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In the future more stringent emission regulations will enforce closed loop control of engine management systems for a large number of inexpensive low displacement motorcycles in markets like China and other Asian countries. Specific low cost Electronic Fuel Injection (EFI) systems have been developed or are under development to meet these requirements. This study presents a comparison of heated vs. unheated oxygen sensors in such a system. The exhaust gas temperature rise and variation during the emission test cycle in this class of motorcycles and its impact on the light-off time, the dynamic response behavior as well as other small engine specific parameters are investigated. Most experiments have been carried out on a 125cc motorcycle equipped with water cooled 4 stroke engine with 3 way catalyst.

In electric fuel injection (EFI) systems the intake air pressure is used as system load signal for calculating injection and ignition parameters together with engine speed. Part of an EFI system for motorcycles is a throttle body module with integrated pressure sensor. As motorcycle systems require smaller components than automotive applications the target for engineering is to minimize the component size and still fulfill other system requirements. Therefore the pressure sensor sampling point should be as close as possible to the throttle shaft to reduce the module size but with a sufficient distance to avoid signal distortion by unsteady flow. This paper describes how to find a suitable sampling position by combining static bench testing, dynamic vehicle testing and CFD analysis.

This paper presents advanced planar ZrO2 oxygen sensors being developed at Robert Bosch using a modified tetragonal partially stabilized zirconia (TZP) with high ionic conductivity, high phase stability and high thermo-mechanical strength. Green tape technology combined with highly automated thickfilm techniques allows robust and cost effective manufacturing of those novel sensing elements. Standardization of assembling parts reduces the complexity of the assembly line even in the case of different sensing principles. The sensor family meets the new requirements of modern ULEV strategies like fast light off below 10 s and linear control capability as well as high quality assurance standards. High volume production will start in 1997 for European customers.

Bosch/UAES has developed a low cost EMS special for small gasoline engines. The article will introduce this system from view of components design and system design. In components design part special component design for small gasoline engine to reduce cost is described. To reduce cost a special low end ECU and fuel deliver system has been designed, other low-end components are chosen into the system. Features of the components are described. In system design part the requirement of system design is described. To reduce cost normal components configuration should be redesigned. Special design and consideration of load detection, engine speed detection, system components configuration and optional solutions is expressed. For load detection, both P-system and alpha/n system is introduced. For engine speed detection both segment and increment system is introduced. System components configuration for low cost EMS is introduced and feasibility is explained.

In new exhaust system specifications such as single cylinder balancing, closed coupled catalyst systems, sensor locations close to the engine, turbo applications, fast light off situations and diesel engine applications the dynamic behavior of the lambda sensor becomes more important. This demands a detailed knowledge and modeling of the relevant parameters. In former analysis of exhaust gas sensors the main focus has been the electrochemical processes in the sensor. The influence of flow structure and protection tubes had lower priority. In this paper we present the numerical and experimental analysis of cold air flowing in a pipe including mounted exhaust sensors. Two double-protection tubes from the Robert Bosch GmbH have been examined named (a) and (b). The predicted results have been compared with values measured with Laser Doppler Anemometry (LDA). The flow pattern in the protection tube type (a) depends on the geometric configuration of the sensor element and the tubes.

Modern zirconia oxygen sensors are heated internally to achieve an optimal detection of the oxygen concentration in the exhaust gas and fast light off time. The temperature of the gas in the exhaust pipe varies in a wide range. The zirconia sensor is cooled by radiation and forced convection caused by cold exhaust gas. If the zirconia temperature falls, the oxygen detection capability of the sensor decreases. To minimize the cooling effects, protection tubes cover the zirconia sensor. However, this is in conflict with the aim to accelerate the dynamics of the lambda sensor. In this paper, the heat transfer at the surface of a heated planar zirconia sensor with two different double protection tubes of a Bosch oxygen sensor is examined in detail. The geometric configuration of the tubes forces different flow patterns in the inner protection tube around the zirconia sensor. The zirconia sensor is internally electrically heated by a platinum heater layer.

Engine management systems (EMS) for small engines require some specific solutions that are different from EMS for automotive engines. The specific requirements are due to special behavior of these engines on one hand, and the need for cost saving by reduction of the number of components on the other hand. Some special functions for small engines are introduced: engine load detection for P-n system, ambient pressure detection, stroke detection and anti reverse rotation function. In single cylinder engines, the intake air pressure and engine speed signal fluctuate periodically. At first, the special behavior of these two signals is investigated for different working conditions. Then functions for load detection and ambient pressure estimation are designed based on intake air pressure signal, and functions for stroke detection and anti-reverse are developed on the basis of engine speed detection. Test results show that these functions work well.