Sensors for Automotive and Aerospace Applications (eBook)

Shantanu Bhattacharya (PhD) is a Professor of Mechanical Engineering and the Head of Design Program at the Indian Institute of Technology Kanpur. Prior to this he completed his MS in Mechanical Engineering from the Texas Tech University, Lubbock, Texas and a PhD in Bio-engineering from the University of Missouri at Columbia, United States of America. He also completed a post-doctoral training at the Birck Nanotechnology Center at the Purdue University. Dr. Bhattacharya’s main research interests are Design and development of micro- nano sensors and actuation platforms, nano-energetic materials, micro and nanofabrication technologies, water  remediation using visible light photocatalysis and product design and development. He has many awards and accolades to his credit which includes the Institution of Engineers Young engineer award, the Institute of Smart structures and systems young scientist award, the national design research best mechanical engineering award, fellowship from the high energetic materials institute at Australia, fellowship of the Institution of Engineers of India etc. Dr. Bhattacharya has guided many PhD and masters students and has many international journal publications, patents, books and conference proceedings.   Avinash K Agarwal is a Professor in the Department of Mechanical Engineering in Indian Institute of Technology Kanpur. His areas of interest are IC engines, combustion, alternative fuels, conventional fuels, optical diagnostics, laser ignition, HCCI, emission and particulate control, and large bore engines. He has published 24 books and 230+ international journal and conference papers. Prof. Agarwal is a Fellow of SAE (2012), ASME (2013), ISEES (2015) and INAE (2015). He received several awards such as Prestigious Shanti Swarup Bhatnagar Award-2016 in Engineering Sciences, Rajib Goyal prize-2015, NASI-Reliance Industries Platinum Jubilee Award-2012; INAE Silver Jubilee Young Engineer Award-2012; SAE International’s Ralph R. Teetor Educational Award-2008; INSA Young Scientist Award-2007; UICT Young Scientist Award-2007; INAE Young Engineer Award-2005.   Om Prakash is the Director of Materials & Manufacturing Research in Boeing's Research and Technology Division in Bangalore, India. He has done his  ME in Mechanical Engineering and PhD in Engineering Materials from IISc Bangalore and the University of Cambridge respectively.  He has since worked in McMaster University (Canada), IIT Kanpur (India) and GE Global Research (India). He has published more than 20 technical reports, 30 journal articles and filed 18 patents.    Shailendra Singh is Vice President for warehouse-parts and accessories-marketing and sales in Maruti Suzuki India Limited. After completing his B.Tech. from HBTI Kanpur, India, he has done his MBA from ICS Hitotsubashi (JAPAN) and is a EFPM candidate at IIM Lucknow.

Preface 6
Contents 9
Editors and Contributors 11
1 Introduction to Sensors for Aerospace and Automotive Applications 15
Abstract 15
2 Functional Films for Gas Sensing Applications: A Review 21
Abstract 21
2.1 Introduction 21
2.2 Types of Sensing Films 23
2.3 Fabrication Methodologies of Functional Films 23
2.3.1 Fabrication Techniques 23
2.3.2 Review of Some of the Fabrication Methodology of Sensing Film 36
2.4 Sensing Mechanisms of Functional Films 37
2.4.1 Sensing Mechanism of Metal/Semiconductor-Based Films 37
2.4.2 Sensing Mechanism-Based Polymer-Based Film 40
2.5 Other Important Aspects of Sensing Films 43
2.6 Application of Sensing Films in Aerospace and Automotive Field 44
2.7 Conclusion 45
References 45
3 Corrosion Monitoring and Control in Aircraft: A Review 52
Abstract 52
3.1 Introduction 52
3.1.1 Pitting Corrosion 53
3.1.2 Intergranular Corrosion 55
3.2 Corrosion Monitoring 56
3.2.1 Visual Testing (VT) 56
3.2.2 Ultrasonic Testing (UT) 57
3.2.3 Thermographic Testing (TG) 58
3.2.4 Electromagnetic or Eddy Current Testing (ET) 58
