Electrostatic Particle Sensor Guard Electrode Leakage Control

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Solution Overview

Problem

Electrostatic particle sensors in vehicle exhaust systems face issues with condensation causing instability and electrical leakage, leading to inaccurate measurements and corrosion due to electromigration or solder migration, especially when cold and exposed to high humidity and temperature.

Innovation Solution

The method involves using a guard electrode and electrical limiting resistors to manage leakage currents, ensuring they remain below a predetermined threshold, thereby reducing corrosion and instability by actively controlling and regulating these currents through separate resistors and MOSFETs, ensuring the sensor operates reliably even when cold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the particle sensor is operated cold in high humidity conditions, then the sensor can detect particles, but condensation water deposits on the electrodes and isolation body causing measurement instability and electrical leakage

Engineering Contradiction:
Improvemeasurement stabilityVSAvoidcondensation water deposition
Core Design Contradiction:
ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies preliminary action by implementing a pre-heating phase before particle measurement begins. The sensor is heated to a temperature above the dew point of the exhaust gas before starting measurements, ensuring that condensation water cannot form on the electrodes or isolation body during operation. This preliminary thermal preparation eliminates the harmful condensation effect before it can occur.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent changes the temperature parameter of the sensor to resolve the contradiction. By maintaining the sensor temperature above the dew point through active heating, the physical state of water in the exhaust gas changes from condensing liquid to remaining vapor, eliminating condensation water deposition while preserving particle detection capability.

Inventive Principle:
Principle #35Parameter changes

2Measurement precision

If high voltage is applied to the electrodes for particle measurement, then particle detection sensitivity is improved, but electrical leakage currents increase causing corrosion and electromigration

Engineering Contradiction:
Improveparticle detection sensitivityVSAvoidelectrical leakage current
Core Design Contradiction:
Measurement precisionVSObject-generated harmful factors

Solution Approach 1:

The patent introduces an intermediary element - a high-value resistance - between the voltage source and the electrodes. This resistance acts as a current-limiting mediator that allows the necessary high voltage to be applied for sensitive particle detection while simultaneously restricting leakage currents to negligible levels, preventing corrosion and electromigration effects.

Inventive Principle:
Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent employs a disposable or replaceable high-value resistance component that is inexpensive and can be easily replaced if degraded. This resistance element serves as a sacrificial protective component that prevents costly damage to the sensor electrodes and isolation body from leakage currents, while being cheap enough to replace periodically without significant cost impact.

Inventive Principle:
Principle #27Cheap short-living objects (Disposable)

3Reliability

If the sensor is heated to prevent condensation, then measurement reliability is improved, but energy consumption increases

Engineering Contradiction:
Improvemeasurement reliabilityVSAvoidheating energy consumption
Core Design Contradiction:
ReliabilityVSUse of energy by moving object

Solution Approach 1:

The patent implements periodic action by using intermittent heating cycles rather than continuous heating. The sensor is heated to the required temperature before measurement begins, then maintained at this temperature only during active measurement periods. During idle periods, the heating is reduced or stopped, significantly reducing overall energy consumption while maintaining measurement reliability when needed.

Inventive Principle:
Principle #19Periodic action

Solution Approach 2:

The patent applies dynamics by making the heating system adjustable and adaptable to actual operating conditions. The heating power and duration can be dynamically adjusted based on ambient temperature, exhaust gas temperature, humidity levels, and measurement requirements, optimizing the balance between preventing condensation and minimizing energy consumption.

Inventive Principle:
Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach significantly reduces the risk of corrosion and electromigration, allowing for precise particle measurement by maintaining sensor stability and accuracy across varying conditions, ensuring reliable operation and extending component durability.

Implementation Method 1

a voltage supply (6), which in the measurement operation of the particle sensor (1) creates a first electrical potential (14) on the first electrode (2), creates a second electrical potential (18) on the second electrode (3) in such a way that an electrical voltage is created between the first electrode (2) and the second electrode (3)

Methodology Applied
Scientific EffectElectrical field: Electric Field

Implementation Method 2

As long as the particle sensor is cold, the water condenses from the exhaust gas into liquid water on the electrodes and the isolation body

Methodology Applied
Scientific EffectCondensation: Condensation

Implementation Method 3

These electrical leakage flows can have a disadvantage on, for example, soldering connections within the particle sensor, especially in such solder compounds, can cause so -called electromigration or soldering migration, which can lead to a deterioration of the durability of the solder connection

Methodology Applied
Scientific EffectElectromigration:

Data Source

PatentEP3586102B1Method for operating an electrostatic particle sensor and electrostatic particle sensor
Publication Date: 2022.12.21 EMISENSE TECHNOLOGIES LLC
  • EP3586102B1 patent drawingFigure 1

AI summary

The present invention relates to a method for operating an electrostatic particle sensor (1) and to an electrostatic particle sensor (1), which comprises a first electrode (2), a second electrode (3) electrically isolated from the first electrode (2) by means of an isolation body (5), a guard electrode (16) electrically isolated from the first electrode (2) and the second electrode (3) by means of an isolation body (5) and a power supply (6). The method comprises applying a first electrical potential (14) to the first electrode (2), applying a second electrical potential (18) to the second electrode (3) and applying an electrical guard potential (19) to the guard electrode (16), and limiting a first leakage current flowing between the first electrode (2) and the guard electrode (16) via the isolation body (5) to a first leakage current limit value by means of a first electrical limiting resistor (22) arranged between the guard electrode (16) and the power supply (6).