A Metal Substrate with Integrated Oxygen Sensor; Functionality and Influence on Air/Fuel Ratio Control 2003-01-0818

In order to achieve ultra low emission levels with three-way catalysts, an early accurate air/fuel ratio control is essential. Positioning the oxygen sensor in the first part of the substrate helps to protect the oxygen sensor from being splashed by water during cold start, so that early heating and activation becomes a less limiting factor. For emission control purpose, a position of a rear sensor in the warm part of the catalyst gives improved possibilities for oxygen buffer control during catalyst warming up conditions. This enhances balancing HC and NOx in an early phase. In addition, for OBD reasons it is possible to locate the sensor in any axial position in the catalyst, which improves design possibilities for cold start detection, even for single brick catalyst systems.

The paper describes the construction of the catalyst with an integrated oxygen sensor. In addition, it details flow distribution measurements with and without internal mixing at the position of the oxygen sensor. Test results of the influence of an integrated oxygen sensor on lambda control of a SULEV concept engine demonstrate its function.