Development of Ultrasonic Oil Condition and Level Sensors for Use with NEXCEL

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Project Aim:The aim of this project is to develop an ultrasonic sensor that can predict the state and measure the level of the lubricant inside the NEXCEL oil cell over an extended period. The use of ultrasound for this application will greatly help with the design of the oil cell because it will remove the necessity to have a channel across the cell wall, for wires leading to an internally mounted oil sensor, thus removing a potential leak path and failure mode.Objectives: Explore the synergy of ultrasonic sensing with current level sensing methods. Identify sensor parameters and wave conditions to achieve most accurate level measurement within the NEXCEL. Identify the most suitable properties to measure as oil degrades and which sensor type is more capable at taking those measurements Identify which lubricant parameters can be measured to determine oil condition. Determining the best ultrasonic pulsing method to achieve measurement of the lubricant state through the NEXCEL cell wall. Create second prototype sensor on the NEXCEL dock, which will have sufficient contact with the bottom of the NEXCEL. Investigate and minimise variability where possible - Temperature, dimensions, comparisons between sensors (uniform loads and adhesive bonding layers) and more. Build prototype ultrasonic sensors using low cost parts that adhere to the requirements of the NEXCEL objectives. Test developments on the NEXCEL vehicle fleet or an engine dynamometer fitted with the NEXCEL system.Potential Application and Benefits:NEXCEL is a novel and superior oil sump that has been designed to reduce carbon dioxide emissions, ensure quick and easy oil and filter changes, safely collect and recycled oil, ensure a precise oil-engine match and finally, it helps the oil to warm up more quickly, stopping prolonged cold starts. This project aims to add sensors that will help predicted oil level and state, which in turn will lead to better use of engine oil, timely oil changes and the longer life of engine components.