In the demanding world of motorsport, precise and reliable data acquisition is critical for optimizing performance and ensuring vehicle reliability.
This guide explores the specialized sensor technologies – encompassing pressure, temperature, position, and force – that are engineered to withstand the extreme conditions of racing. From the intense vibration and G-forces to the elevated temperatures and corrosive fluids, these sensors provide the crucial data needed by race engineers to monitor, analyze, and fine-tune every aspect of a vehicle’s performance, all while minimizing weight and maximizing durability.
Low Cost Miniature Pressure Transducer – ASL - The ASL low cost miniature pressure transmitter, has a piezoresistive ceramic pressure sensor which is chemically inert and has very fast dynamic response.
AS Autosport Pressure Transducer - Motorsport pressure transducer with 21mm diameter and and 24mm body length for pressure ranges from 0.5 up to 600 bar gauge or absolute. Available with millivolt and amplified voltage output signals.
ASM 13mm Diameter Miniature Pressure Transducer - Miniature size 1/2 inch diameter stainless steel pressure sensor with an amplified 0.5 to 4.5 Vdc output. Pressure ranges start from 10 up to 400 bar.
Motorsport applications demand a range of sensing technologies that can withstand extreme conditions while maintaining high accuracy and reliability. Component weight is a critical consideration across all aspects of a race vehicle design, so minimizing sensor mass is paramount. These transducers are engineered for minimal weight contribution without sacrificing performance.
Miniaturization is also key. Sensors destined for engine bays, fuel lines, hydraulic brake circuits, suspension systems, or aerodynamic components on racing vehicles must fit into extremely tight spaces. Compact form factors are essential for optimal placement and to avoid interference with other components.
The harsh environment of motorsport presents significant challenges. All sensors, whether measuring pressure, temperature, position, or force, are specifically designed to endure the constant high-frequency vibration and G-forces experienced during racing. Robust construction and specialized internal components ensure consistent readings even under intense stress.
Elevated temperatures, particularly in engine compartments and near exhaust systems, necessitate the use of sensors with extended operating temperature ranges. Materials and electronic designs are carefully selected to maintain accuracy and prevent drift in these extreme heat conditions. Materials selected for sensors in contact with fluids, have high resistance to corrosive chemicals such as methanol and ethanol-based racing fuels, along with synthetic lubricants.
Data acquisition systems used on racing vehicles require precise and repeatable measurements from all sensor types. These transducers provide highly accurate outputs that are suitable for integration with sophisticated telemetry systems, allowing race engineers to monitor and analyze vehicle performance in real-time.
Pressure Sensors
Pressure transducers for motorsport are designed to monitor critical parameters such as fuel pressure, oil pressure, brake line pressure, and manifold absolute pressure (MAP). These sensors often utilize specialized sensing elements and packaging to ensure accuracy and reliability in the presence of rapid pressure fluctuations and high vibration levels. Differential pressure sensors are also employed, for instance, to measure pressure drops across filters or aerodynamic components.
Temperature Sensors
Temperature sensors, often employing thermocouples or RTDs (Resistance Temperature Detectors), are crucial for monitoring engine coolant, oil, exhaust gas, and brake temperatures. Specialized designs ensure fast response times and resistance to thermal shock. Non-contact infrared temperature sensors are also finding a role.
Position Sensors
Position sensors, including linear and rotary potentiometers, LVDTs (Linear Variable Differential Transformers), and string potentiometers, are used to track suspension travel, throttle position, steering angle, and other critical movements. These sensors must be robust and provide precise feedback even with rapid changes in position.
Force Sensors
Force sensors, typically strain gauge-based load cells, measure aerodynamic downforce, suspension loads, and forces acting on various components. These sensors are designed for high stiffness and overload capacity to withstand the dynamic forces encountered in racing.
Many sensors used in racing applications have an IP rating of 65 and above, this type of environmental protection allows the sensor to operate in wet conditions and withstand regular wash-downs.
Electrical connection of sensors on race cars is often made using robust motorsport-specific connectors which can withstand prolonged vibration and harsh operating conditions, ensuring a robust data connection to the logging system.