through a wire coil and
generates an oscillating magnetic field. If the probe and its magnetic field are brought
close to a conductive material, such as a metal test piece, a circular flow of electrons
known as an eddy current begin to move through the metal like swirling water in a
stream. That eddy current flowing through the metal in turn generates its own
magnetic field, which interacts with the coil and its field through mutual inductance.
Changes in metal thickness or defects, such as near-surface cracking, interrupt or alter
the amplitude and pattern of the eddy current and the resulting magnetic field. This in
turn affects the movement of electrons in the coil by varying the electrical impedance
of the coil. The eddy current instrument plots changes in the impedance amplitude
and phase angle.
Eddy-current Diagram
Page 6 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2.2.2 SHORT-CIRCUITING SENSOR
A short-circuiting ring sensor is an inductive sensor that operates using a highly
conductive ring placed around the limbs of a soft magnetic core. This arrangement
allows for the detection of changes in magnetic flux, which can be interpreted as
positional or angular information. The sensor can measure variables such as travel or
angular displacement by analysing changes in inductance caused by the movement of
the short-circuiting ring relative to the core.
The core principle behind short-circuiting ring sensors is based on the interaction
between eddy currents and magnetic fields. An alternating current passes through the
sensor's coil, generating a magnetic field in the soft magnetic core. This magnetic field
interacts with the short-circuiting ring, which produces eddy currents. These eddy
currents effectively "insulate" the magnetic field, confining it to the area between the
coil and the ring. As the ring moves, the inductance changes, and this variation can be
measured to determine the position or angle of the object attached to the sensor.
The sensor's output is often processed as an inductive voltage divider or a frequency-
modulating element, which makes it highly interference-proof and easy to digitize. This
allows for the accurate measurement of the object’s position even in the harsh
conditions typically found in automotive environments.
Steering Angle Sensor
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2.3 MAGNETOSTATIC
Magnetostatics is the study of magnetic fields in systems where
the currents are steady (not changing with time). It is the magnetic analogue
of electrostatics, where the charges are stationary. Magnetostatic sensors measure
non-changing (DC) magnetic fields. They are used in various applications to detect
position, speed, or proximity by sensing magnetic fields from permanent magnets or
other sources.
These sensors work based on the Hall effect or Magnetoresistive effect, which convert
magnetic field strength into an electrical signal.
Page 8 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2.3.1 HALL EFFECT SENSOR
An automotive Hall effect sensor is an essential part of contemporary vehicles, utilized
for sensing the presence, intensity, or variations in magnetic fields. This sensor
functions based on the Hall effect principle, a phenomenon that happens when a
current-carrying conductor is subjected to a magnetic field that is perpendicular to the
current's flow. Consequently, a voltage known as the Hall voltage is produced across
the conductor. This voltage can be measured and analyzed to identify changes in the
magnetic field, making Hall effect sensors vital in numerous automotive applications.
The principle of Hall voltage is used as a working principle of the Hall Effect sensor.
On a thin strip of a conductor, electrons flow in a straight line when electricity is
applied. When this charged conductor comes in contact with the magnetic field which
is in a perpendicular direction to the motion of electrons, the electrons get deflected.
Some electrons get collected on one side while some on another side. Due to this, one
of the conductor’s plane behaves as negatively charged while the other behaves as
positively charged. This creates potential difference and voltage is generated. This
voltage is called the Hall voltage.
The electrons continue to move from one side of the plane to other till a balance is
achieved between the force applied on charged particles due to an electric field and
the force that caused magnetic flux that caused this change. When this separation
stops, the hall voltage value at that instant gives the measure of magnetic flux density.
Hall Effect Sensor Diagram
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
2.3.2 MAGNETORESISTIVE SENSOR
A magnetoresistive sensor, also known as a Magneto-Resistive Element (MRE) sensor,
is a device that detects changes in magnetic fields to provide information about a
vehicle's rotation, direction, speed, and more. They are used in many vehicle safety
systems and active type sensors These sensors can be used in several applications.
They are commonly used to measure path and angle, detect magnetic fields, and
measure electrical current quickly. They also function as contactless switches and can
perform well in harsh environments.
Magnetoresistive sensor measurement starts with utilisation of the AMR-effect
(“anisotropic magnetoresistive effect”) is particularly well-known. The resistance in
this case is dependent on the angle between the current direction and the
magnetisation (M), which can be influenced through an external magnetic field. The
resistance is smallest at a 90-degree angle and highest when the current flows in
parallel.
In simplified form, a magnetoresistive sensor functions as follows: An object with its
own magnetic field approaches the sensor. As a result, the electrical resistance
changes. This makes it possible to detect at what angle the external magnetic field
(and thus the object) is positioned in relation to the sensor. The magnetisation of the
field also makes it possible to determine the distance.
The measurements are particularly precise, even under difficult conditions. These
sensors are thus primarily used in extreme conditions.
Wheel Speed Sensor
Page 10 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
3. FUNCTION OF 2 POSITION SENSOR IN TPS
3.1 SAFETY AND RELIABILITY
AEB works by maintaining a constant watch on the traffic ahead and if an impending
collision is detected, it will automatically apply the brakes in those vehicles that are
fitted with this technology. Throttle Position Sensor (TPS) — Accurate and reliable
throttle position data is an essential element of the AEB system.
