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Engine

Combustion
Analysis
Pressure Sensors
and Innovative
System Solutions

Kistler Pressure Sensors


From pioneer to technological leader
Kistler has been involved in the development, production and use of piezoelectric
sensors since the 50s. The company's
sensors have also played a key role in the
development of combustion engines over
this extended period. This striking success
reects their "inside view" of the combustion chamber as the only source of the
information needed to optimize combustion for better efficiency and to minimize
harmful emissions.

Reliable Development
Partner for Research and
Industry
From small-/mid-sized engines and racing
engines to large marine Diesel engines and
power plants engine development without Kistler pressure sensors is inconceivable.
Innovative capacity, close contact with the
world's leading engine manufacturers and
application expertise help to explain why
Kistler now sets the pace for engine measurement. Kistler always offers the best
solution for accurate pressure measurement
over a wide spectrum from high-precision
research to demanding racing applications.

Piezoelectric
Pressure Sensors
Piezoelectric sensors can only be used for
quasistatic rather than truly static measurement. They are ideal for dynamic applications. Piezoelectric pressure sensors can be
employed wherever rapidly changing pressures at temperatures of up to 400 C have
to be measured and recorded as accurately
as possible.
In addition to quartz, particularly for uncooled sensors, Kistler uses crystals developed and grown in-house. These PiezoStar
crystals are characterized by high sensitivity
and high thermal stability.

M8 cooled piezoelectric pressure sensor,


Type 6041B

Piezoresistive
Pressure Sensors
The piezoresistive principle is based on the
semiconductor effect first described in
1954, which states that under mechanical
stress semiconductors change their electrical
resistance. Compared with the conventional
strain gage measurement of the time, this
opened up completely new applications.
Since then further similar breakthroughs
have included the thin film technique on
metal and its thick layer counterpart on
ceramic.

M5 uncooled piezoelectric pressure sensor,


Type 6052C

Piezoresistive sensors from Kistler measure


static pressures in gases and liquids. The results achieved under even the most adverse
conditions are precise and reproducible.

Piezoresistive miniature pressure sensor,


Types 4005B and 4007B...

PiezoStar Kistler has been growing


their own crystals with high sensitivity
and temperature stability for more
than ten years

CrankSmart, KiBox, PiezoStar and PiezoSmart are registered trade marks of Kistler Holding AG.

...Innovative System Solutions


The KiBox To Go Type 2893A... allows
very accurate determination of the key
combustion parameters in real time under
actual operating conditions for in-vehicle
and engine test bed applications.

In vehicle ...

Plug & Go

User-friendly
and Quick

Integrated and
Simple to Use

Simple and Innovative

Dynamic and Precise

Modular System,
Secure Investment

... and on engine test bed

Hardware and Software Optimized for Convenience and Portability


Key features of the KiBox are its compact size, modular vehicle accessories and the fact
that all sensor connections are located on the front panel. The measuring parameters can
be configured using a graphical user interface featuring a simple and intuitive layout.

Optimum Functionality with PiezoSmart and INCA Integration


The sensor signals are configured automatically by means of the electronic data sheet
(TEDS) and the running time is acquired and saved for sensor management purposes.
Designed with engineers in mind, the data can be processed and displayed in the familiar
INCA environment. The "KiBox Cockpit" graphical interface also provides a fully independent data display for simple analysis of measuring data.
Interface to the Calibration System PC
The system offers high-performance, integrated computing with key parameters in real
time and a time synchronous transmission of results to the ECU calibration tool. Setup
is performed directly on the calibration systems laptop, which is also used for any custom
visualization required.

CrankSmart for Enhanced Measurement Quality


CrankSmart is a brand new method for measuring indication signals precisely without an
optical crank angle encoder. The existing engine speed sensor is used for the crank angle
and the TDC reference. Time-based measurement means that aliasing effects can at last be
prevented.

Reliable Combustion Analysis in All Operating Conditions


With no additional effort required for any engine operating condition starting, accelerating, stopping measurements are acquired dynamically and delivered with precision, even
before the crankshaft begins to rotate.

Standard PC Processors and Plug-in Amplifiers


To protect your investment, the KiBox is based on standard PC processors combined with
specific data acquisition hardware, ensuring that the system remains cost-effective.
The amplifier modules come from the established Kistler SCP Slim series, making
the KiBox the perfect tool for combustion analysis in test vehicles. Practical modular
accessories, such as the bracket for securing the KiBox in the vehicle are part of the system.

