Rail Pressure Sensors for Common Rail Fuel Systems

Engineered for high reliability and full localization, the Rail Pressure Sensor delivers stable and accurate measurement of dynamic fuel rail pressure in modern diesel common-rail and gasoline direct-injection (GDI) systems. Accurate rail pressure measurement is a critical factor in achieving precise fuel injection control, optimized combustion efficiency, reduced emissions, and stable engine performance under varying operating conditions.

This rail pressure sensor is designed to operate reliably in high-pressure, high-temperature environments where fuel pressure fluctuates rapidly during engine operation. Its customizable mechanical and electrical design allows it to be adapted to a wide range of engine platforms and fuel systems, supporting not only conventional diesel and gasoline engines but also advanced powertrain applications, including natural gas and hydrogen engine pressure regulation.

Measurement Principle and Performance

The sensor continuously monitors fuel pressure within the rail and converts it into a proportional electrical signal for engine control units (ECUs) or test systems. With pressure ranges reaching up to 300 MPa, the sensor is capable of capturing fast transient pressure changes associated with high-pressure injection events. This enables precise real-time feedback for closed-loop fuel control strategies.

Across the full operating temperature range of –40 °C to +140 °C, the sensor maintains consistent accuracy, with a specified accuracy of ±1.5% full scale (F.S.) over the entire temperature range. This thermal stability ensures reliable operation during cold starts, high-load conditions, and continuous high-temperature engine operation.

Electrical and Mechanical Characteristics

The rail pressure sensor operates on a 5 V ±0.25 V power supply and provides a linear analog output signal (10%–90% Vcc), making it compatible with standard automotive ECUs, data acquisition systems, and test benches. Low power consumption, with supply current below 15 mA, supports efficient system integration.

Multiple thread specifications (including M12×1.5, M14×1.5, and M18×1.5) and connector options are available, such as BOSCH-compatible connectors and AMP EI(II) series connectors. This flexibility simplifies mechanical integration and replacement in existing fuel systems while supporting OEM and test applications.

Typical Applications

Rail pressure sensors are widely used in:

• Diesel common-rail fuel systems, enabling precise injection pressure control

• Gasoline direct-injection engines, supporting combustion optimization

• Engine development and testing, including pressure characterization and validation

• Alternative fuel engines, such as natural gas and hydrogen platforms

• Automotive and powertrain research, where accurate pressure data is essential

In all these applications, reliable rail pressure measurement directly impacts engine efficiency, emissions compliance, and durability.

System Integration

The rail pressure sensor integrates seamlessly with Dynatronic data acquisition systems, engine test benches, and control platforms. When combined with temperature, vibration, speed, and combustion pressure measurements, it enables comprehensive analysis of fuel system behavior and engine performance.

Reliable Pressure Feedback for Advanced Engines

By combining high-pressure capability, wide temperature tolerance, stable accuracy, and flexible configuration options, this rail pressure sensor provides dependable pressure feedback for modern and next-generation engines. It is a robust solution for engineers who require precise, repeatable fuel pressure measurement in demanding automotive and powertrain environments.