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Pressure Sensors

Affordable in-cylinder pressure measurement has never been so attainable! Our sensors are all standalone units, no additional amplifier is required for them. There are two main possibilities to insert a cylinder pressure sensor inside a cylinder:
  • Drill-in sensors
  • Sensor integrated into the spark plug or glow plug
Those sensor types have both advantages and disadvantages. It always needs to be considered that selecting a sensor type (not to mention the sensor itself) could have an influence on the captured cylinder pressure trace. Therefore, all the collected results need to be evaluated accordingly. Due to these facts the sensor type should be selected for the needs of the given application. General engineering truth applies here, there is no perfect solution, you must find the best trade-off.

Drill in sensors

  • Usually, the sensor does not have a direct contact with the combustion chamber – lower resolution due to the limited frequency respond
  • Easy to mount, machining is not required
  • Mainly used for customer projects / calibration

Spark plug/glow plug mounted sensors

  • Usually, the sensor does not have a direct contact with the combustion chamber – lower resolution due to the limited frequency respond
  • Easy to mount, machining is not required
  • Mainly used for customer projects / calibration
Beru PSG
Optrand drill-in
Optrand spark-plug
Mazda
Piezoelectric (AVL, Kistler…)
Signal quality
Robustness
Knock
Dimensions
Price

Optrand AutoPSI

Optrand’s AutoPSI is our best-selling sensor, which has a proven track record not only at us, but race teams, OEMs, and other industries (marine, off-highway) as well. It has been running in industrial gas engines and marine applications for years without any wear and has already covered more than 30 thousand kilometres in our test vehicles! This is what we call reliability!

The dimensions and geometry of the sensor are similar to Kistler’s 6052 piezo type pressure transducer, which makes it eligible as a replacement for industrial and OEM applications as well. Due to its small size (M5x0,5), almost every cylinder head could be modified to it those, in which we can also assist you. The signal quality is seamless. The high frequency range (up to 60kHz) makes it perfect for knock recognition, while the signal to noise ratio is the best we have seen ever. This is due to the fiber optic measuring principal, which eliminates the effect of electrical components like ignition coils or injectors.

This sensor is the best for you if you would like to have no compromise in signal quality and reliability, however, it comes with a trade-off, as additional modifications are needed in the cylinder head. If you would like to use it as a mapping tool, check out the spark plug version as well!
Image
£ 1,295 + VAT
Parameters
Pressure range
7-700 bar (different ranges available)
Nominal bandwidth
Up to 60 kHz
Power voltage
5 V
Used for
Cylinder pressure measurement, low pressure indication (intake/exhaust)
Thread
M5 x 0.5
Tightening torque
2Nm

Optrand PSIPlug (KnockPlug)

A great valuable alternative of the piezoelectric sparkplug sensors is the Optrand PSIPlug. It consists of an AutoPSI pressure transducer, and a bespoke modified OEM spark plug. Although it has a lower frequency range due tot he passage in between the sensor and the combustion chamber, BDN Automotive has developed a method to capture knock with these sparkplugs indirectly, which is only available at us!

When it comes tocombustion analysis, most people are worried about high price, unreliable operation and complexities. With a sensor built in to your spark plug (or glow plug alternatively) the instrumentation takes only some minutes. There is no neeed to modify the cylinder head, and the spark plug’s behaviour will not change either! This is the best choice for you, if you wish to use our combustion analyser as a tool for example to map customer cars on a rolling road, or even while driving.

The spark plug and the 3.5mm sensor are 2 separate compoents, which means that you do not need to have multiple sets for different cars, you can just swap the sensor between your modified spark plugs.
Optrand PSIPLUG
£ 1,745 + VAT
Parameters
Pressure range
200 bar
Nominal bandwidth
Depending on the spark plug’s geometry
Power voltage
5 V
Used for
Gasoline engine mapping, diesel mapping (glow plug)
Thread
M3.5 x 0.6
Tightening torque
Sensor (M3.5): 1.5 Nm Spark plug/Glow plug: Use manufacture recommended torque

Mazda Skyactive-X

Mazda developed a spark assisted HCCI version for their Skyactive engine family, which has a cylinder pressure sensor in it. As it is an OEM off-the-shelf part, quality and availability will never be an issue!

This is a drill-in sensor with an M8 thread, and 160mm length, which is clearly a drawback for it, as it is sometimes hard to fit into a tight engine bay. Signal quality is amazing, knock recognition orks perfectly. Due to its larger size, it is not that sensitive for thermal drift, which might occur in smaller sensors (the BDN CA-6 compensates for that).

This is mainly for people with a lower budget, who are willing to spend more time on the instrumentation, as it might need some welding for the oil/coolant chambers as well, however, it does not mean that it is any worse than an Optrand, just a bit bigger.
£ 595 + VAT
Parameters
Pressure range
200 bar
Nominal bandwidth
> 15 kHz
Power voltage
5 V
Used for
Projects where the size is suitable
Thread
M8 x 1

Beru PSG

Beru announced their PSG glow plug in the early 2000’s, which then became an OEM part for VW and Opel/Vauxhall diesel engines. This is clearly the cheapest sensor on the market, but it comes with some limitations as well. The nominal frequency range is 5Khz, which is in reality about 1.5 times more approximately, however, still not enough for a reliable knock detection.

