3.

VEHICLE SENSOR AND DRIVER INSTRUMENTATION

3.i. Air Flow Sensor
Function
In order to achieve optimum idle mileage control for a electronically controlled fuel injection system,
accurate measurement of intake air is required. AFS(air flow sensor) measures intake rate of air that is filtered
by air cleaner, and one of the most important components of EMS.
Therefore AFS shall have:
o Accurate response characteristic over wide air rate range.
o Immediate response characteristic against rapid change of air flow rate.
o Easy processing of signal.
AFS may be classified depending on measuring type as follows.
(1) Direct Detecting Type
① Air Volume Detecting Type
A. K / V (Karman Vortex) Type
- Ultrasonic Type
- Mirror Type
- Pressure Sensing Type
B. Vane Type
② Air mass Detecting Type
A. Hot Wire Type
B. Hot File Type
(2) Indirect Detecting Type
① Speed Density Type
② Throttle Speed Type
Configuration and Operation Principle
(1) K / V Type
① Configuration of Ultrasonic Type
A. Main Route and By-pass Route
Main route maintains air flow to generate constant swirl using a triangular prism, and consists of
swirling prism and plane plate. By-pass route controls air flow rate as required by engine by increasing/
decreasing the route section area, not by changing main route shape.

K / V AFS

Ultrasonic Type Configuration

B. Ultrasonic Transmitter
When air flows through main route, ultrasonic wave sent from ultrasonic transmitter, will pass
through swirl to the receiver. Then the frequency of ultrasonic wave will be modulated periodically by the
generated swirl.
C. Control Circuit
Control circuit detects potential difference of ultrasonic wave that passed through K / V, and
generates electrical pulse signal that is proportional to air flow speed, out of the wave form passed through filter.
The circuit consists of hybrid IC.
D. Thermistor Sensor
K / V AFS measures air temperature at AFS inlet in order to compensate intake air density, using air
volume detecting type.
② Measuring Principle(Swirl Detecting Type)

Measuring Principle
When installing triangular prism (swirling pillar) in fluid flow using K / V phenomenon,
asymmetrical and regular swirl occurs behind the prism. The sensor detects the swirl using ultrasonic wave and
transform it to electrical pulse signal. Then relation between detected frequency and air flow speed may be
represented as the below.
u
f  St
d
f: generated frequency [Hz]
St: Strouhal number
d: swirling pilar width [m]
u: air flow speed [m/s]
When actual air flow is of Reynolds number 10 2 ~ 105, Strouhal number is almost constant at
approx. 0.2. Therefore if the route is designed to provide engine's air intake rate with in the said Reynolds
number range, then Strouhal number will be almost constant through measurement range, and it will be allowed
to decide air flow rate by detecting K / V's generated frequency of the said formula. Therefore intake air volume
will be [air flow speed u] x [air route's effective area]. Air flow rate measurement of K / V type depends on
volume flow rate, and then requires compensation against mass variation by air temperature and pressure using
intake air temperature sensor and barometric pressure sensor.
 Strouhal Number
③ K / V AFS Output Characteristic
A. Output Signal
Fig. illustrates that K / V AFS control unit's output signal is digital signal of spheric wave. Higher air
intake rate generates more swirls raising output signal frequency. Control unit calculates air intake rate using the
output signal.
B. Output Features by Engine Condition
 In idling : F>28HZ
 At pull load: F<2Khz
 In dynamic range: approx. 70 times

Frequency Variation and Output Features by Air Flow Rate Change

④ Mirror Type & Pressure Sensing Type
In addition to the said ultrasonic detection type, types of AFS using K / V phenomenon are those that induce
pressure varying by swirls generated alternatively at both ends of swirling pillar, through pressure inlet opening,
and then detect the pressure variation through mirror's twisting vibration (mirror type) or pressure
sensor(pressure sensing type), and finally convert it to electric signals.
Mirror type relies on the principle that electrical signal will be generated when light emitted
from LED that is located at mirror's top side is reflected by mirror and then emitted to photo transistor. When
mirror vibrates by pressure change, light intensity will change according to reflecting angle, then it will be
detected as current variation that then will be converted to pulse signal. Therefore we can get electric pulse
signal corresponding to swirl occurrence.
 Mirror Type

