AIRFLOW SENSOR FLAP INFORMATION DATA

SYSTEM INTEGRATION
Akma Khairiah Mohd Izaan, Dr Sukarnur Che Abdullah (Supervisor)
School of Mechanical Engineering
College of Engineering
MARA University of Technology
akma23khairiah@[Link]

Dr Mohamad Dzulhelmy Amari (Co-Supervisor)

School of Engineering
KDU University College
40150 Shah Alam, Selangor, Malaysia
dzulhelmy.a@[Link]

ABSTRACT

Airflow sensors are utilized in a variety of applications. The current airflow sensor is based on a combination of multiple
sensors. Smart control may be used for airflow sensors to incorporate airflow sensors with monitoring systems to
provide data. The purpose of this study is to demonstrate the integration of a flex sensor into an Arduino circuit. A flex
sensor is a variable resistor that is used to determine the resistance generated by sensor bending. The system will handle
the bend data from the flex sensors based on the speed of air flow. It consists of the integration of two approaches
investigated in previous works which is high flap and lower flap, each one appropriate for the analysis of specific
parameters of the sensor. Further method was to make the system performs the automated assessments data of four flex
sensor for high flaps and low flaps of the airflow sensor. Thus, this process simulation was created using Arduino Uno
and PLX-DAQ excel to monitor the output data. The approach process equipped with a monitoring controller system
designed to make it easier for users and administrators to interact with the system. The result demonstrated represents
of integrated data using resultant of each parameter. It was found that the voltage of each flex sensor which is in range
of 1 V to 3 V. It has an excellent sensitivity of 3.695 mV (ms-1)-1 for the sensor developed. Implications features
confirmed that the integrated sensor could be reliably employed as a self-managed system for automated and remote
assessment sensor. This simulation could be considered an example of a new accurate and improvement in technologies.

Keywords: airflow sensor; sensor control system; flap; flex sensor

I. INTRODUCTION

Nowadays, the development of high-sensitivity, low-cost sensors that are capable of detecting and integrating
various inputs is critical for wearable electronics. Sukarnur.C.A, M. Dzulhelmy.A, M. Azzeim.J, and F.
Ameeri.A.(2020) previously created a macrofluidic dynamic airflow sensor (360 degree airflow) with a high sensitivity
to the surrounding environment. Flap is one of the parameters or indicators that the Airflow Sensor uses. However, the
flap structure established in earlier study is insufficient for detecting the speed of air flow, which is why the flap
structure's development design should be optimised[1]. The purpose of this work is to combine multiple outputs into a
single data set, and to analyse the combined data from the constructed sensor system. Flex sensor had been used to
detect very sensitive airflow movement by deflection[2]. The originality of past research is the ability to accurately and
sensitively assess airflow movement when an item is in motion. The high sensitivity of the airflow sensor enables the
system to recognise and analyse the user's behaviour with more precision than traditional systems. According to the
vertical displacement approach, this flap will be able to cover both low and high-speed areas. The bending moment
principle also takes into consideration the speed area covered by each flap construction, which must be elastic and very
responsive[3][4]. The voltage value of the flap detecting structure will be used to distinguish between various speed
intervals. On the flap detecting structure, the flex sensor was mounted. Additionally, the sensor was incorporated into
the flap structure and bent in a positive direction, resulting in elongation of the detecting structure's top surface[5]. This
stage is completed in order to provide a clear way for doing calibration testing on the flex sensor component. Resistive
Flex Sensors (RFSs) are the most popular kind of flexion sensor. They are created by embedding a resistive element on
or inside a thin flexible substrate that is capable of bending, vibrating, thermal stress, and stretching[6] It is a passive
resistance device composed of strips of carbon resistive components arranged in a thin flexible substrate. Increased
carbon content results in decreased nominal resistance. Sandwiched between these carbon components are layers of thin
copper and plastic sheets. When the substrate is bent, the sensor generates a resistance signal proportional to the radius
of the bend[7].

Figure 1:Flex Sensor 2.2"

The flex sensor connected to microcontroller programming with a fixed value resistor 47kΩ to create a voltage
divider. The conductive ink printed on the sensor acts as a resistor[8]. The resistance is about 25kΩ when the flex sensor
in flat condition. In this study, flex sensor 2.2-inch will be selected. These sorts of flex sensors have been used in a
variety of applications, including security systems, rehabilitation, computer interfaces, music interfaces, servo motor
control, and intensity control, among others[9]. In this paper, will be present a novel flexible deflection capable to detect
air flow movement that have high sensitivity. Perpendicular to the longitudinal direction, the sensor may be installed.
Mini portable fan will be used in this experiment as a source of air. When the flex bends due to internal or external
pressures, the film is subjected to normal pressure along the bending direction[10]. The resistance change and speed
may be used to determine the flex deflection and bending direction[11]. The sensor's construction and working concept
will be discussed in depth in the next parts of this study. Then the prototype and methods will be discussed, as well as
the technique for determining the bending value. Finally, the created prototype's experimental findings will be described.

Figure 2:Deflection of Flex Sensor

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II. METHODOLOGY

The conceptual design and development of the software were carried out using a mix of two key pieces of
software: Excel Communication (PLX-DAQ) and Arduino (IDE). Both software packages served unique purposes, with
the PLX-DAQ programme focused on data integration and value movement creation for the four flex sensors. The
Arduino Uno microcontroller was selected for this project because it is capable of detecting voltage changes between
the flex sensor and resistance and converting them to integrated data[12].

