Use Cases
Turbocharger shaft speed tracking
for ultra-fast turbo systems
Summary
Monitoring the rotational speed of turbochargers is a critical requirement in both R&D environments and operational testing of internal combustion engines. Traditional methods such as optical encoders or magnetic pickups can struggle under the extreme operating conditions of turbochargers—high temperatures, vibration, limited accessibility, and contamination from oil mist or dust.
The challenge
Modern turbochargers present extreme measurement conditions due to their speed and integration constraints.
- Shaft speeds exceed 200,000 rpm, requiring ultra-fast detection
- High temperatures, vibration, and oil mist compromise traditional sensors
- Limited space restricts sensor size and integration options
- Accurate and real-time speed tracking is vital for control and validation
Typical Applications
- Turbocharger testing on engine test benches (automotive, aerospace, industrial)
- Real-time turbo speed measurement for combustion control optimization
- Validation and calibration of exhaust gas and air intake systems
- Performance benchmarking of boosted engines in motorsport
- High-speed shaft monitoring for small rotating turbomachinery
The solution
Is a dedicated capacitive-based solution developed by FOGALE Sensors to monitor turbocharger speed with exceptional precision. It detects the passage of the compressor blades using a capacitive probe mounted on the turbo body, delivering one pulse per revolution (or more depending on configuration).
The system consists of:
- A triaxial capacitive sensor, available in high-temperature variants
- A conditioning module, offering analog and TTL outputs
- A dynamic detection mode based on DSP technology with auto-threshold adjustment
- Optional USB (TTY mode) configuration and visualization interface
- Shielded triaxial cable up to 20 m, adapted to challenging integration constraints
The output signal can be analog (0–10 V) or TTL, allowing direct acquisition by DAQ systems or integration into digital speed counting tools. A guided installation process using visual positioning indicators makes the setup quick and accurate.
Key Benefits
- Direct, non-contact speed measurement with high precision
- Fully operational up to 125 °C ambient (sensor & electronics)
- Dual output modes: analog voltage & TTL digital pulse
- Compact and robust: easy to install on most compressor housings
- No requirement for target modification or special blade coatings
- Immunity to EMI and vibration, ideal for test bench environments
- Flexible integration with PC or DAQ software (e.g., COM-port mode)
- Cost-effective and scalable for both R&D and embedded monitoring
The results
This solution ensures reliable, high-speed shaft monitoring in ultra-demanding conditions. It supports performance optimization, early anomaly detection, and robust validation.