Haptic pedals will reduce the flashing and beeping in the car

The accelerator pedal as an interface: Haptic driver communication is perceived as discreet and effective

Our vehicles are being equipped with more and more driver assistance systems, leading to better supported drivers and protected occupants. If necessary, errors are not only indicated, but even corrected. Plans are afoot to further improve the protection of pedestrians in road traffic. Current discussions in the EU Commission are examining the use of driver assistance systems to reduce the number of fatal traffic accidents.read more

Differential Pressure Sensors for the challenges of Euro 6

The region between particulate filter and catalyst needs differential pressure sensors for higher accuracy

Following my latest post about pressure measuring at the particulate filter, I would like to talk specifically about Euro 6 today. To meet the requirements and to achieve a reduction in nitrogen oxides, we need another catalyst behind the particulate filter. This approach will increase the technical requirements and results a need for differential pressure sensors.

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Step on the accelerator pedal – but protect the environment at the same time

Electronic accelerator pedals support today’s challenges

Can you remember? Those were the days of carefree motoring: stepping on the accelerator pedal, the wind in your hair, and ‘Born to be Wild’ blaring out over the radio.
Today, mobility is more important than ever, as transport of people and goods drives prosperity and growth. Yet our romantic attitude to motoring has developed into a pronounced environmental awareness, and exhaust emissions from all kinds of vehicles is the challenge we have to face. For several years, legislative initiatives have been in place: in Europe we recognize Euro 6, but other countries have also realized the need to reduce emissions and are acting accordingly.
India is a good example, and is taking a big step in a very short time to meet an emissions level which is similar to Euro 6. For new cars, the BS VI standard will take effect from the start of 2020.

Vehicle electronics – a key role for dynamic drive and emission reduction

Future challenges lie primarily with sensors and electronic systems like accelerator pedals and hand throttles. The constant reduction of limits for exhaust emissions needs increasingly accurate electronic signals and their execution in vehicles within milliseconds. Only if this complex interaction is performed in perfect synchrony, will vehicles be able to reduce fuel consumption and be more efficient, and therefore better for our environment.
For more than three decades, AB Elektronik has been a proven design partner for pioneering solutions, exemplified by its optimized portfolio of accelerator pedals. The European Competence Center at Werne an der Lippe, Germany, takes the lead in product and process design for these products, which are transferred for local manufacturing around the Group.

Human Machine Interface: Electronic accelerator pedal and hand throttle

The accelerator pedal is a direct communications interface with the driver, and an integrated sensor is used for continuous capture of the pedal-plate position. In an electronic hand-throttle, a sensor detects the position of the handle. This information is transferred from the sensor to the control unit very quickly and accurately. The control unit communicates with an actuator at the throttle-flap, which will open or close according to the sensor signal.
A complex process chain follows and will influence engine management, and via special control units, will also communicate with the ESC and ASR for example. In addition to ensuring efficiency, several features are provided for safety and comfort, which will be driven from the signals of the very same sensor in the accelerator pedal or hand-throttle.
The complexity of these processes, which all depend on this one sensor signal, create a need for technologies that are precisely designed for the individual needs of each customer application.

Constant improvement of technologies supports additional features

Recognition that the complex process chain, mentioned above, needs to be driven electronically, led AB Elektronik to introduce an electronic accelerator pedal for “Drive by Wire” solutions in 1998 – one of the first companies to do so.
Today, more and more car manufacturers are using this kind of pedal, and the traditional Bowden wires will soon be no more.

AB Elektronik – diversity of technologies leads to optimized solutions

Position sensors are integrated into the latest generation of accelerator pedals and electronic hand throttles, which convert the angle of the pedal plate or the rotary handle to an electronic signal. This way the signal can be sent directly to the control unit without loss.
The sensor technology used for AB Elektronik accelerator pedals is contactless. Two types of contactless technologies are available; HALL and AUTOPAD® technology. AUTOPAD® is a company-owned technology. AUTOPAD® uses a contactless inductive approach, and is operated with a static and dynamic element. Additionally, there are contact technologies – potentiometers – in use.
In all cases, signals are transferred very rapidly, with stability and high accuracy, fully satisfying the requirements of cutting edge vehicles. The majority of the pedals designed by AB use the reliable Autopad® technology, a patented internal development which has already been proven a million times over, and is also integrated into chassis applications, further underlining the robustness of this product and design.
Autopad® operates inductively. The required assembly space needed is compact compared with other systems and can be integrated easily into the pedal housing. The EMC immunity and signal quality meet the highest levels in our premium customers’ applications, and allow very efficient individual customer designs.