This is where the two sensor setup of TPS comes into play.
If the AEB system determines there is a risk of collision and it needs to apply the
brakes, in some cases that may also mean signaling with an engine control system to
back off or shut down throttle input so that vehicle slows as effectively as possible.
The ability of the system to decrease power from the engine may not operate properly,
if one TPS sensor provides wrong throttle position data (caused by a fault); and
because of this can result in braking that is delayed or inefficacious.
Indicator light off by two throttle position sensors for reliable opening Angle detection
behind the scenes of throttles. That way if one sensor fails, or reports faulty data, the
second is there to help twofold so as not to enable an AEB that can cut-off a vehicle's
throttle protected amid crisis braking. This redundancy is an important measure to
enable the vehicle to safely decelerate and avoid or reduce structural damage in a
crash.
Dual TPS also serves as a backup function for the AEB system; providing redundancy
in order to ensure continuous and accurate throttle control under normal operation or
in case of sensor failure. It enables the AEB system to work as it should do, applying
effective emergency braking when required.
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
3.1 Safety and Reliability
For the same throttle position, one of its two sensors would output a different voltage
range than the other. For instance Sensor 1 may have a voltage range of say 0.5V
to4.5v and sensor2 can be designed with ranges like between: 0.3volts to4 volts this
both sensors measure the same throttle position but manufacturer set their output
voltages value bit different so that Engine Control Unit Cross check these readings two
troubleshoot it is accurate or not!
So, picture yourself in a car and you accelerate the gas pedal to half. For example,
Sensor 1 sends a signal of 2.5V which it interprets as the throttle is at 50% throttle
and sensor #2 might be transmitting to have sent an identical message however due
system errors or malfunctions showing its output with double value like (+0.5V)
meaning it just registered deal inner thing ( total voltage reading now will show
something around that i.e., =15%) The ECU will compare the two signals and they
both show a similar throttle position, then it knows that this is in fact how much throttle
is being applied.
If Sensor 1 fails and sends an incorrect signal of let's say 4.0V (a higher throttle
position), but the other sensor sends a correct one at about 3.7-2.6, ECU can detect
this fault eval (noncompliant.) It will then either disregard the spurious signal and use
proper sensor instead. Cause a warning light to appear for the driver and, in some
cases, may also restrict vehicle performance being that an unsafe driving condition
does not exist.
This is a dual sensor setup in the TPS which helps increase precision as it allows for
one signal to be compared against another under real world conditions and
discrepancies easily detected at ECU level. This helps to make sure that the throttle
position is read correctly, so the car can be driven smoothly and safely.
Page 12 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
Voltage TP1 & TP 2 (Graph)
Page 13 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
4. CONCLUSION
Position sensors play a critical role in modern automotive systems, providing precise
and reliable feedback on the position of various components such as throttle valves
and accelerator pedals. This report highlighted three key measuring principles—
potentiometers, magnetic-inductive, and magnetostatic types—each with its specific
applications and benefits. The inclusion of dual sensors, such as in the Throttle Position
Sensor (TPS), enhances system safety and reliability by providing redundancy. This
allows for accurate throttle control even in the event of a sensor failure, ensuring
smooth vehicle operation and contributing to the effectiveness of advanced systems
like Automatic Emergency Braking (AEB). As automotive technology continues to
evolve, the integration of reliable position sensors will remain a fundamental aspect of
vehicle safety and performance.
Page 14 of 15
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AHS 1843 AUTOMOTIVE CONTROL SYSTEM
5. REFERENCES
• https://www.dubizzle.com/blog/cars/symptoms-bad-accelerator-position-
sensor/
• https://www.elprocus.com/throttle-position-sensor-working-principle-
applications/
• https://www.variohm.com/products/position-sensors
• https://www.electronics-tutorials.ws/io/io_2.html
• https://www.pepperl-
fuchs.com/global/en/39731.htm#:~:text=Inductive%20sensors%20function%
20such%20that,switching%20targets%20cause%20remagnetization%20loss.
• https://en.wikipedia.org/wiki/Eddy-current_sensor
• https://www.boschautoparts.com/p/crankshaft-position-sensor
• https://www.olympus-ims.com/en/ndt-tutorials/eca-
tutorial/intro/#:~:text=If%20the%20probe%20and%20its,swirling%20water
%20in%20a%20stream.
• https://en.wikipedia.org/wiki/Magnetostatics#:~:text=Magnetostatics%20is%
20the%20study%20of,where%20the%20charges%20are%20stationary.
• https://autosphere.ca/mechanical/2018/04/03/understanding-tps-sensor-
function-operation/
• https://www.federalregister.gov/documents/2024/05/09/2024-09054/federal-
motor-vehicle-safety-standards-automatic-emergency-braking-systems-for-
light-vehicles
• https://www.elprocus.com/hall-effect-sensor-working-principle-and-
applications/
• https://gvzcomp.it/company/news/381-what-are-position-sensors-and-
encoders#:~:text=Position%20Sensors%20measure%20a%20physical,are%2
0subject%20to%20high%20shock.
Page 15 of 15
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