Design and Development of Engine Electronic Sensors Trainer

Sensor trainer is one of the learning media interactive, because students are
required to interact with in the use of these sensor trainers. Students will interact with
the trainer uses the help of the job sheet that has been provided. The sensor trainer
consists of three parts, namely the sensor section, controller, and output. The sensors
used in this sensor trainer, namely the LM35 temperature sensor, For parts the
controller used microcontroller arduinouno. Whereas for the output section is an LCD,
LED, buzzer, and DC motor.
Sensor trainer is one of the learning media interactive, because students are
required to interact with in the use of these sensor trainers. Students will interact with
the trainer uses the help of the job sheet that has been provided. The sensor trainer
consists of three parts, namely the sensor section, controller, and output. The sensors
used in this sensor trainer, namely the LM35 temperature sensor, For parts the
controller used microcontroller arduinouno. Whereas for the output section is an LCD,
LED, buzzer, and DC motor.
The design development training in the study of engine electronic sensors technologies
will make a long board to place each of the engine sensors such as engine coolant temperature
mass air flow sensor and lambda sensor throttle position sensor. a wooden board will allocate
each other space to place and attach the sensor. The coolant temperature sensor will use a multi-
tester and will also contain two normal readings for two sensor testing tests will use a cup that is
both cold and hot so that the sensor will also be placed for training as well as other sensors will
also be used multi-tester to practice and find out their voltage and temperature measurements.

in figure 1.1 three pins Throttle position sensor schematic diagram, figure 1-2 2 pins
engine coolant sensor schematic diagram

Figure
Figure 1-
1- 1
2
Schematic diagram of Throttle position sensor
Schematic diagram of engine temperature sensor
 Figure 1- 3
Schematic diagram of oxygen sensor

Figure 1- 4
Schematic diagram of mass air flow

Activity 1-4
Car engine sensors resistance test
Objective:

To demonstrate on how to test the different car engine sensors focusing on resistance test
of Throttle position sensor, mass air flow sensor, oxygen sensor, and engine temperature sensor

Activity 1
General description

A throttle position sensor (TPS) is used to monitor the throttle valve position in internal
combustion engines. TPS is usually located on the throttle valve spindle so that it can directly
monitor its position. The TPS sensor is a potentiometer, providing a variable resistance
depending on the position of the throttle valve (and hence throttle position sensor).The sensor
signal is used by the engine control unit (ECU) as an input to its control system. The ignition
timing and fuel injection timing (and potentially other parameters) are altered depending on the
position of the throttle valve, and also depending on the rate of change of that position. throttle
valve modifications have built-in end switches. They are closed throttle position sensor (CTPS)
and often include a wide-open throttle (WOT) sensor which is mounted on the accelerator pedal.
Throttle position signal can be produced from a simple contact (TS) or a potentiometer (TPS),
and also of combined TS/TPS sensor. Some systems use both types as separate elements.

Materials:

1. Multi tester
2. Throttle body
3. Data sheet

Procedure:
1. to check TPS sensor, the resistance between 2,3 terminals ideal value for
resistance 0.5 to 3k ohm.

2. Measuring the resistance between terminal 2, 3

3. When the resistance value is 11.29 k ohm, the sensor will be replaced.

Note:

the ideal value to know if the sensor is functioning well is 0.7 to 3k ohm when the resistance
value is 11. 29 k to 12 k ohm means the TPS sensor needs to be replace.
 Reading Output
Resistance

Activity 2

General Description
a Mass Airflow Sensor (MAF) has two sensing wires. One is heated by an electrical
current, the other is not. As air flows across the heated wire, it cools down. When the
temperature difference between the two sensing wires changes, the MAF sensor
automatically increases or decreases the current to the heated wire to compensate.

Materials Needed:
Digital or Analog Multimeter
Procedure:

To Test Resistance set the multi tester to 2k ohm.

Note:
For the Resistance Test the sensor will produce 1.4k Ohms. That is the normal reading of
the sensor. If the sensor is not showing any reading, the sensor is defective.

Reading Output
 Resistance

Activity 3
General Description
The O2 sensor lets the computer know if the fuel mix is burning rich (not enough oxygen) or
lean (too much oxygen). Knowing the ratio of fuel to air allows your vehicle's engine to make
any necessary changes to ensure that your car runs like it should.

Materials Needed:
Digital or Analog Multimeter
Propane Torch
Testing Sensors:

First, a note on multi-meters: Testing should be done with a good quality digital multi-meter
(DMM). Analog meters impose too much impedance on the circuits and lead to false
readings.

In order for the sensor to function, it must be above 600 degrees. For this reason, there is a
heater built into most O2 sensors to speed up the heating process. That is why the sensor has
four wires. Two are for the ground (black) and signal (black) and the other two are for the
heater (white).

