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Automotive Mass Air Flow Sensor (MAFS) Test Stands 

 


CHALLENGE

OEMs, their suppliers, and aftermarket performance shops require accurate, repeatable, robust solutions for setting and measuring the mass flow rate of air through Mass Air Flow Sensors (MAFS) and other induction components.

SOLUTION

FLOW SYSTEMS offers (3) three levels of systems, each utilizing state-of-the-art Sonic Nozzle technology for flow measurement.  Uncertainty, automation and software functionality have been optimized for best economy at each level.


TECHNOLOGY

      The core of each system is the Sonic Nozzle that has been internationally recognized as the best device to measure the flow rate of a gas.  The nozzles are installed in a common plenum and the test setup is shown in the following diagram:





 

This chamber is typically populated with eleven (11) Sonic Nozzles.  Assuming air at ambient conditions of 14.696 psia, 70°F, 36% RH and minimal pressure drop (dP < 1psig) through the MAFS or Unit-Under-Test (UUT), the maximum mass flow will be: 1.5lbm/sec (1225scfm) (694gps) (2498kg/hr) and the minimum resolution or step size is 9.8E-4lbm/sec (0.8scfm) (0.5gps) (1.6kg/hr).  Other ranges are optional.

Level 3 -  Fully Automated System
 

Automated Test Sequencing of Mass Flow.  Measurement of Air Mass Flow Rate, MAFS voltage or 
frequency and ambient test conditions (P, T and RH) from a pre-configured array of set points.

 Optional Configurations for Throttle Body/Chamber and Cylinder Head Testing are available upon request.  


FEATURES

Custom LabVIEW® Software for:

Ø   Test Configuration
Ø   Data Acceptance Criteria.
Ø   On-Screen Tabular and Graphical Results.
Ø   Data Analysis and Storage.
Ø   Historical Analysis.
Ø   Optional Unit Under Test (UUT) Temperature, RH and P 
     (altitude) controls.
Ø   Optional OEM Compliant Data Analysis (Requires OEM Consent).
Ø   System Diagnostics (Leak Testing).
Ø   12vdc Power Supply.
Ø   PC with Printer.
Ø   Internet Diagnostics.  

 

 

 

LEVEL 3 SPECIFICATIONS:
(All measurements are traceable to NIST standards.)

Ø      Mass Flow Rate:            Range as previously mentioned, +/-0.4% of reading.

Ø      Repeatability:               < +/-0.25% as defined as 2 standard deviations divided by the mean of 20 identical samples.  

Ø      UUT Voltage:                 0-5 VDC, +/- 0.02% Full Scale.   0-10 VDC +/- 0.02% Full Scale.

Ø      UUT Frequency:            0 to 20 kHz, 50 ppm.

Ø      UUT Pressure:               0-15psia, +/-0.02% Full Scale.

Ø     UUT Temperature:        +/-0.5°F.

Level 2 - Semi - Automated System

The user provides the desired Mass Flow via Ethernet command or FLOW SYSTEMS software interface.  The system, FC500-FC Flow Controller, will set and record the Mass Flow Rate, MAFS voltage, and ambient test conditions (T and RH, P optional.)


FEATURES

Custom LabVIEW® Software for:

Ø      Mass Flow Setpoint.
Ø       Display of Results and Stability.
Ø      Data Logging.
Ø      12vdc Power Supply Optional.
Ø      PC Optional.
Ø      Frequency Measurement Optional. 
Ø      Internet Diagnostics Optional.

 

LEVEL 2 SPECIFICATIONS:
(All measurements are traceable to NIST standards.)

Ø      Mass Flow Rate:            Range as previously mentioned, +/-0.54% of reading.

Ø      UUT Voltage:                 0-5 VDC, +/- 0.03% Reading.   0-10 VDC +/- 0.03% Reading.

Ø      UUT Frequency:            Optional, 100 to 20 kHz, +/-0.01 Hz.

Ø      UUT Pressure:               Optional, 0-15psia, +/-0.05% of Full Scale.

Ø     UUT Temperature:        +/-0.5°F.

 

 

Level 1 - Manual System

The user opens the nozzles manually via toggle switches (provided) labeled with estimated Mass Flow.  The FC175-MCFV Flow Computer calculates the Mass Flow and displays UUT voltage and ambient test conditions (T and RH, P optional.)


FEATURES

Custom LabVIEW® Software for:

Ø      Approximate Mass Flow Setpoint.
Ø      Display of Results and Stability.
Ø      Data Logging.
Ø      12vdc Power Supply Optional.
Ø      PC Optional.
Ø      Optional Frequency Measurement. 
Ø      Optional Internet Diagnostics.

 

 

LEVEL 1 SPECIFICATIONS:
(All measurements are traceable to NIST standards.)

Ø      Mass Flow Rate:            Range as previously mentioned, +/-0.65% of reading.

Ø      UUT Voltage:                 0-5 VDC, +/- 0.02% Full Scale.   0-10 VDC +/- 0.02% Full Scale.

Ø      UUT Frequency:            Optional, 100 to 20 kHz, +/-0.01 Hz.

Ø      UUT Pressure:               Optional, 0-15psia, +/-0.05% of Full Scale.

Ø     UUT Temperature:        +/-0.5°F.

 


REQUIRED FACILITIES for all 3 Levels:


Ø      Shop Air:                       5scfm, 70 to 120 psig, 60 to 90°F; Pressure Dewpoint < 39°F; Particulates: < 5 microns; 
                                             Oil Content: < 10ppm.

Ø      Electrical Power:           100-240 VAC / 50 to 60 Hz / 1pH / 7.5 to 15 A.
 
Ø      Vacuum:                        1838acfm at 9.5" Hg based on previously defined Mass Flow Range.

          The above Facility Requirements are to be supplied by the Customer at the Installation Site.
                         Engineering / Hardware available upon request.

 

LEVEL 3 Fully Automated System General Arrangement Drawing:


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