Sensor Selection Guide


Piezoelectric Sensors
n Small sized engines
(motorbikes, ...)

n Possibility of

n yes

engine
modification

Cylinder Pressure

n no

n Medium sized engines


(passenger cars, ...)

n Possibility of

n Gasoline

n yes

engine
modification

n no

n Gasoline
n Diesel

n Heavy duty engines

n General purpose
n Thermodynamic
n Knock detection

n Type 6052C...
n Type 6054BR...
n Type 6054BRU20

n Spark plug

n Type 6113B.../6115B...

n General purpose
n Thermodynamic
n Knock detection

n Type 6125C.../6045A...
n Type 6041B...
n Type 6045AU20

n Spark plug
n Glow-plug

n Type 6115B.../6118B...
n Type 6056A...
n Type 6058A...

Type 6542Q...
Type 6544Q...

n General purpose

n Type 6125C.../7013C...

n Thermodynamic

n Type 6061B.../6067C...
n Type 7061C...

n General purpose

n Type 6054BRU20

n Formula 1

n Type 6054BRU55

(trucks, ...)

6045A...

n Racing engines

Piezoresistive Sensors

Injection/High Pressure

Gas Exchange Pressure

n Compact Solution

n un-cooled
n cooled

n Type 4005B...
n Type 4007B...
n Type 4049A...

n Highest Accuracy

n Switching adapter, water cooled M14


Type 7533B...
M12

n Type 4045A...
n Type 4075A...

n Sensor

n Clamping adapter

n Type 4065A...
n Type 4067C...

Type 6533A...

n Transmitter

up to 125 C
up to 200 C

M7
M10

n Type 4069C...

Piezoelectric Sensors
Pressure Measurement in Combustion Engines
Sensors and measuring probes, uncooled

T
T

L
D

D
T

L
D

Technical data

Type 6052C...

Type 6053CC.../6055C... Type 6054BR...

Type 6056A.../58A...

Type 6125C...

Type 6045A...

Pressure range bar


Sensitivity
pC/bar
Temperature range C
Dimensions D mm

L mm
T
Characteristics

0 ... 250/... 300*


20
20 ... 350
4,4
10
M5x0,5
Low thermal sensitivity
drift over engine operation map, compensated
for acceleration, ideal
thermal shock behavior,
long life.

0 ... 250/ ... 300*


20
20 ... 350
4,4
14,5/33,5
M5x0,5
Sensor properties as Type
6052C... constructed
for direct mounting in
6,0 mm hole, even possible to install through
coolant passages.

0 ... 250/ ... 300*


14
20 ... 350
4,4
7
M5x0,5
Very compact, rugged
design for high performance measurements
even in limited space
and for applications
with high vibrations.

0 ... 250 (300*)/0 ... 250


20/17
20 ... 350
4,4/4,0
33,5
M5x0,5
Sensor properties as Type
6052C... constructed
for glow plug application in adapter Type
6542Q.../6544Q... or
direct mounting.

0 ... 300
36
20 ... 350
6,2
9,9

Swivel-nut construction, low thermal shock


and ground isolation,
suitable for high performance measurements
free of interference.

0 ... 250/... 300*


45
20 ... 350
9,8
7,9
M8x0,75
Shoulder-sealing,
mounting dimensions
compatible with Type
6041B high sensitivity, low thermal sensitivity drift, long life.

Data sheet

6052C_000-552

6053CC_000-571
6055C_000-572

6054BR_003-046

6056A_000-529,
6058A_000-573

6125C_000-695

6045A_000-618

* U20 version with reinforced diaphragm

Piezoresistive Sensors
Pressure Measurement in the Intake and Exhaust Systems

Injection Pressure Measurement

Low-pressure sensors

High-pressure sensors

T
T
T

L
D

Technical data

L
D

Type 4005B..., 4007B...

Type 4045A...

Type 4075A...

Type 4049A...

Type 4065A...

Type 4067C...

0 ... 5 / ... 101)

0 ... 2 / ... 5/ ... 101)

0 ... 101)

0 ... 5 / ... 10

0 ... 200 / ... 500

0 ... 2 000 / ... 3 000

Min. / Max. temp. C


Dimensions
D mm

L mm
T
Characteristics

40 / 125, 40 / 200
6,2
4
M5x0,5
Miniature pressure sensor
for intake pressure
measurements. Ideal
for applications with
limited space.

0 / 1402)
12
14
M14x1,25
Media separated pressure sensor. Highest
accuracy. Ideal for use
with cooled switching
adaptors.

0 / 1402)
9,5
35
M12x1
Media separated pressure sensor. Highest
accuracy. Ideal for use
with cooled switching
adaptors.

0 / 120
18
6,7
M14x1,25
Compact pressure sensor
with integrated water
cooling. Media separated. Digital temperature
compensation.

0 / 120
5
25,3
M7x0,75
Compact high-pressure
sensor. Robust steel
diaphragm for harsh
and high dynamic
applications.

