ANALYSIS AND CALIBRATION OF FUEL PRESSURE SENSOR FOR DIESEL ENGINE INJECTOR FAULT DIAGNOSTICS

Ennsuring the reliable and efficient operation of a diesel engine is impossible without accurate control of key parameters of the fuel system. One of the most important parameters is the fuel pressure in the high-pressure rail, whose dynamic fluctuations reflect the technical condition of the injectors and high-pressure fuel pump. Modern electronic engine control systems, including IIoT solutions, operate with large volumes of data, requiring high-precision, high-speed data acquisition and real-time analysis. The pressure sensor, as a critical element of such systems, must meet strict requirements: wide measurement range (up to 180 MPa or higher), high frequency response (≥ 1 kHz), accuracy of at least ±1 %, and stability under temperature and mechanical stresses. Compatibility with microcontrollers (such as Arduino Portenta H7) is equally important to ensure flexibility for use in both modern Common Rail and older mechanical diesel systems. For accurate diagnostics of pressure pulsations generated by injector operation, a sampling rate of at least 24 kHz is required at engine speeds up to 4000 rpm. This imposes additional requirements on the performance of both the microcontroller and the ADC. The use of edge computing technologies allows for the reduction of transmitted data volumes and enables preliminary signal processing at the data acquisition level, reducing network and server load. This paper presents the selection process, calibration methodology, and experimental validation of a piezoresistive Bosch 0281006188 pressure sensor for diesel engine fuel system condition monitoring. The calibration procedure using an Arduino Portenta H7 microcontroller is described, along with the results of linearity assessment and measurement uncertainty analysis. The system achieves a total measurement error of approximately 1–2 %, which is sufficient for reliable injector diagnostics and integration into advanced IIoT-based engine monitoring systems.