SIAR Congress, CAR 2026

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Analysis of automotive air flow meters and experimental determination of voltage versus mass air flow
Dragos Tutunea, Cristian Florin PALIU, Alexandru OPRICA, Adrian GIURA

Last modified: 2026-08-14

Abstract


Air flow meters (MAF sensors) are critical components in modern engine management systems, directly influencing fuel metering accuracy and emissions control. This paper provides a structured overview of common automotive air flow meter technologies—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. To examine the voltage-response behaviour in detail, an experimental test bench was developed. The stand comprises a calibrated mass flow reference, a controlled blower, and data acquisition instrumentation that simultaneously records the sensor voltage output and the true air mass flow rate in grams per second. A representative voltage-output hot-film MAF sensor was characterized over its full operating range. The resulting steady-state calibration curve highlights the non-linear relationship between output voltage and mass air flow, with a pronounced sensitivity increase at low flow rates. The measured data were fitted to empirical models, confirming the expected sensor behaviour and establishing a baseline for diagnostic algorithm development. This preliminary framework will be extended in the complete article to include frequency-output sensors, transient response analysis, and on-vehicle validation. The setup proves to be a low-cost, reproducible tool for educational and R&D purposes in automotive engineering laboratories.