Laser-Structured Thin Film Sensor Technology for Sliding Bearings in Internal Combustion Engines

This paper deals with research work related to advanced sensor technology that is highly integrated into sliding bearings so that information is obtained nearly directly from relevant areas such as the bearing running layer and the lubrication gap. An isolated, sputtered sensor layer with a thickness of a few micrometers is employed in combination with a laser structuring process to form the desired thin film sensor structure below the bearing running surface. While several measurement parameters and corresponding sensor types are conceivable, this paper focuses on temperature and strain measurements that rely on a change in the electrical resistance of the sensor layer material. Promising sensor layouts and positions targeted for use in condition monitoring applications in ICEs are elaborated in detail. Developments and challenges in implementing the sensor technology concept - in particular with regard to the process of manufacturing the sensor as well as the wire contacting - are outlined in depth. The paper concludes by presenting measurement results obtained with this sensor technology at lab scale as well as an outlook towards implementing the instrumented bearings in ICEs. (the abstract has been shortened for the web input form, please find the complete abstract included in the submitted publication manuscript)