Accelerator Pedals and Hand Throttle – High demand for flexibility

Electronic Accelerator Pedals by AB Elektronik are distinguished by their electronic design and high flexibility in special customer applications for the car market. There is also a proven portfolio for truck design and two-wheelers, in series production for market leading OEM´s.

Individual Design for different electronic applications and volumes

AB Elektronik GmbH, accelerator pedal, standing, hanging, hand throttles, contactless, aktive, passenger cars, truck, two wheeler

AB Elektronik manufactures more than four million accelerator pedals and hand-throttles for the global market each year. The portfolio of customer specific designs is built on a basic pedal design that can be cost effectively upgraded to a customer design.

AB Elektronik GmbH, hanging pedal, passenger cars AB Elektronik GmbH, hanging pedal, truck AB Elektronik GmbH, standing pedal, passenger cars










Thank you very much for your interest.
For further information, please get in touch!

Roger Möllers

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Pressure Sensors in the exhaust system

With this blog I should like to make another contribution to the discussion of pressure sensing and control in the exhaust system.

Today`s topic: Pressure sensors before and after the particulate filter.

As stated in my last post, the exhaust after treatment for combustion engines is largely determined by thermodynamic processes. Temperature and pressure conditions play a major role. The monitoring of various pressures with special sensors in the exhaust pipe, among other locations, can give information about the load condition* of the particulate filter.read more

Exhaust System: Temperature measuring in the particulate filter

Temperature sensors – proven in diesel cars but also demand for petrol-cars in future

An important part of reducing the emissions of diesel combustion engines depends on knowing the temperature of the exhaust gases – let’s take a closer look at this topic:

AB Elektronik Sachsen GmbH High temperature sensor double

Diesel Cars: Temperature sensors are controlling some of the most important parts of the after-burning process.

Starting in the early 1990s, legislators around the world began to limit the amount of pollutants emitted by motor vehicles to protect the environment. While CO2 and other emissions from petrol-engines is a concern, a more significant focus has clearly been on the diesel engine.

The result – despite all the negative headlines – is, that today’s diesel vehicles are significantly cleaner than 10 or 15 years ago. There are a lot of improvements but importantly amongst these are temperature sensors, measuring directly in the exhaust pipe. This is a very demanding environment and, since the introduction of the EURO 5 emission standard in 2008 that demands diesel particulate filters, AB Elektronik has been actively involved in meeting this requirement.

Diesel particulate filters need temperature sensing for the regeneration process

To be effective, diesel particulate filters must be regularly regenerated during operation. Regeneration is an internal burning process, which starts at about 500 °C, and takes place without any involvement from the driver. Due to exothermicity, the release of heat during a chemical reaction, temperatures in the range of 700 to 800 °C can be achieved, which allow accumulated soot to be burnt off. In addition to pressure monitoring, which will be discussed in a later blog, temperature detection plays an important role in this process.

Since 2005: Project start for exhaust system temperature sensors

AB Elektronik’ engineering involvement in such applications began in 2005. At that time, AB Elektronik was able to purchase a license for a very robust temperature sensor setup. Subsequently based on the company’s long term experience with temperature sensors and with significant further engineering investment, AB Elektronik has refined its exhaust sensor design and made it ready for high volume production.

AB Elektronik Sachsen GmbH High temperature Sensor diesel particulate filter

AB Elektronik Sachsen GmbH high temperature sensor with electronic







The outcome is a very robust temperature sensor, based on a passive resistance measuring element that responds with different resistance values at different temperatures. Platinum is used as the resistance material as this element is characterised by a nominal resistance of 200 Ohm at 0 °C (PT-200).

