Theoretical and numerical investigation of introduced errors in surface temperature measurements of pistons applied in internal combustion engine

DMP (Differences in Material Properties) often exists between temperature sensors and combustion chamber components of ICE (Internal Combustion Engine), resulting in IEs (Introduced Errors) in the temperature measuring process. In this paper, we present a comprehensive theoretical analysis of the correlation between introduced errors on chamber components and the DMP. The analysis process considers the characteristics of the chamber's heat transfer BC (Boundary Condition). Then, simulations are used to investigate the introduced error of hardness plug and thermocouple sensors on the top surface of an ICE aluminum alloy piston. The theoretical analysis results indicate that heat transfer BC can be segmented into the time-averaged and fluctuation parts, and IEs are linearly superimposed under these two parts of BCs. The heat conductivity impacts the time-averaged error and the product of heat conductivity, density, and heat capacity impacts the fluctuation error. The experimental and simulation results indicate that the max time-average error of the hardness plug on piston is 2.4 °C, with a fluctuation introduced error of 3.6 °C and a total introduced error of 6 °C; and the time-average introduced error of thermocouple sensor is 9.4 °C, with a fluctuation error of 5.8 °C and a total introduced error of 15.2 °C. Finally, a fluctuation error correction method is proposed to reduce error. After correction, the error is reduced by 71 % and 66 % for hardness plug and thermocouple, respectively.