Today’s cars are packed with an impressive array of sensors — electrical components that enhance passenger safety, enable predictive maintenance, and optimize overall performance.
As the industry shifts its focus to EVs, autonomous vehicles, and alternative fuels, these sensors are not only becoming more complex but are also increasing in number. Many modern ICE vehicles are estimated to have up to 100 sensors, while a new EV might house up to three times as many.
To keep pace with these changes, it’s crucial for both professionals and consumers to understand the functions of these sensors, how they work together, and their impact on the future of the automotive industry.
Understanding the Role of Sensors: 3 Critical Categories
Vehicle sensors perform a host of functions and can be found in almost every part of the car — from the engine to the exhaust.
These sensors track the temperature, pressure, or performance of a specific component, and relay information back to one of many Electronic Control Units (ECUs). The ECUs, in turn, process this data to make real-time adjustments and improvements.
The scope of applications is immense. A sensor could be used to measure oil levels and prevent engine failure; deploy airbags that save a passenger’s life; or detect whether it’s raining outside to automatically turn on the windscreen wipers.
For convenience’s sake, let’s categorize these sensors based on their functionality.
1. Engine and Transmission Management Sensors
It’s estimated that the engine of a car alone has anywhere between 15-30 sensors. These devices monitor key performance metrics such as temperature, pressure, or air-fuel mixture to ensure optimal engine performance and efficiency. Some examples include:
- Oxygen sensors: Monitor the oxygen levels in the exhaust pipe of a vehicle to determine if the engine is burning fuel efficiently
- Engine oil sensors: Monitors oil levels to prevent premature wear and tear.
- Coolant level and temperature sensors: Prevent engines from overheating
- Mass airflow sensors: Measure the amount of air entering the engine to determine how much fuel to release
- Engine speed sensors: Monitor how fast the engine is rotating to enable ABS systems, and more
- Throttle and camshaft positioning sensors: Monitor camshaft positioning and timing, as well as the throttle valve’s position
Similarly, several other sensors contribute to the overall performance of a vehicle, ensure fuel efficiency, and ensure the longevity of crucial components.
2. Driver Assistance Sensors
At the same time, modern devices can enhance the experience of being behind the wheel. These devices can be broken down into the following categories.
Camera Sensors
Today’s cars are fitted with on-board cameras that offer rich real-time information about a vehicle’s surroundings. This includes lane markings, speed limits, traffic lights, and more — providing valuable data to help drivers make better decisions.
Certain infrared cameras are capable of spotting movement in the dark, while others enable easier parking. Modern computer vision systems don’t just improve driver experience — they’ve proven to be critical in the development of autonomous vehicles.
Ultrasound Sensors
These sensors use acoustic signals to help drivers maneuver through tight spaces while avoiding any potential collisions. These cost-effective sensors are best used to detect obstacles at short distances and are thus a handy parking assist tool.
Radar sensors
Radar systems can be fitted to both the front and rear of the vehicle. These devices use electromagnetic signals to sense metal objects and can help a driver navigate traffic, or identify a car approaching from behind.
Lidar sensors
In their current state, Lidar sensors are more capable of detecting non-metal obstacles than radar systems, making them integral to emergency braking, among other functions. However, in the near future, Lidar technology is expected to grow further, contributing to the real-time 3D monitoring of a vehicle’s surroundings.
3. Safety Sensors
Sensors are not just crucial for the performance of a vehicle — they also actively ensure the driver and passenger’s safety.
Automotive airbag sensors are, of course, an obvious example. However, even lesser-considered devices, like tire pressure monitoring sensors, can be exceptionally crucial to ensuring safe handling of a car.
Meanwhile, collision sensors not only warn of a potential accident but also deactivate crucial components of a car in case of a crash — protecting both vehicle and passenger.
ABS sensors and traction control systems enhance handling and grip, while advanced camera sensors warn a driver in case they unintentionally veer from their lane, come close to surrounding objects, or go dangerously above the speed limit.
How Sensors Enable Predictive Maintenance
As we’ve seen, the vast amount of data collected by these advanced sensors go a long way in ensuring the efficiency of a vehicle and safety of a passenger. But sensor technology is also crucial for another reason — it enables predictive maintenance.
At a time where one in three American car owners say they cannot afford an unexpected auto repair bill, predictive maintenance has emerged as a top trend in 2024. And none of it would be possible without recent advancements in automotive sensors.
Repair shops, fleet managers, and car owners can leverage the real-time data offered by various IoT devices, maintenance logs, and onboard cameras to identify issues long before they become extremely expensive to fix.
The data can be visualized with advanced automotive repair software and analyzed with the help of AI algorithms to detect anomalies. The reports generated help devise more accurate maintenance schedules and minimize the likelihood of component failures.
But predictive maintenance isn’t just valuable in passenger vehicles — it’s also crucial for larger transportation companies tasked with ensuring the uptime of a fleet.
It’s estimated that some modern trucks can have 400 sensors and 130 million lines of code. Fleet management telematics helps trucking companies ensure that their assets are working at an optimum and minimal cost.
What’s Next for Automotive Sensor Technology?
In 2023, the automotive sensor market was estimated to be worth $30.8 billion. However, as manufacturers strive to make vehicles more autonomous and electrified, the market is expected to double to $62.2 billion by 2028.
The shift from traditional internal combustion engines towards electrified power trains will require temperature and pressure sensors to take on a more crucial role.
These sensors will be expected to prevent batteries from overheating or monitoring pressure in hydrogen fuel cells — all while maximizing power and torque. Modern sensors will also prove crucial in improving the range and safety of EVs.
The rise of autonomous vehicles, too, is linked to the evolution of various sensors.
In the near future, Radar, Lidar, and onboard cameras will be expected to work in tandem with various other devices to give the vehicle a comprehensive overview of its environment — and be able to navigate its surroundings on its own.
At the end of the day, the next generation of sensors will not only be more accurate and interconnected — leveraging the latest in AI, machine learning, and 5G technologies — they will make cars safer, smarter, and more eco-friendly.
Steven Meyers writes on consumer automotive topics and industry trends, specializing in vehicle technology and business technology innovations for manufacturers and mechanics. With a 20-year career in the industry, his articles provide valuable insights for professionals and enthusiasts navigating the ever-evolving world of cars and automotive technology.
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