Sealed Engine Control Module with Integral Air Pressure Sensor
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Solution Overview
Problem
Existing engine control modules (ECMs) with environmentally-sealed housings cannot reliably sense ambient air pressure, necessitating the use of external wired sensors, which increases system cost.
Innovation Solution
An integral ambient air pressure sensor is mounted directly on the ECM housing, with a sensor element protruding through a sealed opening to interface directly with the control circuit board, eliminating the need for external sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an environmentally-sealed housing is used for the ECM, then protection against environmental factors is improved, but the ability to sense ambient air pressure deteriorates
Solution Approach 1:
The pressure sensing function is segmented from the sealed ECM housing by providing a separate sealed opening that allows selective communication with the ambient environment. This segmentation enables the housing to remain sealed for protection while the opening provides pressure sensing capability.
Solution Approach 2:
A sealed opening acts as an intermediary element between the sealed housing interior and the ambient environment. It selectively transmits ambient air pressure to the sensor element while blocking other environmental contaminants, thus mediating between protection and sensing requirements.
2Measurement precision
If a wired external sensor is used to measure ambient air pressure, then measurement reliability is improved, but system cost increases
Solution Approach 1:
The pressure sensor is merged with the ECM housing by mounting it directly on the housing with electrical connection to the control circuit board. This integration eliminates the need for separate external sensors and their associated wiring harnesses, reducing system complexity and cost while maintaining measurement reliability.
Solution Approach 2:
The ECM housing serves multiple functions: it provides environmental protection, structural support, and now also serves as the mounting platform for the pressure sensor. This multi-functionality reduces the need for additional components and simplifies the overall system.
3Device complexity
If sensors are mounted on the circuit board within the ECM, then system cost is reduced, but reliable sensing of ambient air pressure cannot be achieved
Solution Approach 1:
The sensor mounting location is moved from the two-dimensional circuit board plane to the three-dimensional exterior surface of the housing. This dimensional change allows the sensor to access ambient air pressure directly while maintaining integration with the ECM system.
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 solution provides a reliable and cost-effective means to measure ambient air pressure internally within the ECM, enhancing engine control accuracy without the expense of external sensors.
Implementation Method 1
The sensor element is mounted in the body portion, and the riser portion protrudes through an opening in the housing to couple the sensor element to atmospheric air pressure outside the housing
Data Source
AI summary
An engine control module having an environmentally-sealed housing includes a housing-mounted air pressure sensor for providing a reliable measure of atmospheric air pressure to a control circuit mounted within the housing. The sensor is mounted on an inboard face of the housing, and includes a sensor element, a body portion and a riser portion. The sensor element is mounted in the body portion, and the riser portion protrudes through an opening in the housing to couple the sensor element to atmospheric pressure outside the housing. The body portion is sealingly secured to the inboard face of the housing, and a set of conductor pins molded into the body portion extend inward to engage a circuit board enclosed by the housing, and thereby directly couple the sensor element to the ECM's control circuit. The top of the riser portion is capped by a splash-proof lid to prevent water intrusion.