Wednesday, September 15, 2010

Position sensors and hydraulic solenoids

I found this position sensor made by MTS last year while working the original design. I really like them because of the accuracy, response time, and durability. This is a non contact sensor so wear over time is not an issue and it is easy to calibrate and recalibrate as necessary to compensate for thermal expansion as the engine is running. MTS will actually custom make sensors for companies, but I do not have the money to pay for this luxury at this point in time. The major problem with this sensor is its size. It will require a cavity about 2 inches in diameter. I would have to move the bore centerlines which means that the push rods would be drastically angled. I thought about using an offset on the actuators to line the push rods back up with the rockers, but I am not happy with the added mass to the actuators required. Getting this system to operate at at 6000 RPM minimum is already going to be a challenge so adding weight to the reciprocating assembly is not a solution I will accept. I checked out the MTS product line again and found this position sensor. It has a diameter of 1.1 inches which I can squeeze into place by increasing the bore and adding a little material for support.

I am having doubts again about where to place the hydraulic solenoids. I am thinking about mounting them in the valley again. Having remote mounted solenoids would be ideal but that creates more problems than it solves. Having 16 separate hydraulic lines running into the engine block adds too many potential leak points, adds unnecessary clutter in the engine compartment, and complicates the way fluid is routed internally. These lines would also interfere with the accessories at the front of the engine and the bell housing at the rear.

My next major obstacle is going to be a crankshaft position sensor. Accuracy to the half degree would be perfect but, I am going to need something that is at least accurate to the degree. I have quite a bit of work to do before I really have to worry about this so I will just see what's out there for the time being.

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