Wiring a linear position sensor—such as a shock travel sensor or throttle position sensor—into your ECU or data acquisition system (DAQ) is a critical step for accurate data capture and performance tuning. Whether you're logging suspension movement, monitoring steering angle, or tracking pedal travel, proper installation ensures clean, reliable data.
Let’s walk through the basics.
1. Identify the Sensor Type and Output Signal
Before wiring, you need to know the output type of your linear position sensor. At The Sensor Connection, we offer:
- Analog Voltage Output (e.g., 0–5V or ±10V)
- Current Output (e.g., 4–20 mA)
- Ratiometric Output (proportional to supply voltage)
- Resistive (Potentiometer-style) Output
- Digital Output (eg. CANbus)
Most ECUs and DAQ systems accept analog voltage inputs, but be sure to match the sensor output to the input range of your system.
2. Wiring Basics (Typical for Analog Voltage Output)
A standard 3-wire sensor will include:
- +V (Power): Usually 5V or 12V depending on the sensor model
- Ground (GND): Shared with the DAQ/ECU ground
- Signal Out: Analog voltage signal representing position
Wiring Example:
🔧 Always refer to your sensor’s datasheet for exact pinout and voltage requirements.
3. Grounding & Shielding
- Use a common ground between your sensor and ECU/DAQ to avoid ground loop issues.
- If using a shielded cable, connect the shield to ground on one end only (preferably the DAQ side) to reduce electromagnetic interference (EMI).
4. Calibration and Testing
Once wired:
- Power up your system and observe the sensor’s signal output as you move the sensor shaft or core.
- Use your DAQ or ECU software to scale the signal based on your sensor’s stroke length and voltage output (e.g., 0V = 0mm, 5V = 100mm).
- Double-check that the signal responds linearly and matches the expected travel range.
5. Common Wiring Issues to Watch For
- Incorrect voltage supply: Too high or too low can damage the sensor or cause incorrect output.
- Reversed wiring: Can lead to erratic signals or no response.
- Noise in signal: Use shielded cable and proper grounding.
- Sensor not responding: Verify continuity, check grounds, and test signal line.
Summary: Key Wiring Tips
- Match sensor output to ECU/DAQ input type
- Confirm proper power supply and ground
- Use shielded cable and proper grounding to reduce noise
- Scale signal correctly in software for accurate readings
Need Help?
We include detailed datasheets and wiring guides with every sensor, contact us and our support team is here to help.