KPZ Linear Sensor Applied to Racing Car Shock Absorber Monitoring

The Challenge: Capturing Dynamic Suspension Data at Racing Speed

In competitive motorsport, suspension performance is one of the most critical variables that separates a winning setup from an also-ran. Race engineers need to know, in real time, exactly how much the spring is compressing and rebounding during each corner, braking zone, and acceleration phase. Without precise data, setup adjustments are guesswork — costing lap time and, in extreme cases, risking driver safety.

The challenge is significant: the sensor must survive the intense vibration, heat, oil mist, and mechanical shock of a race environment, while delivering millimetre-accurate readings at sampling rates fast enough to capture transient suspension events. Conventional off-the-shelf solutions were either too bulky, too fragile, or simply not accurate enough for the team's data-logging requirements.

The Solution: SOP KPZ 50mm Linear Displacement Sensor

After a rigorous selection process, the team chose the SOP KPZ 50mm Linear Displacement Sensor — a compact, high-precision potentiometric sensor purpose-engineered for demanding dynamic measurement environments. Key selection criteria:

• Ultra-compact body — installs directly within the tight confines of the shock absorber assembly without modifying the suspension geometry
• High linearity & repeatability — delivers consistent ±0.05% linearity across the full 50mm stroke, essential for accurate suspension mapping
• Rapid response — analogue output responds instantaneously to spring movement, capturing even the fastest transient suspension events
• Vibration & shock resistance — the robust housing and wear-resistant resistive track maintain accuracy under the extreme mechanical loads of racing
• Lightweight construction — adds minimal unsprung mass, preserving the vehicle's handling balance

As shown in the installation photograph, the KPZ sensor is integrated directly into the coilover spring/damper unit. The sensor body is secured to the fixed damper body, while the sensor rod couples to the moving spring perch. As the suspension compresses and extends under cornering and braking loads, the sensor rod travels with it — translating mechanical movement into a precise, continuous voltage signal.

How It Works

Results & Key Parameters

With the KPZ sensor in place, the race engineering team gained access to high-fidelity, per-corner suspension data for the first time. They were able to identify spring bind, detect bottoming events, and optimise damper settings between sessions — directly translating sensor data into faster lap times and more consistent tyre behaviour.

Why SOP KPZ for Motorsport Applications?

The KPZ series is designed for applications where compactness and dynamic performance matter most:
• Stroke range: 10mm to 300mm — suitable for a wide variety of suspension travel requirements
• Linearity: ±0.05% — precision comparable to optical encoders at a fraction of the cost
• Operating temperature: -40°C to +85°C — reliable across the full temperature range of motorsport environments
• IP64-rated housing — protected against dust ingress and water splash from wet track conditions
• OEM/custom configurations available — cable lengths, connector types, and mounting brackets tailored to vehicle packaging

Explore the KPZ Series

Whether you are building a race car data acquisition system, developing an automotive test rig, or engineering any application where precise dynamic displacement measurement is required, the SOP KPZ sensor is proven under the most demanding real-world conditions.
View KPZ Product Page: https://www.sopsensors.com/-kpz
Contact SOP for a Custom Solution: https://www.sopsensors.com/contact