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RESOURCES & SUPPORT

RELUCTOR WHEEL MANUFACTUR ING

COMPACT MOBILITY SOLUTIONS

SENSOR INSTALLATION INFORMATION

PLEX DATA CONFIGURATION

SENSOR MACHINING SERVICES

WIRING HARNESS DOCUMENTS

DC Inc

Showcase the process of adding combustion testing

Test Engine / Sensor Install 850 Polaris Patriot

2 cylinder / 2 stroke
85mm bore x 74mm stroke
Water cooled
Fuel injected
91 octane fuel
Widely used in Polaris performance trail and mountain sled market approx. 165 HP
Same 850 engine platform used with factory turbo charger approx. 185 HP

Device mounting in compact spaces for mobility

PCA 2000 Plus 4×4 inches
250 Grams -Light weight and compact enables easy mounting with adhesive products
Weatherproof / PCA is IP67 sealed
DC wiring is weatherproof 295 grams (mini harness shown)
Amplifier 2×3 inches 85 grams
GPS positioning
Compact battery options available wired for direct connection with DC Inc wiring harnesses
Access to ethernet cable- used for PC viewing, device configuration and data downloading from device when logged internally during mobility

Crank trigger options

Plex uses toothed trigger wheel patterns of 20,24,36,60,90 and 120 with one (1) or two (2) missing tooth formats / patterns
Sensors used are VR (mag) and or Hall effect (powered)
Can utilize and share factory crank trigger signals that meet above criteria
Encoders 360 or 720

Sensor placement considerations

Access to sensor installation
Cable routing clearance for wiring from moving shafts, rotating parts, steering, high temperatures
Sensor cables can reach amplifier
Sensor cables avoid high voltage electronics (IE coils)
Sensor installation avoids water passages
Sensor installation avoids oil
Sensor installation tool passes exterior challenges
Sensor location in combustion space

Sensor machining insights

Making a cutaway is a nice tool to ensure sensor machining is properly located.
Using a CAD model and sensor positioning is a great choice whenever possible.

Determining an angle to machine your sensor in your cutaway

Review of water and oil passages
Casting thicknesses
Areas beyond the casting exterior IE: Head bolts, Exhaust , Chassis constrains
Location and intersection into combustion space (50/50 bisection of quench and combustion space)
Depth of sensor vs angles effect on sensor passage .080-.125 is ideal

Machining for sensor

Setup in mill based on angle required
Spot face using center cutting endmill flat .312 (5/16)
Center drill .125 diameter with sturdy center drill
Form drill to depth (drill is machined for sensor seat face seal)
Tap M5 x.5
All tools are available from DC Inc

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