Pressure Sensing Type

(2) Vane Type
Movable vane type uses the principle that movable vane's angle will correspond to air intake, rate when
intake air flows through the route and movable vane's kinetic force and return spring's recovery force are
stabilized with each other. The opening angle is detected by potentiometer that is linked to movable vane.
① Configuration

1. Ring gear for Spring Preload 1. Idle-mixture Adjusting Screw

2. Return Spring 2. By pass
3. Plate
3. Potentio meter
4. Compensation Plate
4. Sliding Contact 5. Damping Chamber
Vane Type
 As illustrated on fig., compensation plate and dampening chamber stabilizes vane motion against rapid
change of air intake rate and air pulsation. Idle-mixture adjusting screw is installed at by-pass route, and used to adjust
the feature at low air rate. The screw adjusts idling mileage that varies by each engine and system, within specified
objective range by adjusting by-pass route area and consequently changing AFS output.
② Measuring Principle
Movable vane type AFS relies on the principle that measuring plate(vane) is pushed open by pressure gap
generated by flow of air sucked into engine. On turning axis of vane is located return spring of spiral shape.
Vane stops at the position where air flow force to open vane and recovery force of return spring are balanced.
Potentiometer detects the position to obtain voltage value corresponding to intake air rate.

Fig.Measuring Principle
③ Output Characteristic
Vane type AFS ultimately outputs voltage ratio variation from potentiometer that is located at the same axis
with vane. The output and air flow rate Q have the following inter-relation.
Us C

Ub Q
C: Constant, Ub: supply voltage
Q: Volume flow rate (㎥/s) Us: Output voltage
 Potentiometer's output voltage Us varies simultaneously with battery voltage change. Then if
voltage ratio is used for output signal, Us signal will vary in proportion to supply voltage Ub variation approved
by potentiometer, and the AFS signal Us/Ub will be constant. Therefore ECM will use it for calculating air flow
rate.
(3) Hot Wire type
① Configuration

Fig. Hot Wire Type

Configuration of Hot Wire Type Sensor

The sensor consists of air temperature compensation resistance that detects intake air temperature,
circuit part that generates heat corresponding to heat generation, control circuit part for measurement, and
housing.
 ② Measuring Principle
When heating object is placed in the air the object is cooled by emitting heat toward air, and if
there is higher air flow around the object heat loss will increase by air. Hot wire type sensors use the said
phenomenon of heat transfer between a hot object and air. This type is detecting air mass and not affected by air
density variation. Therefore ECU in principle is not required to compensate against temperature or pressure. The
below fig. outlines air flow inlet part and circuit configuration.

Fig. Air Flow Inlet Part

Fig. Circuit Configuration

③ Output Characteristic
Output voltage at both ends of standard resistance, varies significantly by current, and higher
air intake rate raises signal voltage.
(4) Hot Film Type
① Configuration
Hot film type depends on the same principle of heat transfer as hot wire type, but has some
improvement of demerits from hot wire type as follows:
- Simplified by-pass design by reducing sensor wire length. Better connection with throttle body.
- Cost saving
- Eliminates wire dirt build-up(foreign material build-up on sensing resistance surface)
- Faster response
In addition it may be classified by ceramic type HFS installed in air route, say housing.
 Section of Hot Film Type

Hot Film Sensor Element

Sensor element consists of air temperature compensation resistance(Rt) for compensating output
characteristic(Rh), heating resistance, and sensing resistance(Rs). Flow grid is installed to stabilize intake air
flow at housing's air inlet part.
② Measuring Principle
In principle the measurement basically relies on heat transfer system. Sensor resistance(Rs)
that constitute wheatstone bridge circuit, is heated by rear-side heating resistance(Rh) to be constantly 170℃
higher than ambient air temperature. If air flow increases, sensing resistance's temperature will decrease and the
resistance value will drop. Then wheatstone bridge circuit will be unbalanced to generate heating current, and
then heated heating resistance will raise sensing resistance's temperature and resistance value to achieve balance.
The voltage value generated by heating resistance and heating current will be proportional to air flow rate and
consequently possible to measure. Air temperature compensation resistance(Rt) is designed to compensate
resistance variation of sensor output characteristic value by Rh and Rs variation depending on ambient air
temperature.
③ Output Characteristic
Output voltage at both ends of standard resistance, varies significantly by current, and higher
air intake rate raises signal voltage.
 HFM Output Characteristic Curve
(5) Reverse Flow Detecting Hot Film Type
①