3.2.5 Radiographic Testing (RG) 60
3.3 Corrosion Control 61
3.3.1 Different Corrosion Control Schemes in Aircrafts 61
3.3.2 Corrosion Control in Space Launch Vehicles 62
3.3.3 Techniques for Coating Removal 64
3.4 Conclusion 64
References 65
4 Energy Harvesting Techniques for Powering Wireless Sensor Networks in Aircraft Applications: A Review 67
Abstract 67
4.1 Introduction 67
4.2 Energy Sources in the Aircrafts 69
4.2.1 Vibrations 69
4.2.2 Thermal Gradients 69
4.2.3 Solar Energy 71
4.3 Energy Harvesting Techniques 71
4.3.1 Vibration Energy Harvesting Techniques 72
4.3.1.1 Piezoelectric Technique 72
4.3.1.2 Electromagnetic Technique 74
4.3.1.3 Electrostatic Technique 75
4.3.2 Thermal Energy Harvesting Techniques 76
4.3.3 Solar Energy Harvesting Techniques 78
4.4 Recent Progress in the Development of the Integrated Energy Harvesting, Energy Storage, and Sensor Hybrid Devices 79
4.4.1 Hybrid Nanogenerator and Supercapacitor Device 80
4.4.2 Hybrid Nanogenerator and Sensor Device 80
4.4.3 Hybrid Solar Cell and Supercapacitor Device 83
4.5 Conclusion 85
5 Embedded Sensors for Health Monitoring of an Aircraft 89
Abstract 89
5.1 Introduction 90
5.2 Research on Embedded Sensors 91
5.2.1 MEMS-Based or Thin-Film Sensor Embedding 92
5.2.2 Wireless Sensor Embedding 92
5.2.3 Fiber Optic Sensor Embedding 93
5.3 Sensors Used in Aircraft 94
5.4 Embedded Sensors Used for Health Monitoring Purpose in Aircraft 95
5.4.1 Embedded Sensor/Actuator System for Aircraft Active Flow Separation Control 96
5.4.2 Active Health Monitoring of an Aircraft Wing with Embedded Piezoelectric Sensor/Actuator Network 97
5.4.3 Optical Fiber Sensors for Aircraft Structural Health Monitoring 101
5.5 Conclusion 101
6 Sensors Used in Flying: A Comprehensive Study 104
Abstract 104
6.1 Introduction 105
6.2 Six Pack Flight Instruments: Basic Working 107
6.3 Recent Advancements in Flight Instrument Systems 111
6.4 Micro and Nano Air Vehicles 112
6.5 Conclusion 116
References 116
7 Overview of Electric Vehicles (EVs) and EV Sensors 118
Abstract 118
7.1 Introduction 119
7.2 Types of Electric Vehicles 120
7.3 An Overview of Sensors for Electric Vehicles 122
7.3.1 Position Sensors 123
7.3.1.1 Resolvers 123
7.3.1.2 Encoders 124
7.3.2 Battery Monitoring Sensors 125
7.4 MEMS Technology in Automotive Vehicles 126
7.4.1 MEMS-Based Sensors for Passenger Safety 127
7.4.2 MEMS-Based Sensors for Skidding and Rollover Detection 127
7.4.3 Tire Pressure Sensors 127
7.4.4 Electronic Stability Control of Vehicles 128
7.4.5 MEMS Sensors for Engine Management 128
7.4.6 The Electronic Parking Brake System 128
7.4.7 Sensors for Antitheft 129
7.4.8 Vehicle Navigation Based on MEMS 130
7.5 Recent Trends in MEMS-Based Sensors in Electric Vehicles 130
7.5.1 Battery Characterization 130
7.5.2 Longitudinal Velocity and Road Slope Estimation 131
7.5.3 Piezoresistive MEMS Sensor 131
7.5.4 Rotor Flux Sensing 131
7.5.5 Two-Wheel Self-balanced Electric Vehicle 131
7.5.6 State of the Charge Sensing 132
7.6 Negative Impacts of Electric Vehicles 132
7.7 Conclusion 132
References 133
8 Fabrication Processes for Sensors for Automotive Applications: A Review 134
Abstract 134
8.1 Introduction 135
8.2 Materials for Micromachining 137
8.3 Lithography Techniques 137
8.3.1 Photolithography 137
8.3.1.1 Projection Lithography 138
8.3.1.2 Proximity Lithography 138
8.3.1.3 Contact Lithography 138
8.3.2 Electron Beam Lithography (EBL) 138
8.3.3 Maskless Lithography 140
8.3.4 Grayscale Lithography 140
8.4 MEMS-Based Etching Techniques 141
8.4.1 Bulk Micromachining 141
8.4.2 Surface Micromachining 142
8.4.3 LIGA 144
8.5 MEMS-Based Thin Film Deposition Processes 145
8.6 Recent Developments in MEMS-Based Fabrication Process 147
8.6.1 Deposition 147
8.6.2 Etching 149
8.6.3 Printing 151
8.7 Conclusion 152
References 152
9 Wireless Sensing Systems: A Review 154
Abstract 154
9.1 Introduction 154
9.2 Existing Detection Techniques 157
9.2.1 Wire-Based Detection Technique 157
9.2.1.1 Electrical-Based Detection Scheme 157
