Vehicle Operator Safety: The Advantages of Using Electronic

Sensors in Off-road Vehicles

Technical Paper Presentation
Electrolytic tilt sensing
The first technology is referred to as electrolytic tilt sensing 1. Sensors filled with electrically
conductive liquid are fitted with two internal measuring cells. By applying an alternating
voltage between the cells electrodes, current flows through the liquid and generates an
electrical field. If the sensor tilts, the fluid surface remains level, so the electrical field
changes as well as the fluids level-dependent resistance. The measuring cells monitor any
change in the liquids conductivity and thus detect angle variations of the X and Y axes with
precision. Sensors using this technology are appropriate for platform leveling (narrow tilt
angle 15) or where high precision (0.025) and a flexible network connection are
advantageous.

Figure 1. Electrolytic tilt sensing technology: measuring cells monitor any change in the
liquids conductivity to detect angle variations.

MEMS sensing technology

The second technology is micro electromechanical sensing (MEMS). A silicon mass is
suspended in the sensor body by two resilient beams between two stationary capacitor plates.
When the body tilts, the movement is transferred to the beams. The beams deflect to take the

inertial forces of the mass. The deflection changes the relative position of the mass between
two plates. Because each of the above plates is part of two separate capacitors, the deflection
creates a reciprocal change in capacitance in each of the two.

Figure 2. Micro electromechanical sensing (MEMS) technology: When the vehicle tilts, the
movement is transferred to the beams that deflect to take the inertial forces of the mass. Any
change in capacitance is proportional to the tilt of the sensor.

Any change in capacitance is proportional to the tilt of the sensor, which then is converted to
a change of voltage and transferred as an analog value to the vehicle controller. Sensors
incorporating this technology are better suited to applications where a single-axis wide tilt
angle (90) and lower precision (1) are needed.

Inductive Position Sensors Monitor the Position of Moving Parts on a Vehicle

Inductive position sensors are designed to detect the position of moving parts on an off-road
vehicle. Multiple sensors can be used on one machine to maximize the operation of the
vehicle and to protect the vehicles operator. For example, a position sensor can be used on an
industrial cranes cable drum to detect the end of its cable, protecting the crane against

machine damage. Position sensors can also monitor the rotational speed of a gear, detect the
position of a platform, or sense the open- and closed-position of vehicle cab door. The
position sensors provide continual feedback on the operating condition of the machines
moving parts and send this information to the vehicle operator.
Position sensors are designed to withstand outdoor conditions and can include the following
features:

Long sensing ranges that increase the distance between the target and sensor and
reduce the chance of impact and damage to the sensor.

Flexible electronic circuitry that resists the effects of shock and vibration.

Stainless steel, zero-leak housings encase and protect the electronics from chemicals
and liquid ingress.

Highly visible LEDs that indicate power and output status that aid in setup and
monitoring, especially in direct sunlight.

Sensing faces made of UV-resistant plastic that wont break down from exposure to
sunlight.

Noise-immune technology that enables the sensors to ignore conducted and radiated
electrical noise.

Operating principle of inductive proximity sensors

Inductive proximity sensors take advantage of changes in a resonant circuit caused by eddy
current losses in conductive materials. An inductive proximity sensor contains four essential
components: a coil of wire wrapped in a ferrite core, an oscillator circuit, an evaluation
circuit, and an output circuit. When voltage is applied to the sensor, an oscillating current

flows through the coil and radiates an electromagnetic field from the active face of the sensor.
This field is directed and shaped by the ferrite core.
When an electrical conductor or metal target enters the electromagnetic field, eddy currents
are drawn from the oscillator and induced into the target. These eddy currents draw energy
from the electromagnetic field. The losses in energy caused by the eddy currents are due to
the conductivity and permeability of the target, the distance and position of the target, and the
size and shape of the target.

Figure 3. An inductive proximity sensor detects all metals with its high-frequency electromagnetic field.

When the metal target is positioned at a precise distance from the active face of the sensor,
the energy loss caused by the eddy currents becomes so large that the amplifier cannot output
sufficient energy to maintain oscillation and the magnetic field collapses. The breakdown in
oscillation is detected by the evaluation circuit, which then changes the state of the output
circuit.

Pressure Sensors Monitor a Vehicles Hydraulic System

The hydraulic system of an off-road vehicle is the heart of the vehicle and is responsible for
operating the main controls. Applications such as loading and unloading, transporting, lifting,
and processing are achieved through the hydraulic system. Loss in power can result in vehicle
downtime and potential injury to the operator. Pressure sensors can continuously monitor a

vehicles hydraulic system and provide feedback on the systems operating condition.
Pressure sensors today are stainless steel and compact. The base of the sensor incorporates a
ceramic sensing element that enables over 100 million switching cycles, withstands pressure
spikes, and resists corrosion. The design of the sensing element ensures excellent
repeatability and accuracy across the entire operating range. Similar to inductive proximity
sensors, electronic components are mounted on flexible film for shock and vibration
resistance up to 1000g.
Additional design features can include:

IP69K rating for washdown environments

EMC protection (>100 V/m radiated HF).

Setpoint, hystersis, delay time and damping values can be configured to meet specific
application requirements.

Pressure sensors operating principle

Pressure sensors that incorporate a ceramic

measuring cell made of aluminum oxide

(A12O3) are highly reliable for off-road vehicles. The ceramic cell element resembles a plate
capacitor with a reference electrode and measuring electrode placed 10 m apart.

The capacitance is inversely proportional to the distance between the electrodes. If the
distance changes by a small value because of an increase in pressure applied to the cell, the
capacitance changes proportionately. This signal is then processed by a microprocessor.

Sensor testing and quality assurance

Extreme heat and cold, rain, dirt and chemicals can slowly deteriorate a vehicle and its
sensors. To ensure resistance to the elements, sensor should be subjected to a variety of tests.
As a guideline, these tests should include an electromagnetic compatibility (EMC),
temperature shock, temperature humidity, salt spray and shock. Following are descriptions of
these tests.

EMC Test
Since all of the electrical devices used in a mobile application are dependent upon the same
source of power, ample consideration must be given to electromagnetic compatibility. Sensor
testing should be placed in an environment that simulate worst-case conditions present in the
environment and tested to ISO11452-2 Test level IV (100 V/m). This level is over five times

higher than the comparable industrial standard.

Temperature Shock Test

Optimal control system performance must be maintained regardless of the temperature
changes that occur in normal operation. This test should be conducted to ensure that rapid
changes in temperature have no impact on the integrity of the system.

Temperature/Humidity Test
Relative humidity is the percentage of water vapor present in the air compared to fully
saturated air at the same temperature. The objective of this test is to simulate conditions that
occur within an operating environment that would cause premature failure of conventional
electronic systems (i.e., metallic component corrosion, electronic component drift,
mechanical reliability of conformed encapsulant, dielectric effects).

Salt Spray Test

This test is designed to accelerate weathering by direct exposure in a highly corrosive

atmosphere. This test is also very useful in predicting the potential for mechanical failure
from corrosion, due to long-term environmental exposure.

Shock Test
Proximity sensors can be exposed to high levels of shock in mobile environments. Sensors
should be tested at a shock level of at least 500g. A sensor test of this caliber is routinely
performed on the proximity sensor line.