SIAR Congress, CAR 2026

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Design and experimental characterization of a test bench for automotive air flow meters: Voltage response versus mass air flow
Dragos Tutunea, Cristian Florin PALIU, Alexandru OPRICA, Adrian GIURA

Last modified: 2026-09-02

Abstract


Air flow meters, particularly Mass Air Flow (MAF) sensors, are critical components in modern automotive engine management systems, directly influencing fuel metering accuracy, combustion efficiency, and emissions control. An overview of common automotive air flow meter technologies is provided including —vane-type, hot-wire, hot-film, and Kármán vortex sensors—focusing on their output signal characteristics and pin configurations. Older designs predominantly generate an analogue voltage signal (typically 0–5 V) proportional to the mass or volume of intake air, whereas newer units increasingly employ a frequency-modulated (digital) output for improved noise immunity and resolution. The number and function of connector pins vary by sensor type, ranging from three to six terminals, accommodating power supply, ground, signal output, and in many cases an integrated intake air temperature sensor. This paper presents the design, construction, and experimental characterization of a test bench for evaluating the voltage response of hot-film MAF sensors under controlled air flow conditions. The experimental setup comprises a centrifugal blower with adjustable speed control, a Pitot tube for reference air flow measurement, and precision instrumentation for simultaneous recording of sensor output voltage and mass air flow rate. A Bosch HFM 5 hot-film MAF sensor (0 281 002 461) was characterized over its operating range using the developed test bench. The resulting steady-state calibration curves reveal the non-linear relationship between output voltage and mass air flow, with pronounced sensitivity at low flow rates. The measured data confirm the expected sensor behaviour described in manufacturer specifications and establish a baseline for diagnostic algorithm development. The proposed test bench proves to be a low-cost, reproducible tool suitable for educational purposes and research and development applications in automotive engineering laboratories.