Thermal airflow sensor design and temperature compensation research based on the thermostatic method

Purpose This paper aims to solve the typical thermal airflow sensor's high power consumption and integration difficulties, based on the FS5 thermal element and constant temperature measurement method, a flow sensor is developed with high measurement accuracy, low power consumption, small size, low cost and easy system integration. Design/methodology/approach A small wind tunnel was used to test and assess the sensor's measurement range, reaction time, stability, repeatability, measurement accuracy and multi-temperature calibration was performed in the temperature range of −10°C to 30°C. The effect of ambient temperature on the sensor's measurement data is investigated, and the coefficient correction method of power function was investigated to implement the sensor's software temperature compensation function. Findings The results show that the sensor is stable and repeatable, the output voltage has a power function relationship with the airflow rate, the flow rate measurement range is 0–18 m/s, the response time is less than 3 s, the measurement accuracy at high flow rates is within 0.4 m/s and the temperature-corrected airflow rate measurement error is less than 5%. Setting the temperature calibration interval to 2°C and 5°C has the same temperature compensation effect, reducing the sensor's calibration effort significantly. Originality/value This paper demonstrates that a thermostatic method is used to construct a thermal wind speed sensor that delivers accurate measurements in the wind speed measuring range of 0–18 m/s under test conditions. In addition, the sensor's performance is evaluated, and calibration tests for a wide range of temperatures are done. Finally, based on the power function correction method, a temperature compensation algorithm is proposed.