SENSING MODULE , METHOD FOR DETECTING POLLUTANTS IN AIR AND VEHICLE
VENTILATION SYSTEM
Field of the invention
The present invention relates to a sensing module for detecting pollutants in air comprising a sensor processor for providing an output signal, the sensor processor being connectable to at least one sensing element, the at least one sensing element comprising a sensing layer of a material, electrodes in contact with the sensing layer to provide electrical characteristics to the sensor processor, and a heating element for heating the sensing layer, in which the sensor processor is connectable to the heating element for controlling the temperature of the sensing layer.
Prior art
Such a sensing module for detecting pollutants is disclosed in European patent EP-B-O 750 191. Two sensor elements are used, one specifically sensitive to oxidizing gasses, and one specifically sensitive for reducing gasses, arranged in a voltage divider arrangement. The output characteristics of the known gas sensor arrangement are dependent on a number of factors, including the operating temperature and the sensor age. Thus, the gas sensor arrangement has to be taken out of its operating environment often and checked for proper functioning and calibration.
Summary of the invention
The present invention seeks to provide a sensing module, e.g. sensitive for air pollutants and for use with a car ventilation control system, which is reliable and allows a long life time without the need for removal of the sensing module for testing and calibration purposes.
According to the present invention, a sensing module according to the preamble defined above is provided, in which the sensor processor is arranged to control the heating element to provide a predetermined temperature profile to the sensing layer, and to record the sensing layer response. From the recorded sensing layer response it can be determined whether or not the sensing module is functioning properly. This may be accomplished by looking at different characteristic values of the response curve, such as resistance peak values, time constants of response, etc.
In a first embodiment, the predetermined temperature profile comprises a rising ramp, followed by a falling ramp. When the structure of the sensing element has a sufficiently low heat capacity, it is possible to obtain such a temperature profile using the heating element, e.g. by driving the heating element with a current in accordance with the temperature profile.
In a further embodiment, the predetermined profile starts at an operating temperature (To), falls to a minimum temperature (Tmin), rises to a maximum temperature (Tmax) above the operating temperature (To), falls to the minimum temperature (Tmin) again, and then rises to the operating temperature (To). This may be accomplished easily, by only setting the operating temperature, minimum temperature and maximum temperature. The form of the temperature profile may alternatively be a triangular shape, or may also have a more complex shape.
The present invention can be advantageously used when calibrating the sensing module. The processor may be arranged to provide the predetermined temperature profile in a calibration environment, and to monitor the functionality of the sensing element based on the recorded response of the sensing layer. This allows to determine the proper functioning of the sensing module, and e.g. the current characteristic base value (e.g. resistance RO) of the sensing element.
Alternatively, the processor is arranged to provide the predetermined temperature profile in a calibration environment, and to determine the sensitivity of the sensing element based on the recorded response of the sensing layer. As the sensitivity of the sensing module may vary over the life time of the sensing module, a re-calibration should be performed on regular intervals. hi an even further embodiment of the present invention, the processor is arranged to provide the predetermined temperature profile in an operational environment, and to determine a degree of pollution of the operational environment by comparing the recorded response of the sensing layer with prerecorded response patterns. The response of the sensing element in an operational environment, i.e. with the presence of pollutants such as CO, NOx, etc, depends on the concentration levels of the pollutants. A different pollution level will result in a different (dynamic) response of the sensing element, thus allowing to determine or predict a pollution level by comparing the actual response to the temperature curve with pre-stored responses.
In a further aspect, the present invention relates to a vehicle ventilation system, in which supply of outside air to an inner space of the vehicle is controlled using a ventilation controller, the ventilation controller being arranged to interface with a sensing module according to the present invention. In an even further aspect, the present invention relates to a method for detecting pollutants in air using at least one sensing element, the at least one sensing element comprising a sensing layer of a material, and a heating element for heating the sensing layer, the method comprising controlling the temperature of the sensing layer. The method further comprises controlling the heating element to provide a predetermined temperature profile to the sensing layer, and recording the sensing layer response. Further embodiments of the present method are described in the dependent method claims. In a particular embodiment, the method further comprises an initial calibration of the sensing element in a controlled environment, and compensating for drift of the calibrated sensitivity during operational use as determined from the recorded response of the sensing layer in an operational environment. This allows to use a sensing module for detecting pollutants in air which has a high quality, and maintains its quality over a long span of time.
Short description of drawings The present invention will be discussed in more detail below, using a number of exemplary embodiments, with reference to the attached drawings, in which
Fig. 1 shows a schematic diagram of an embodiment of a sensing module according to the present invention;
Fig. 2 shows a cross sectional view of a sensing element as used in the sensing module of Fig. 1;
Fig. 3 shows a plot of a temperature profile as applied using the present invention; and
Fig. 4 shows a number of characteristic response plots of a sensing element as used in the present invention.
Detailed description of exemplary embodiments
Electro chemical sensing elements are used presently for detecting pollution in air, such as oxidizable gasses (CO, CHx,...) and reducable gasses (NO, NOx,...). These
kind of sensing elements may be used to control the ventilation system of a vehicle, such as a passenger car. More general, such sensing elements are used in heating, ventilation and air conditioning systems (HVAC). When pollution occurs in outside air, e.g. when entering a badly ventilated tunnel filled with exhaust fumes, the air vent of the vehicle may be closed off (internal air circulation).