The most important advantage of this high-temperature sensor is its robust design. The measuring element is embedded in a monolithically closed tube made of a special stainless steel using a particular ceramic powder mixture. The bubble-free filling of the sensor tip ensures that motor vibrations do not pose a threat to the sensor’s service life. In addition, the sensor can be bent from 0 to 120°. Specially developed seals guarantee a long service life even under the harshest environmental conditions in and around the exhaust pipe.

The next level of high temperature sensor design is up to 1200 °C

The experience gained in the last few years has enabled AB Elektronik to develop a new generation of high-temperature sensors. The aim of this development was to make a sensor technology suitable for use in vehicles that require temperature measurement up to 1200 °C, which is the case in petrol engines.

AB Elektronik Sachsen high temperature sensor design





AB Elektronik’ sensors incorporate N-type thermocouples to send continuous measurement signals to the vehicle’s control electronics. Thermocouples use the physical effect of thermoelectricity. A pair of metallic conductors of different materials are joined at one end. Due to the temperature gradient between the measuring point (hot side) and the plug side (cold side) an electric voltage is generated (see Wikipedia). This electrical voltage is proportional to the temperature change on the hot side and can thus be processed as a sensor signal. An electronic unit, which is integrated into the plug housing, provides the necessary signal processing.

Thermocouples have been used for many years in industrial electronics for temperature measurement. AB Elektronik’ sensor has been specially adapted to the requirements of automotive applications and only use welded or soldered connections to avoid signal interruption. Protective housings at the sensor tip are made exclusively from high-temperature-resistant stainless steel, using deep-draw technology. The sensors can be attached to the exhaust pipe with a union nut or hollow screw of various dimensions. Cable shields are used to allow high temperature resistance measurements in the vicinity of exhaust pipes.

Temperature Sensor : Various electronic interfaces are available

The electrical signal, as already mentioned, is processed electronically. Users can choose between different digital interfaces. To date, AB Elektronik has implemented PWM, SENT and CAN (according to SAE J1939). Like the entire sensor, the electronics unit offers protection class IP6K9K (with its mating connector).

This sensor is suitable for temperature measurements in the range -40 to 1200 °C. With these characteristics, the sensor can be used at any point in the exhaust pipe of petrol engines. Manufacturers of turbo-charged vehicle engines can also use this sensor in the exhaust manifold (before the turbocharger) to warn against excessive temperatures, which can be dangerous for the turbocharger.

Double high temperature sensors will be required for next generation of petrol engines

With the introduction of the latest emission standard (EURO 6c), direct-injection petrol engines must also be equipped with particulate filters for the first time. These use slightly different regeneration processes that, while similar to the particulate filters in diesel engines, need to operate at higher temperatures and require temperature measurements at two points.

Precisely for this application, AB Elektronik has developed a thermocouple sensor as a double module that combine two sensors with one electronics unit. Apart from cost benefits, this allows the sensors to be matched with tolerances of +/- 1 °C.

AB Elektronik Sachsen high temperature sensor optimized design






Best regards

Frank Rothe

Complete overview of our sophisticated sensor portfolio for the exhaust pipe.

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Blog exhaust system pressure sensors for particulate filter

Blog: Exhaust gas systems – Sensors are critical to enabling greener vehicle emissions

Frank Rothe, Product Application Manager Sensors at AB Elektronik Sachsen GmbH, considers the importance of sensors for exhaust gas systems in the drive to greener vehicle emissions

Mobility is essential to modern life, and is a key driver for economic growth. At the same time, the world’s ever-increasing traffic volumes are a major source of pollution, which poses a fundamental threat to our future.

AB Elektronik a trusted partner for specific sensors in exhaust gas systems

The solution lies in emission-free transport, an aim that leading car manufacturers and developers around the globe are working towards intensively. Until that goal can be fully achieved, new sensors, electronic systems and technologies will be instrumental in reducing emissions from combustion engines and their exhaust-after-treatment modules.


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