O2 Sensor Bench Test

Remove the sensor from the vehicle and attach a DMM to the black and Black leads. Heat
the sensor with a propane torch. Within 20 seconds the sensor should produce a voltage
when in the flame. Now pull it from the flame. The voltage should drop off to near zero
within a second. Now put it back into the flame and check that the voltage climbs rapidly. If
it passes so far, let it set in the flame for several minutes. If its reading stays consistent, its
good. If it fails these bench tests, it’s time for a new one.
 Reading Output
Resistance

Activity 4
General Description
A coolant temperature sensor (CTS) (also known as an ECT sensor or ECTS (engine
coolant temperature sensor) is used to measure the temperature of the coolant/antifreeze mix in
the cooling system, giving an indication of how much heat the engine is giving off. The sensor
works with the vehicle’s ECU, continually monitoring the coolant temperature to make sure the
engine is running at the optimum temperature.

STEP PROCEDURE HOW TO COOLANT TEMPERATURE SENSOR

1. Attach the multimeter leads to the outer connectors on the sensor. On the plug-end of the
temperature sensor are 3 connectors that look like metal prongs. Take your red lead and clip it to
1 of the connectors on the far right or far left. Then, clip your black lead to the connector on the
far side across from your red lead so they aren’t touching each other.
The connectors are used to plug the sensor into the wire harness.
If the leads are touching you won’t get an accurate reading.
Most temperature sensors have 3 connectors, but some may have 5. No matter how many
connectors, always attach the leads to the ones on the outside to keep them spaced apart.
2.Fill a cup or small container with ice and water. Take a clean cup and fill it with about 6 fluid
ounces (180 mL) of clean water and add few ice cubes to bring down the temperature. Wait a
few minutes to allow the ice to chill down the water.
The cold water will serve as a reference measurement for your sensor.

3. Use a thermometer to make sure the water is 33 °F (1 °C). After a few minutes, use a digital or
analog thermometer to take a temperature reading of the water. If the water is around 33 °F
(1 °C), then you’re good to go. If not, wait another 2-3 minutes to allow the ice to cool it down
further, then take another reading.

4. Turn on your multimeter and set it to DC. With your temperature sensor still attached to the
multimeter, press the power button to activate it. Locate the DC setting on the dial of the sensor
and turn the dial to select it or select the DC setting if your multimeter doesn’t have a manual
dial.
The DC setting will give you a voltage reading that you can use to test your sensor.
5.Submerge the sensor in the water and take a reading. Gently lower the end of the sensor into
the water until the entire device is fully submerged. Wait a minute or so for the screen to give
you a reading of the cold water. Once you have a reading, write down the measurement for
reference.
A common reading for a temperature sensor in cold water is around 5 volts.
Note: If you don’t get any reading, try removing the sensor and reconnecting the wires to make
sure they’re properly connected. Try taking another reading, if you still don’t get anything, your
sensor may be broken and needs to be replaced.

6. Move the sensor to a cup of boiling water and take another reading. Heat up roughly 6 fluid
ounces (180 mL) of water in a kettle or in a pot on the stove until it’s boiling. Then, pour the
water into a mug or container. Submerge your temperature sensor in the hot water and wait a few
seconds to let your multimeter take a reading. Write down you’re reading so you can easily
reference it.
A hot water reading should give you around .25 volts.
Make sure the cup you use can hold boiling water safely.
Be careful not to burn your fingers in the hot water.

7. Compare your readings to the correct readings for your vehicle. Every make and model use a
specific temperature sensor, which will give you specific readings whenever you test them with a
multimeter. Look online for the hot and cold readings of your vehicle’s temperature sensor and
compare your readings to see if they closely match. If they do, your sensor is functioning
properly, and you may have an issue elsewhere. If not, you’ll need to replace your sensor.
For example, if your vehicle’s temperature sensor is supposed to have around 5 volts in a cold
reading, check your measurements to see if yours closely match the correct reading.

Reading Output
Resistance

Activity 5
Car engine sensors voltage test

Objective:

To demonstrate on how to test the different car engine sensors focusing on resistance test
of Throttle position sensor, mass air flow sensor, oxygen sensor, and engine temperature sensor.

General Description
a Mass Airflow Sensor (MAF) has two sensing wires. One is heated by an electrical
current, the other is not. As air flows across the heated wire, it cools down. When the
temperature difference between the two sensing wires changes, the MAF sensor
automatically increases or decreases the current to the heated wire to compensate.

Materials Needed:
Analog Multimeter or Digital Multimeter
12V Battery

To Test Voltage set the multi tester to 20V~ DC. Make sure pin number 1 and pin number 2 is
connected to battery. Put the red probe of the multi-tester to the number 4 pin and the black
probe to the number 5 pin.
Note:
For the Voltage Test the MAF sensor will produce .3 to .6 volts. If airflow is applied the
voltage will rise to 2.9 volts. If the sensor is not showing any reading the sensor is defective.
Reading Output
Voltage