0 / 120
8,5
18,6
M10x1
Compact high-pressure
sensor with front sealing
and robust steel diaphragm for harsh and
high dynamic applications. Ideal for use with
clamping adaptors.

Application

Intake pressure
General pressure

Intake pressure
Exhaust pressure

Exhaust pressure

Exhaust pressure

Injection pressure

Injection pressure

Data sheet

4005B_000-594,
4007B_000-614

4043A_000-003

4043A_000-003

4049A_000-727

4065A_000-005

4067C_000-708

Measuring range

bar

Pressure Measurement in Combustion Engines

Pressure Measurement in Combustion Engines

Sensors and measuring probes, cooled

Measuring spark plugs

T
L

T
L

D
T

Type 6041B...

Type 6061B...

Type 6067C...

0 ... 250/...300*
40
20 ... 350
11,5
7,9
M8x0,75
Smallest water cooled
pressure sensor, ideal
thermal shock behavior
and excellent thermal
drift stability. Ideal
reference sensor.

0 ... 250/... 300*


25
20 ... 350
13,5
10
M10x1
Water cooled pressure
sensor, ideal thermal
shock behavior and
excellent thermal drift
stability. Ideal reference
sensor.

0 ... 250/... 300*


25
20 ... 350
9,9
9,5

6041BA_000-516

6061B_000-020

6067C_000-021

Type 7061C...

0 ... 300
92
20 ... 350
16
13
M14x1,25
Water cooled pressure
Sensor properties as
sensor, best thermal
Type 6061B... .
Special mounting sleeve shock behavior and
excellent thermal drift
construction, easy to
stability. Best reference
install and remove.
sensor.
7061C_003-042

Type 6113B...

Type 6115B...

Type 6118B...

0 ... 200
10
20 ... 200
17,5
12/17,5/19/22/26,5
M10x1
M10 measuring spark
plug, sensor flush
mounted with high
natural frequency.
Ceramic insulator and
cable replaceable.

0 ... 200
10
20 ... 200
18
18/19/26,5/28/25
M12x1,25
M12 measuring spark
plug, sensor flush
mounted with high
natural frequency.
Ceramic insulator and
cable replaceable.

0 ... 200
10
20 ... 200
18,5
9,5/19/21,5/25/26,5
M14x1,25
M14 measuring spark
plug, sensor flush
mounted with high
natural frequency.
Ceramic insulator and
cable replaceable.

6113B_000-732

6115B_000-697

6118B_000-699

PiezoSmart
Automatic Sensor Identification
Recording of operating time, cycles and classification of pressure values

PiezoSmart is an active system for identifying


individual piezoelectric and piezoresistive pressure
and acceleration sensors. The main element of
SCP charge amplifier Type 5064C...
PiezoSmart is an electronic data sheet called TEDS
(TEDS = Transducer Electronic Data Sheet). This
contains all the essential data of an individual pressure sensor and can exchange these with ancillary
equipment.
All piezoelectric and piezoresistive pressure sensors
from Kistler are available with PiezoSmart.

Data
base

Type 4069C4000
Charge or voltage amplifiers automatically set the
correct parameters by exchanging data with the
TEDS of the pressure sensor.

0 ... 4 000
40 / 150
8,5
18,6
M10x1
Heavy duty high-pressure transmitter up to
4000 bar.
Same mounting as
4067C... .

Injection pressure
4069C_003-045

1)
Other measuring
ranges available
2)
Other temperature
ranges available

Correct assignment of the sensor data is


always guaranteed. Your benefit:
enhanced process reliability
Measurement can take place independently without any database
The modular system design allows system configurations which meet specific
customer requirements

TEDS template with working


time for a piezoelectric
pressure sensor

Automatic recording of operating


time of PiezoSmart pressure sensors
with classification of pressure values

Signal Conditioning
Signal Conditioning Platforms and Amplifier Modules

Amplifier

Multichannel

Single channel

Signal conditioning
platform

2852A...

2854A...

2854A111

2853A110

2853A120

2853A...

Module

Application
Type
Cylinder pressure

5064C...

4665

5247

5269

5271

2207A

Intake pressure

Exhaust pressure

5018A...