Configuration

Reverse Flow Detecting HFM

 Reverse Flow Detecting HFM configuration
This type HFM has plug-in sensor integrated at the same air route part as air cleaner housing, on used
as plug-in sensor module integrated onto cylinder housing as the above picture. In addition various size cylinder
housings are designed depending on required air flow rate for combustion engines. Then this type HFM may be
said to have basically same configuration with conventional HFM type. However some difference exists for
sensor element that senses air flow rate and basic measuring principle.
Sensor element consists of thin silicon diaphragm manufactured using MEMS(micro electro
mechanical system) technology, and heating resistance and a number of temperature sensors which are installed
on the diaphragm. Sensor's signal processing circuit is configured on ceramic board(hybrid IC) located inside
plug-in sensor housing, and includes sensor dement and Au-wire bonding. In addition EPROM type is used to
adjust output characteristic against air flow value, and the circuit is filled with Si-Gel to protect the circuit.
HFM5f includes separate intake air temperature sensor installed on plug in sensor housing.
② Measuring Principle
The thin diaphragm integrated on sensor element is made by etching technology. On
diaphragm, heating resistance is located at center, and temperature sensors T1 & T2 each at front and rear side
of heating zone at air flowing direction. The two sensors will have same temperature when there is no air flow.
However when air flows, T1 sensor located in front of heating zone will be cooled by heat recirculation. On the
contrary T2 sensor located at rear of heating zone will maintain almost same temperature by air heated through
heating zone. Therefore the two sensors will indicate temperature gap by air flow rate through the route, and the
temperature gap will depend on air flow rate that will pass through sensor element. If reverse air flow occurs
through sensor element, the temperature between T1 and T2 will be reversed, as well. Therefore detecting the
temperature gap will enable detecting possible reverse flow.

Measuring Principle
 Electric Circuit
③ Output Characteristic
Reverse flow detecting HFM outputs voltage value by intake air flow rate, and provides
reverse flow detection. The below figure illustrates reverse flow detecting characteristic in pulsation test of hot
wire type and reverse flow detecting HFM devices.

Fig. 44 Reverse Flow Detecting HFM Output Characteristic.

(6) Speed Density Type

① Pressure Sensor
Pressure Sensor detects intake manifold's pressure variation as voltage variation, and
connected with surge tank via rubber hose or directly attached at surge tank. Pressure sensor is constituted of
pressure conversion element and circuit part that processes conversion element's output signal. The sensor's
output is proportional to intake manifold's vacuum pressure.
② Intake Air Temperature Sensor.
Intake air temperature sensor detects engine intake air temperature. In case of direct
measurement type, the sensor is installed at air intake hose or AFS. In case of speed density type the sensor may
be installed at surge tank in order to sense intake air temperature at pressure induction part. (MAP with IAT
sensor)
(7) Throttle Speed Type
This type detects air intake rate by estimating air intake quantity into engine per cycle based on throttle
opening angle and engine rpm, and calculate gasoline injection rate. However air intake rate and the two
measurements have complicated functional correlation, and consequently detecting air quantity is not easy.
Therefore currently no vehicle of this type is at market. Only some systems that take other type of AFS are using
this type as backup mode in case of AFS failure.
3) Sensor Checking
(1) Circuit Configuration and terminal
① Hot Film Type
Fig. 45 illustrates hot film type air flow sensor's circuit diagram and terminal configuration.
Terminal 1 indicates output signal, terminal 2 is for sensor power supply, and terminal 3 is for grounding.
However terminal configuration may differ by car models. Please refer to relevant service manuals.

Fig. 45 Example of Hot Film Type AFS Circuit and Terminal Configuration
② Karman Vortex Type
Fig. 46 illustrates Karman Vortex Type air rate sensor's circuit and terminal. The sensor is
usually installed together with intake air temperature sensor and barometric pressure sensor. Therefore it is
required to be careful when finding terminals.

