Design of a Mass Air Flow Sensor Employing Additive Manufacturing and Standard Airfoil Geometry

Abstract

This work concerns the design, fabrication, and preliminary characterization of a novel sensor for determining the air intake of low and medium power internal combustion engines employed at various applications in the marine industry. The novelty of the presented sensor focuses on the fabrication process, which is based on additive manufacturing combined with PCB technology, and the design of the sensing elements housing geometry, which is derived through suitable CFD simulations and is based on standard airfoil geometry. The proposed process enables low-cost, fast fabrication, effective thermal isolation, and facile electrical interconnection to the corresponding circuitry of the sensor. For initial characterization purposes, the prototype device was integrated into a DIESEL engine testbed while a commercially available mass air flow sensor was employed as a reference; the proper functionality of the developed prototype has been validated. Key features of the proposed device are low-cost, fast on-site manufacturing of the device, robustness, and simplicity, suggesting numerous potential applications in marine engineering.