Design of a Low-Cost Thermal Dispersion Mass Air Flow (MAF) Sensor

Abstract

There is a need for a low-cost sensor to be used in many practical applications, such as the control of the air–fuel ratio in combustion burners, which measures the mass flow rate of fluid. This paper focuses on the design, calibration, and testing of a mass flow sensor operating on the principle of thermal dispersion. The developed sensor implements a digital proportional-integral controller which regulates the body temperature of a heated element, recognized as a thermistor, located in the stream of the fluid flow to a constant difference with respect to the ambient air temperature. The power dissipated by this heated element was referenced to known mass flow rates of air to determine the relationship between the dissipated power and ambient temperature to the measured mass flow rate. The inclusion of air flow conditioners, which filtered unwanted debris and delivered a more laminar air flow, was imperative to the success of the design. The designed sensor was proven to measure the incoming mass air flow through a duct, in the presence of moderate disturbances in the intake air pipe and for a wide range of ambient air temperatures, with a maximum full-scale error of 5.5% and a range up to 80 kg/h.