This is the best choice for you if you would like to tune a Diesel engine. It is available in 2 different diameters (M9 and M10), and several lengths, but usually you need to modify the stock glow plug holes for it unless you have an Opel/VW Diesel engine. NOTE: Not recommended for gasoline vehicles, as the tip could heat up, and act as a hot spot, which then generates auto-ignition!
Beru PSG
£ 245 + VAT
Parameters
Pressure range
200 bar
Nominal bandwidth
5 kHz
Power voltage
3.3 V / 5 V (depending on part number)
Used for
Diesels up to 200 bars cylinder pressure
Thread
M9 / M10
Tightening torque
See attached chart

Optrand AutoPSI

Optrand’s AutoPSI is our best-selling sensor, which has a proven track record not only at us, but race teams, OEMs, and other industries (marine, off-highway) as well. It has been running in industrial gas engines and marine applications for years without any wear and has already covered more than 30 thousand kilometres in our test vehicles! This is what we call reliability!

The dimensions and geometry of the sensor are similar to Kistler’s 6052 piezo type pressure transducer, which makes it eligible as a replacement for industrial and OEM applications as well. Due to its small size (M5x0,5), almost every cylinder head could be modified to it those, in which we can also assist you. The signal quality is seamless. The high frequency range (up to 60kHz) makes it perfect for knock recognition, while the signal to noise ratio is the best we have seen ever. This is due to the fiber optic measuring principal, which eliminates the effect of electrical components like ignition coils or injectors.

This sensor is the best for you if you would like to have no compromise in signal quality and reliability, however, it comes with a trade-off, as additional modifications are needed in the cylinder head. If you would like to use it as a mapping tool, check out the spark plug version as well!
Image
£ 1,295 + VAT
Parameters
Pressure range
7-700 bar (different ranges available)
Nominal bandwidth
Up to 60 kHz
Power voltage
5 V
Used for
Cylinder pressure measurement, low pressure indication (intake/exhaust)
Thread
M5 x 0.5
Tightening torque
2Nm

Optrand PSIPlug (KnockPlug)

A great valuable alternative of the piezoelectric sparkplug sensors is the Optrand PSIPlug. It consists of an AutoPSI pressure transducer, and a bespoke modified OEM spark plug. Although it has a lower frequency range due tot he passage in between the sensor and the combustion chamber, BDN Automotive has developed a method to capture knock with these sparkplugs indirectly, which is only available at us!

When it comes tocombustion analysis, most people are worried about high price, unreliable operation and complexities. With a sensor built in to your spark plug (or glow plug alternatively) the instrumentation takes only some minutes. There is no neeed to modify the cylinder head, and the spark plug’s behaviour will not change either! This is the best choice for you, if you wish to use our combustion analyser as a tool for example to map customer cars on a rolling road, or even while driving.

The spark plug and the 3.5mm sensor are 2 separate compoents, which means that you do not need to have multiple sets for different cars, you can just swap the sensor between your modified spark plugs.
Optrand PSIPLUG
£ 1,745 + VAT
Parameters
Pressure range
200 bar
Nominal bandwidth
Depending on the spark plug’s geometry
Power voltage
5 V
Used for
Gasoline engine mapping, diesel mapping (glow plug)
Thread
M3.5 x 0.6
Tightening torque
Sensor (M3.5): 1.5 Nm Spark plug/Glow plug: Use manufacture recommended torque

Mazda Skyactive-X

Mazda developed a spark assisted HCCI version for their Skyactive engine family, which has a cylinder pressure sensor in it. As it is an OEM off-the-shelf part, quality and availability will never be an issue!

This is a drill-in sensor with an M8 thread, and 160mm length, which is clearly a drawback for it, as it is sometimes hard to fit into a tight engine bay. Signal quality is amazing, knock recognition orks perfectly. Due to its larger size, it is not that sensitive for thermal drift, which might occur in smaller sensors (the BDN CA-6 compensates for that).

This is mainly for people with a lower budget, who are willing to spend more time on the instrumentation, as it might need some welding for the oil/coolant chambers as well, however, it does not mean that it is any worse than an Optrand, just a bit bigger.
£ 595 + VAT
Parameters
Pressure range
200 bar
Nominal bandwidth
> 15 kHz
Power voltage
5 V
Used for
Projects where the size is suitable
Thread
M8 x 1

Beru PSG

Beru announced their PSG glow plug in the early 2000’s, which then became an OEM part for VW and Opel/Vauxhall diesel engines. This is clearly the cheapest sensor on the market, but it comes with some limitations as well. The nominal frequency range is 5Khz, which is in reality about 1.5 times more approximately, however, still not enough for a reliable knock detection.

This is the best choice for you if you would like to tune a Diesel engine. It is available in 2 different diameters (M9 and M10), and several lengths, but usually you need to modify the stock glow plug holes for it unless you have an Opel/VW Diesel engine. NOTE: Not recommended for gasoline vehicles, as the tip could heat up, and act as a hot spot, which then generates auto-ignition!
Beru PSG
£ 245 + VAT
Parameters
Pressure range
200 bar
Nominal bandwidth
5 kHz
Power voltage
3.3 V / 5 V (depending on part number)
Used for
Diesels up to 200 bars cylinder pressure
Thread
M9 / M10
Tightening torque
See attached chart
Hiventures
bdn automotive

BDN Automotive Kft.