Fig. 46 Example of Karman Vortex Type Air Rate Sensor Circuit Diagram and Terminal
Configuration
(2) Checking Procedure
① Hot Film Type Air flow Sensor
A. When using volt-meter
Fig. 47 illustrates example measurement of sensor output voltage using a volt-meter, and table 4
provides specified values. At harness side, terminal2 is used for sensor supply power checking, and terminal 3 &
4 are for grounding circuit break.
 Fig. 47 Example of Output Voltage's Specified Value for Thermal Film Type Air Rate Sensor
<Table 4> Example of Output Voltage's Specified Value for Thermal Film Type Air Rate Sensor
Specified values(in
Check items Engine type
idling)
Alpha 1.5 DOHC engine 0.7 ~ 1.1 v (At 800 rpm)
Delta 2.5V 6DOHC
Output voltage 0.5 ± 0.5v (At 700 rpm)
engine
Sigma 3.5V6DOHC 0.5 ± 0.5v (At 700 rpm)

B. When using oscilloscope

Fig. 48 illustrates example of measuring output waveform of hot film type air rate sensor during
idling, using oscilloscope.

Fig. 48 Hot Film Type Air flow Sensor's Output Waveform(2000rpm)

When air intake rate does not varies output voltage will be constant. Fig. 49 illustrates
measurement using oscilloscope when air intake rate varies.

Fig. 49 Air Rate sensor's Output Waveform Analysis

Part A indicates wide open state(WOT) of throttle valve to provide maximum acceleration.
Part B indicates flow of idling compensation intake air into intake manifold. Part D represents attenuation by air
flap motion. Usually higher air intake rate raises output voltage.
 ② Karman Vortex Type
A. When using a volt-meter
Fig. 50 provides example of sensor output voltage measurement using a voltmeter. Though sensor
input is 5V, output signal represents frequency characteristic with values of approx. 2.7~3.2V. Sensor's supply
voltage or grounding circuit's break and short are checked.

Fig. 50 Example of Output Voltage Measurement of

Karman Swirl Type Air Rate Sensor Using a Voltmeter
B. When using oscilloscope
As Karman Swirl type air rate sensor represents frequency type output signal, it is recommended to use
oscilloscope for checking output signal. Fig. 51 illustrates example of output waveform of Karman swirl type air rate sensor
during idling. Read frequency from the output waveform and compare with specified value, and check the waveform's
varying condition. <Table 5> provides specified values for Karman swirl type air rate sensors.

Fig. 51 Example of Output Waveform of Karman Swirl Type Air Rate Sensor
<Table 5> Example of Specified Output values for Karman Swirl Type Air Rate Sensor
Check Engine Specifie
Checking Condition
items Condition d Values
 Coolant temp.: 80~95℃ 750rpm( 30~35
 Various lamps, cooling fan, accessories: all in idling) Hz
off 2000 70~130
Output
frequency  Shift stage: neutral(N or P for A/T) rpm Hz
 Steering wheel: neutral Depends
Running on running
condition

Fig. 52 describes implication of Karman swirl type air flow rate sensor's output waveform.
Part A represents horizontal type of reference voltage. Part B indicates peak-to-peak voltage that is same to
reference voltage value. Part C implies almost grounded condition as horizon. Then voltage drop to ground shall
not be more than 400mV. If the voltage drop is more than 400mV, check the sensor and ECM for poor
grounding.
 Fig. 52 Karman Swirl Type Air Rate Sensor's Output Waveform Analysis
(3) Troubleshooting
Air flow rate sensor shall be checked for the followings:
① If engine stops intermittently, with engine running shake air flow rate sensor harness. Then if
engine goes off, air flow rate sensor connector connection may be poor.
② With ignition switch on(engine does not running), if air flow sensor frequency is not 0Hz,
AFS or ECM may be faulty.
③ If engine goes on idling though AFS output frequency (or sensor output voltage) is outside
specified value, check the following possible defects except AFS.
A. Air flow in air flow sensor is constrained due to disconnected air intake hose or clogged air
filter element.
B. Imperfect combustion in cylinder due to defective ignition plug, spark coil, or injector, or
insufficient compression pressure.
C. Air leak in intake manifold.
D. Poor seating of EGR valve.

(4) Failure Symptoms

 Cranking is possible but engine start-up is poor.
 Engine running is unstable during idling.
 Engine goes off during idling or running.
 Poor acceleration during car-running.
 If air rate sensor output value is incorrect, shock may occur during shift of a auto transmission,
and in case of complete failure delayed shift may occur.