In Fig. 1, a schematic diagram is shown of a sensing module 1 for use in a vehicle ventilation system. The sensing module 1 comprises one or more sensing elements 3, which are connected to a processor 2. The processor 2 may be a dedicated electronic circuit which processes the signals from the sensing elements 3 (analog or digital circuitry, or a combination of both), or may be in the form of a general purpose processing unit 2 connected to a memory 4 (e.g. an integrated memory). The memory 4, e.g. in the form of semiconductor memory units, may comprise (software) program instructions which control the functioning of the processing unit 2. The processor 2 is arranged to provide an output signal 5, which may be transferred to the vehicle ventilation system (not shown) for controlling the operation thereof.
The sensing elements 3 are usually electro chemical sensing elements, which comprise a sensing material of which a physical property, such as its resistance, changes under the influence of the concentration of certain compounds in the ambient air around the sensing element 3. The sensing elements 3 may be especially suited for detecting oxidizable gasses, such as CO and hydrocarbons, reducable gasses, such as NO and NOx, and other compounds, e.g. volatile organic compounds (VOC). Volatile organic compounds may e.g. originate from manure, compost or asphalt. When these compounds or gasses are present in the ambient air of a vehicle, the normal operation of the vehicle's ventilation system would allow these to enter the vehicle interior, which can be unpleasant or even dangerous for the occupants of the vehicle. Thus these sensors are normally used to shut of the external air intake when too high a concentration of any of these compounds is detected. hi Fig. 2, a cross sectional view is shown of an embodiment of an electrochemical sensor 3 which may be used in the present invention. On a silicon substrate 11, a thin membrane layer 12 is formed, and the substrate 11 is etched to provide a cavity under the membrane layer 12. On the membrane layer 12, a heating element 14 is positioned, on top of which an insulating layer 13 is deposited. Then, electrodes 15 (e.g. finger form electrodes) are provided on top of the insulating layer 13, above the heating
element 14. Finally, a sensitive layer 16 is formed on top of the electrodes 15, e.g. by drop deposition of a material such as polycrystalline SnO2. The sensitive layer 16 has an electrical characteristic, e.g. its resistance, which depends on the concentration of certain compounds, such as reducing or oxidizing gasses, in the environment of the sensing element 3. This resistance may be measured using the electrodes 15. As the structure of the actual sensing part of the sensing element 3 is very thin resulting in a low thermal mass, the temperature of the sensing layer 16 is accurately controllable using the heating element 14.
Multiple sensing elements 3 may be provided on the same substrate 11 (using multiple cavities), which would e.g. allow to measure the concentration of both reducing and oxidizing gasses. Also, signal processing electronics (such as processor 2 and memory 4) may be integrated in the substrate 11, providing an integrated sensing module 1.
Due to the physical nature of the sensing element 3, the output signal of the sensing element 3 is not only dependent on the concentration of the compounds to be detected, but also dependent on other physical parameters, such as temperature, age of the sensing element 3, etc. Thus, a calibration is required of the sensing element 3, which may be provided by the processor 2 of the sensing module 1.
The processor 2 may be programmed to apply a temperature profile, of which an exemplary embodiment is shown in Fig. 3, to the sensing layer 16 using the heating element 14, when the sensing element 3 is in a calibration environment, e.g. comprising clean air. The temperature profile e.g. starts at a first temperature (To), e.g. an operating temperature of 3000C, decreases to a minimum temperature (Tmin), e.g. room temperature, and subsequently increases linearly to a maximum temperature (Tmax), e.g. 4000C. Then, the temperature again decreases to the minimum temperature Tmax. After that, the temperature increases again to the operating temperature To. The response of the sensing layer 16 is measured, e.g. by measuring the resistance between the electrodes 15, and stored by the processor 2 in memory 4.
From the stored response, a number of characteristics related to the sensing element 3 can be deducted. Firstly, it can be established that the sensing element 3 still provides its basic function, i.e. a response is received from the sensing element 3 which is within predetermined boundaries. Furthermore, from the stored response it is possible to determine or estimate the sensitivity of the sensing element 3. E.g., in the
stored response, peak values of resistance may be determined with the associated temperature. Also, time constants of response profiles maybe determined.
Alternatively, a subset of resistance values as measured during the temperature ramp profile are used, which show a correlation to the sensitivity. For the skilled person, it will be clear that other temperature profiles may be used in the present invention, e.g. a triangular profile starting at room temperature, rising to a maximum temperature above the operating temperature, and then decreasing again to room temperature.
The parameters determined from the calibration response, such as the sensitivity of the sensing element 3, or the entire calibration response, may be stored in the memory 4.
The temperature profiling may also be applied to the sensing element 3 during operation. The response of the sensing element 3 to the temperature profile will depend a.o., on the concentration of the pollutant in the environment of the sensing layer 16, for which the sensing element 3 was designed. It is possible to store a number of characteristic response profiles or characteristic parameters of response profiles as a function of e.g. the concentration of pollutants, and to compare or match the actually measured response characteristic with the stored response characteristics to determine or predict the actual pollution concentration. The initial calibration of the sensing element 3 may then be performed in a controlled environment using known gasses, and during operational use, the method of using the temperature profile calibration maybe executed to compensate for drift of the calibrated sensitivity.