Simulation-based guidelines were developed for designing tube-mounted gas sensors in the exhaust pipes of diesel and petrol engines, taking into account thermal constraints and gas flow conditions. Different block and tube mounting alternatives for SiC-based gas sensors were studied by means of temperature measurements and simulation of steady state heat transfer and gas flow. Design variables included the number of fins in the heat sink mounted on the inlet tube, the inlet construction, the mounting tube orientation, and the micro-heater substrate placement inside the mounting tube. The most preferable tube mounting design was determined with respect to the thermal performance of the sensor structure and with respect to the gas flow parameters, which are important for the sensor's selectivity, sensitivity and response time.
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