GERMAN-MALAYSIAN INSTITUTE

AHS 1853
AUTOMOTIVE SENSOR & ACTUATOR
Academic Period: July 2024

Temperature Sensor Report

GROUP MEMBERS :
1) MUHAMMAD AKIFFULLAH BIN MOHAMMAD AZMI
(AET23070519)
2) MUHAMMAD RAFIQ IMAN BIN SAIDI (AET23070026)
3) MUHAMMAD DANISH DARWISY BIN KHAIRUL ANUAR
(AET23070122)
4) MUHAMMAD RAFEIQ FURQAN BIN MOHD REDZHUAN
(AET23070405)

GROUP: SEM 3 DAET 2

TTO: MR. HAIRULAZMI

SUBMISSION DATE: 5TH SEPTEMBER 2024

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Table of Contents

1. OVERVIEW ....................................................................... 2

2. THERMISTOR ............................................................... 3-9

3. INTAKE AIR SENSOR ................................................ 9-13

4. CONCLUSION ................................................................ 14

5. REFFERENCES ............................................................. 15

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 1. OVERVIEW
This report takes a close look at how thermistors work, particularly in measuring
temperature. It starts by explaining the basics—how thermistors change their
resistance with temperature and what materials are used to make them. To bring these
concepts to life, the report focuses on a real-world example: the car air intake
temperature (IAT) sensor. This sensor is vital for cars because it helps the engine
control unit (ECU) manage the air-fuel mixture for better performance. The report goes
into how the sensor is calibrated and how its signals are processed to ensure accurate
temperature readings. In the end, it shows how this sensor plays a key role in making
engines more efficient, cutting down on emissions, and improving overall vehicle
performance.

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 2. THERMISTOR
2.1 DEFINITION
A thermistor is a type of semiconductor with higher resistance compared to traditional
conductors, designed to respond to changes in temperature. Its resistance varies
based on the specific materials used in its construction. Typically, thermistors are
made from a combination of metal oxides, binders, and stabilizers, which are molded
into wafers and then sliced into chips. The proportions of these materials influence the
thermistor's resistance characteristics and temperature response.

The term “thermistor” describes temperature-sensitive resistors known for their

precision and efficiency in temperature measurement. There are two main types of
thermistors: Positive Temperature Coefficient (PTC) and Negative Temperature
Coefficient (NTC). An NTC thermistor's resistance decreases with rising temperature,
whereas a PTC thermistor's resistance increases as the temperature goes up.

Thermistor symbol in electrical circuit.

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 2.2 TYPES
Thermistor are usually ceramic semiconductors. They are composed mainly of metal
oxides that dried to obtain the desired form factor.

2.2.1 NTC Thermistor: cobalt, nickel, iron, copper and manganese are the
primarly used material.

NTC Thermistor

NTC thermistor is used when a change in resistance over a large temperature range
is required. Range: -55*C to 2200*C. Even though they can be produced for measuring
either much lower or higher temperature, they have quick response, reliability,
robustness and low price.

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2.2.2 PTC Thermistor: barium, strontium, and lead titanates are primarily used.

PTC Thermistor

When a sudden change in resistance at a specific temperature is required, they exhibit

a sudden change or increase in resistance above a defined temperature (Curie
Temperature). Switching temperature ranges from 60*C to 120*C. They are used for
self-regulating heating elements, self-resetting, and over-current protection.

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2.3 ADVANTAGES AND DISADVANTAGES

Thermistors are temperature-sensitive resistors commonly used in temperature

measurement and control applications. They offer several advantages and
disadvantages.

2.3.1 ADVANTAGES

i. High Sensitivity: Thermistors exhibit high sensitivity to temperature changes,

allowing for precise temperature measurements, especially within a narrow
temperature range.
ii. Wide Temperature Range: Depending on the type (NTC or PTC), thermistors
can cover a wide temperature range, from cryogenic temperatures to several
hundred degrees Celsius.
iii. Small Size: Thermistors are compact and lightweight, making them suitable for
integration into small electronic devices and systems.
iv. Fast Response Time: They have a rapid response time to temperature
changes, enabling real-time monitoring and control of temperature-sensitive
processes.
v. Low Cost: Thermistors are relatively inexpensive compared to other
temperature sensing technologies, making them cost-effective for many
applications.