Fuel pressure

pMax monitoring

5227A1Q1

n
n

Needle lift measurement

Temperature measurement

Voltage measurement

Strain gage measurement

Sensor identification

Recording of working time

n
n

Combustion Analysis System


KiBox To Go

KiBox To Go

Combustion analysis

Accessories

Technical data

Type 2893AK1

Analog inputs for any voltage signals channels


Digital inputs
channels
Input voltage range
V
ADC resolution
Bit
ADC sampling rate (per channel, MS/s) MHz
Bandwidth
kHz
Low-pass filter
kHz
Min. / Max. temperature
C
Weight
kg
Dimensions (WxHxD)
mm
Characteristics

8
8
10 ... 10
16
1,25
100
5/10/20/30
2105A...
2619A...
2614C...
5064C11/
C12*/C13*
30 / 50
8 (amplifiers included)
2105_000-953
2893_000-724
2614C_003-049 5064C_003-047
265,5x212x440
* with
The KiBox is a complete combustion analysis system
PiezoSmart
for on-board and test bed applications. The KiBox
function
enables visualization of the quality of combustion.
The combustion parameters are conveniently integrated into the application system and synchronized
with other measurement data and the controlled
variables of the ECU via a software interface.
2893_000-724

Data sheet

Current clamp

Crank angle
adapter

Crank angle
encoder

Charge
amplifier

Kistler Worldwide
Europe
Austria
Kistler GmbH
1230 Wien
Tel. +43 1 867 48 67 0
sales.at@kistler.com

France
Kistler France
91953 Les Ulis cedex
Tel. +33 1 69 18 81 81
info.fr@kistler.com

Spain
Kistler Ibrica S.L, Unipersonal
08402 Granollers, Barcelona
Tel. +34 93 860 33 24
info.es@kistler.com

Czech Republic/Hungary/
Poland/Slovakia
Kistler, s.r.o.
140 00 Praha 4
Tel. +420 296 374 878
sales.cz@kistler.com

Germany
Kistler Instrumente GmbH
73760 Ostfildern
Tel. +49 711 34 07 0
info.de@kistler.com

Sweden/Norway
Kistler Nordic AB
431 53 Mlndal
Tel. +46 31 871 566
info.se@kistler.com

Italy
Kistler Italia s.r.l.
20149 Milano
Tel. +39 02 481 27 51
sales.it@kistler.com

Switzerland/Liechtenstein
Kistler Instrumente AG
8408 Winterthur
Tel. +41 52 224 12 32
sales.ch@kistler.com

Netherlands
Kistler B.V. Nederland
2811 DT Reeuwijk
Tel. +31 182 304 444
sales.nl@kistler.com

United Kingdom
Kistler Instruments Ltd.
Hook, Hampshire RG27 9GR
Tel. +44 1256 74 15 50
sales.uk@kistler.com

Denmark
Kistler Nordic DK
4681 Herflge
Tel. +45 70 20 85 66
info.dk@kistler.com
Finland
Kistler Nordic AB
00210 Helsinki
Tel. +358 9 612 15 66
info.fi@kistler.com

Asia
China, People's Republic of
Kistler China Ltd.
Hong Kong
Tel. +852 25 915 930
sales.cn@kistler.com

Taiwan
Kistler Instrumente AG, Taiwan Branch
Taipei 114
Tel. +886 2 7721 2121
sales.tw@kistler.com

India
Kistler Instruments (India) Pvt. Ltd.
Faridabad 121 007, Haryana
Tel. +91 129 4113 555
sales.in@kistler.com

Thailand
Kistler Instrument (Thailand) Co., Ltd.
Bangkok 10120
Tel. +66 2678 6779-80
sales.thai@kistler.com

Japan
Kistler Japan Co., Ltd.
Tokyo 108-0022
Tel. +81 3 3769 9501
sales.jp@kistler.com
Korea, Republic of
Kistler Korea Co., Ltd.
Anyang-City, Gyeonggi-Do 430-731
Tel. +82 31 465 6013
sales.kr@kistler.com

gall2 000

2012, Kistler Group

Singapore
Kistler Instruments (Pte) Ltd.
Singapore 573968
Tel. +65 6570 5377
sales.sg@kistler.com

100-459e-08.12

Australia

Headquarters
Switzerland
Kistler Group
Eulachstrasse 22, 8408 Winterthur
Tel. +41 52 224 11 11
Fax +41 52 224 14 14
info@kistler.com

America

Australia
Kistler Instruments Australia Pty Ltd
Wheelers Hill, Victoria 3150
Tel. +61 3 9560 5055
sales.au@kistler.com

Other Countries
Kistler Instrumente AG
Export Sales
Eulachstrasse 22, 8408 Winterthur
Switzerland
Tel. +41 52 224 11 11
sales.export@kistler.com

Brasil
Kistler Brasil Ltda
CEP 040 28-001, So Paulo-SP Brasil
Tel. +55 11 50520308
sales.br@kistler.com
Mexico
Kistler Instruments S de RL de CV.
Apodaca, NL. 66629
Tel. +52 81 4170 8075
sales.mx@kistler.com
USA/Canada
Kistler Instrument Corp.
Novi, MI 48377
Tel. +1 248 668 6900
sales.us@kistler.com

www.kistler.com