9.2.1.2 Optical-Based Detection Scheme 159
9.2.2 Wireless-Based Detection Technique 161
9.2.2.1 Bluetooth 162
9.2.2.2 Near-Field Communication (NFC) 165
9.2.2.3 RFID Tag 167
9.2.2.4 Zigbee Module 170
9.2.2.5 Radar Systems 173
9.3 Various Wireless Circuits: A Review 183
9.3.1 Solid-State Gas Sensor-Based Used for Wireless GIS Network 183
9.3.2 A Wireless Sensor Network for Wireless Monitoring of Sevoflurane 185
9.3.3 A WSN for Real-Time Monitoring of Industry Carbon Monoxide 185
9.3.4 RFID Based Gas Sensor for H2S 190
9.3.5 NFC-Based Gas Sensor for Biochemical with a Smartphone 191
9.3.6 A Bluetooth Module-Based Alcohol Gas Sensor 193
9.4 Advantages of Wireless Gas Sensors 194
9.5 Challenges in Setting up Wireless Sensor 195
9.6 Different Commercially Available Wireless Modules 197
9.7 Conclusion 198
References 198
10 Sensors in Assembly Shop in Automobile Manufacturing 204
Abstract 204
10.1 Introduction 205
10.2 Application of Assembly Line in Automobile Industries 205
10.2.1 Trim Line 206
10.2.1.1 Code Reader 207
10.2.1.2 Inductive Sensor 207
10.2.1.3 Capacitive Sensor 207
10.2.1.4 Photoelectric Sensor 208
10.2.1.5 Pressure Sensor 210
10.2.2 Chassis Line I 210
10.2.2.1 Vision Sensor 211
10.2.2.2 Capacitive Sensor 212
10.2.2.3 Laser Sensor 212
10.2.3 Chassis Line II 212
10.2.3.1 Inductive Sensor 213
10.2.3.2 RFID TAG Sensor 213
10.2.3.3 Laser Sensor 213
10.2.4 Final Line 214
10.2.4.1 Vision Sensor 215
10.2.4.2 Inductive Sensors 215
10.2.4.3 Photoelectric Sensor 215
10.2.4.4 RFID Sensor 215
10.2.4.5 1D/2D Code Reader 215
10.2.4.6 Pressure Sensor 216
10.2.4.7 Flow Sensor 216
10.3 Potential Failures in Assembly Shop Due to Sensor Failure 216
10.4 Conclusion 217
References 217
11 Leakage Monitoring in Inflatable Space Antennas: A Perspective to Sensitive Detection of Helium and Nitrogen Gases 219
Abstract 219
11.1 Introduction 220
11.2 Sensor System for Inflatable Space Antenna 223
11.2.1 Design Considerations 223
11.2.2 Sensor Layer Substrate 223
11.3 Metal Oxide Semiconducting Materials for Gas Sensors 224
11.4 Considerations for Gas Sensor Development 225
11.5 Vanadium Pentoxide (V2O5) for Helium Gas Detection 226
11.6 Sensing Mechanism 229
11.7 Hydrogen Gas Detection Through V2O5 229
11.8 High Precision Gas Sensor 230
11.9 Conclusion 230
References 231
12 MEMS Sensors for Automotive Applications: A Review 233
Abstract 233
12.1 Introduction 234
12.2 MEMS Fabrication Techniques 237
12.3 Tire Pressure Monitoring Systems 238
12.4 Pressure and Flow Sensors for Engine Management 240
12.5 Vehicle Stability/Passenger Safety Sensors 241
12.5.1 Crash Sensing Systems 242
12.5.2 Rollover Detection 242
12.5.3 Vehicle Dynamic Control 243
12.6 Gas Sensors for Emitted Exhaust Gases 244
12.6.1 Carbon Monoxide (CO) 245
12.6.2 Carbon Dioxide (CO2) 245
12.6.3 Nitrous Oxides (NOx) 245
12.7 Conclusions 246
References 247
13 Sensors in the Joining and Welding Process in Automobile Manufacturing 250
Abstract 250
13.1 Introduction 250
13.2 Different Types of Welding 251
13.2.1 Resistance Spot Welding 251
13.2.2 Resistance Seam Welding 251
13.2.3 Laser Beam Welding 252
13.2.4 Friction Welding 253
13.2.5 Magnetic Pulse Welding 254
13.3 Different Types of Sensors Used in Welding and Joining Processes 255
13.3.1 Voltage Sensor 256
13.3.2 Current Sensor 256
13.3.3 Pressure Sensor 257
13.3.4 Thickness Sensor 258
13.3.5 Position Sensor 258
13.3.6 PICA–PICA Sensor 259
13.3.7 1D/2D Code Reader 259
13.3.8 Capacitive and Inductive Sensor 260
13.3.9 Laser Sensor 261
13.3.10 Safety Sensor 262
13.4 Potential Failures in Welding and Joining Due to Sensor Failure 263
13.5 Environment and Health Issues 263
13.6 Conclusion 264
References 264
14 Sensors Used in Automotive Paint Shops 266
Abstract 266
14.1 Introduction 267
14.2 Paint Shop Process 267
14.3 Sensors Utilised for the Paint Job 268
14.4 Major Classes of Sensors (Processes IFM) 270
14.5 Potential Failures in Paint Shop Due to Sensor Failure 272
14.6 Conclusion 272
References 273