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2.3.2 DISADVANTAGES

i. Nonlinear Response: The resistance-temperature relationship of thermistors is

nonlinear, requiring complex calibration and compensation algorithms for
accurate temperature measurements over a wide range.
ii. Limited Accuracy: Despite their high sensitivity, thermistors may have limited
accuracy, especially at temperature extremes and in applications requiring high
precision.
iii. Self-Heating: When current flows through a thermistor, it generates heat due to
its resistance, potentially affecting the accuracy of temperature measurements,
particularly in low-power circuits.
iv. Limited Long-Term Stability: The electrical and mechanical properties of
thermistors may drift over time, leading to a decrease in accuracy and reliability
unless proper calibration and maintenance are performed.
v. Limited Operating Conditions: Some thermistors may have restricted operating
conditions in terms of temperature, voltage, and current, which can limit their
suitability for certain applications.
vi. Susceptibility to Environmental Factors: Environmental factors such as
humidity, pressure, and vibration can influence the performance of thermistors,
requiring additional measures for compensation and protection.

Thermistors offer high sensitivity, compact size, and cost-effectiveness, making them
widely used in temperature measurement and control applications. However, their
nonlinear response, limited accuracy, self-heating effects, and susceptibility to
environmental factors are important considerations when selecting and using
thermistors for specific applications. Proper calibration, compensation, and
environmental control are essential to mitigate these disadvantages and maximize the
performance and reliability of thermistor-based temperature sensing systems.

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2.4 NTC Thermistors Steinhart and Hart Equation

The Steinhart and Hart Equation is an empirical expression that has been determined
to be the best mathematical expression for resistance temperature relationship of NTC
thermistors and NTC probe assemblies.

The most common equation is:

Where:

“T” is in degrees Kelvin and “A”, “B”, and “C” are coefficients derived as follows:

First, measure the thermistor at three different temperatures. The temperatures should
be evenly spaced and at least 10 degrees apart. Use the three temperatures to solve
three simultaneous equations using these steps:

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Knowing A, B and C for a thermistor allows you to use the Steinhart and Hart equation
in two ways.

1) If resistance is known and temperature desired then use Equation 1 above.

2) If temperature is known and expected resistance is desired, use Equation below:

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 3. INTAKE AIR SENSOR

3.1 OVERVIEW
The IAT sensor is used to measure the temperature of the air entering the engine.
This measurement is used by the ECU to establish the amount of fuel to add to
provide optimal combustion.
The purpose of measuring the air temperature is to identify the density of the air. Cold
air is denser than hot air and therefore more fuel has to be added to cold air than hot
air in order to ensure optimal combustion. The density of the air is established by air
temperature and air volume (as measured by the MAF sensor).

IAT Sensor

3.2 LOCATION IN CARS

IAT sensor is typically located in the

engine's intake air system and plays a
crucial role in the engine control system by
providing input to the Engine Control Unit
(ECU) or Powertrain Control Module
(PCM).

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 3.3 SENSOR SIGNAL CONDITIONING

3.3.1 OVERVIEW

Signal conditioning is the preparation of an analog signal before it becomes digital.

This manipulation of a signal prepares it so technicians and engineers can accurately
and precisely measure it using digital tools.
Signal conditioning protects desired signals from unwanted components or effects by
using isolation or filtration. Signal conditioning devices use isolation to minimize the
effects of interference caused by ground loops or noise, which can affect
measurement accuracy. Filters are designed to minimize noise by rejecting signals
within a specific frequency range while allowing others to pass.

