Product Integration of Established Crash Sensors for Safety Applications in Lightweight Vehicles.

Linda Klein,Yvonne Joseph,Matthias Kröger

doi:10.3390/s21216994

Linda Klein, Yvonne Joseph + Show 1 more

Open Access

https://doi.org/10.3390/s21216994

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Abstract

The functionality of products increases when more sensors are used. This trend also affects future automobiles and becomes even more relevant in connected and autonomous applications. Concerning automotive lightweight design, carbon fibre-reinforced polymers (CFRP) are suitable materials. However, their drawbacks include the relatively high manufacturing costs of CFRP components in addition to the difficulty of recycling. To compensate for the increased expenditure, the integration of automotive sensors in CFRP vehicle structures provides added value. As a new approach, established sensors are integrated into fibre-reinforced polymer (FRP) structures. The sensors are usually mounted to the vehicle. The integration of sensors into the structure saves weight and space. Many other approaches specifically develop new sensors for integration into FRP structures. With the new approach, there is no need for elaborate development of new sensors since established sensors are used. The present research also showed that the range of applications of the sensors can be extended by the integration. The present paper outlines the functional behaviour of the integrated sensor utilized for crashing sensing. First of all, the integration quality of the sensor is relevant. Different requirements apply to the usual mounting of the sensor. The self-sensing structure must fulfil those requirements. Moreover, unfamiliar characteristics of the new surrounding structure might affect the sensing behaviour. Thus, the sensing behaviour of the self-sensing composite was analyzed in detail. The overarching objective is the general integration of sensors in products with reasonable effort.

Highlights

The functionality of vehicles, and products in general, increases and is often solved by sensor applications
To evaluate the integration quality served the scans of a computer tomograph Vltomelx with a microfocus tube of 225 kV (GE Sensing and Inspection Technologies, Pforzheim, Germany)
For the valuation the position of the sensor module inside the structure, the electrically contacted lower surface of the sensor module was referenced to the bottom of the structural plate

Summary

Introduction

The functionality of vehicles, and products in general, increases and is often solved by sensor applications. Sensors become even more relevant in connected vehicles and autonomous applications (e.g., autonomous driving), especially for safety-relevant applications. A challenge is the number of sensors, especially when the installation space of the vehicle or the product is limited. Automotive applications where sensors are involved will increase in the future. Due to high demands on functional safety, the development effort for new sensors is time- and cost-intensive. The complexity of sensor systems raises and the logistics and assembly effort gets higher. One solution is the integration of sensors into the product. The combination of the sensor and the product enables a space-saving solution that shortens the process chain during production

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