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3.3.2 PROCEDURE
1. Understand the IAT Sensor
 Type: The IAT sensor is usually a thermistor, which changes resistance with
temperature (more resistance at low temperatures, less at high).
 Output: It produces a varying voltage signal based on the temperature.
2. Inspect the Sensor
 Check for Damage: Look for any physical damage or corrosion on the sensor
and its connectors.
 Inspect Wiring: Ensure that the wires connected to the sensor are not frayed
or damaged.
3. Measure Resistance
 Disconnect Sensor: Turn off the engine and unplug the sensor.
 Use a Multimeter: Measure the resistance across the sensor’s terminals.
Compare the reading to the manufacturer’s specs for room temperature (e.g.,
2-5 kΩ at 20°C).
4. Measure Voltage
 Reconnect Sensor: Plug the sensor back into the harness.
 Power On: Turn the ignition key to "ON" (engine off).
 Measure Voltage: Use a multimeter to check the voltage output from the
sensor. The voltage should change with temperature: high when cold, low when
warm.
5. Signal Conditioning
 Amplify (if needed): If the signal is too weak, use an amplifier to boost it.
 Filter Noise: Use a simple RC (resistor-capacitor) filter to remove noise,
ensuring the signal is smooth and reliable.
6. Test in Real Conditions
 Warm Up the Engine: Start the engine and let it warm up. Monitor the sensor’s
output to see how it changes with the air temperature.
 Check ECU Response: Make sure the ECU adjusts fuel and ignition based on
the IAT readings, and that the engine runs smoothly.
7. Final Check
 Check for Errors: Use an OBD-II scanner to ensure there are no error codes
related to the IAT sensor.

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 3.4 APPLICATION
The intake air temperature sensor measures the temperature of the air entering the
engine. This information is essential for the engine control unit (ECU) to optimize fuel
injection and ignition timing, ensuring efficient engine performance and reducing
emissions. Here are some applications of IAT in a car:

1. Measuring Incoming Air Temperature:

 The primary function of the IAT sensor is to measure the temperature of the air
entering the engine’s intake manifold. This temperature can vary based on
ambient conditions and engine operation.
2. Optimizing Air-Fuel Mixture:
 The ECU uses the temperature data from the IAT sensor to adjust the air-fuel
ratio. Colder air is denser and contains more oxygen, requiring more fuel for
proper combustion, while warmer air is less dense and requires less fuel. This
helps in achieving optimal combustion efficiency.
3. Improving Engine Performance:
 By providing accurate air temperature data, the IAT sensor helps in optimizing
ignition timing and fuel injection. This leads to better throttle response,
smoother acceleration, and overall improved engine performance.
4. Enhancing Fuel Efficiency:
 With precise air temperature measurements, the ECU can fine-tune the air-fuel
mixture, which improves fuel efficiency. This means the engine can run more
economically, saving fuel and reducing operating costs.
5. Reducing Emissions:
 Proper air-fuel mixture and combustion timing, informed by accurate IAT sensor
data, help reduce harmful emissions. Efficient combustion means fewer
unburned hydrocarbons and other pollutants are released into the atmosphere.

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4. CONCLUSION

This report highlights the critical role that thermistors, specifically the Intake Air
Temperature (IAT) sensor, play in modern automotive engines. Thermistors,
with their temperature-sensitive resistance, are widely used for precise
temperature measurement in various applications, despite certain limitations
like non-linear response and environmental susceptibility. The IAT sensor
exemplifies how thermistors are applied in real-world scenarios, where
accurate temperature data is essential for the efficient operation of a vehicle's
engine.

By providing accurate temperature readings, the IAT sensor enables the

Engine Control Unit (ECU) to optimize the air-fuel mixture, improve engine
performance, enhance fuel efficiency, and reduce emissions. Signal
conditioning techniques ensure that the sensor's output is reliable and precise,
which is crucial for maintaining optimal engine operation.

In summary, the IAT sensor demonstrates how thermistor technology

contributes to achieving better engine performance, lower emissions, and
greater fuel economy, thereby supporting the broader goals of automotive
innovation and environmental sustainability.

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5. REFFERENCES

o https://www.boosttown.com/electrical_system/iat_sensor.php

o https://www.fluke.com/en-my/learn/blog/calibration/signal-conditioning-
ensures-measurement-accuracy
o https://medium.com/@promracing69/what-is-the-function-of-an-intake-
air-temperature-sensor-50bbae80d879
o https://blog.win-source.net/q-a/what-are-the-advantages-and-
disadvantages-of-thermistors/.

o https://www.ametherm.com/thermistor/ntc-thermistors-steinhart-and-
hart-equation/.
o https://www.iqsdirectory.com/articles/thermocouple/thermistors.html

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