The flowchart in Figure 3 illustrates the full procedure of this integrated monitoring system's software system.
To begin, connect the microcontroller to the PLX-DAQ software through a USB connection and then open the fan to
provide airflow for the flex sensor to detect deflection. After that, the sensors begin communicating voltage, degree, and
resistance data to Microsoft Excel through the PLX-DAQ programme.

Figure 3: Flowchart of flex sensor

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 A. Hardware Design

For this hardware product, the components include an Arduino uno, four 2.2" flex sensors, and four 47k
resistors. Apart from the sensor, the following components are used: breadboard and jumper wires. Arduino's analog-
to-digital converter is used to read the sensor's varying resistance[13]. Following that, the resistor served as the primary
support component for this system. The resistor converts the changing resistance of the flex sensor to a readable
voltage[8]. If the flex sensor's terminals are compatible with a breadboard, then use jumper wires to connect the
breadboard to the Arduino. Due to the 47k resistor on the ground side and the flex sensor on the 5V side, the voltage on
A0 will drop as the flex sensor's resistance rises. The following voltage divider formula will be used to get Vo, the
output voltage across the fixed resistor. Connect the flex sensor to a fixed resistor to acquire a reading. Owing to the
fact that the flex sensor operates as a variable resistor due to its bending effect, it will be configured as a voltage divider.
Below is the formula of Vo:

Vo = (4.7k/4.7k+R flex) x VC C

Figure 4: circuit board

B. Sensor Data Collection

This data collecting system is controlled by a number of sensors. Programming using the Arduino uno. To
begin, declare a few variables that will be used later in the programme design. This contains the ADC pin integrate
variable, which stores the Arduino ADC pin associated with the flex sensor. Additionally, provide four floating-point
variables. The first is VCC, bending degree, and the second is the fixed resistor used to construct the voltage divider
circuit. In this project, the resistance is 4700 ohm, or 4.7k ohm.

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 C. Data Analysis

Data analysis is the act of analysing, cleansing, manipulating, and modelling data with the objective of
emphasising relevant information, recommending conclusions, and assisting in decision making. Additionally, data
analysis is the process of evaluating and synthesising data in order to get answers prior to interpreting it. Data are
interpreted using the quantitative approach. It is sometimes referred to as numerical data due to the fact that this kind of
data is dependent on numbers[14]. Tables and line charts are two quantitative tools that may be employed. Tables may
be used to display statistical data by organising data in rows and columns. This technique is advantageous for contrasting
two or more similar subjects.

Data for this monitoring system will be analysed using line charts. A line chart depicts the progression of data
across a specific time period or time range[12]. It is described by a proclivity to observe changes in items through time
or by the use of ordered categories. The data records in the line graph should be more important than two, since this
enables trend comparison of large data volumes.

D. Software System

Data is sent from the nodes to PLX-DAQ, a real-time operating system. On a laptop or personal computer, this
data collecting operating system will be shown (PC). It includes the Parallax Data Acquisition tool from Microsoft Excel
(PLX-DAQ). The system will provide voltage and current data in both tabular and graphical representations in real time.
The PLX-DAQ platform offers data collection, sensor value analysis, and real-time equipment monitoring. Microsoft
Excel enables the production of charts and graphs in real time in reaction to data entry[15].

The flowchart shown in Figure 3 illustrates the full process of integrating airflow sensor data into this system. To begin,
connect the microcontroller via USB to the PLXDAQ software. When the board is switched up, the Arduino's serial
monitor shows the message "INTERFACING FOUR (4) FLEX SENSOR." The sensors then begin collecting data on
the parameter components and transferring it to Microsoft Excel through the PLXDAQ programme.

Figure 5: Serial Monitor Data from Arduino

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III. RESULT AND DISCUSSION

This project's interface circuit continuously measured input parameters such as ADC, voltage, resistor, and
bending angle content. The collected data is presented on the serial display of the Arduino IDE. A spreadsheet was used
to document the system's results and performance. The connected sensors determined the value of each of the four flex
sensors at various angles and transmitted it to a Microsoft Excel spreadsheet via the PLX-DAQ software. This flex
sensor works by bending the strip away from the ink. When a strip is bent, its resistance changes, which may be detected
using any controller[10]. In this project, a mini portable fan with 5-9 V used to bend the flex sensor. The speed of fan
was recorded using tachometer in unit rpm. In other words, this sensor functions similarly to a variable resistance, with
the resistance changing as the sensor is bent. This change in resistance is dependent on the linearity of the surface, which
implies that the resistance of this sensor will vary depending on the angle at which it is seen. This is illustrated in the
table below:

FLEX SENSOR 1
ADC VOLTAGE RESISTANCE (ohm) BEND ANGLE (degree)
569 2.78 37500.88 0
538 2.63 42369.88 8
528 2.58 44062.50 11
526 2.57 44408.75 12
497 2.43 49742.45 21
484 2.37 52340.91 23
491 2.40 50924.64 25
477 2.33 53798.75 28
470 2.30 55300.01 30
462 2.26 57071.42 33
457 2.23 58210.07 35
441 2.16 62027.21 42
432 2.11 64298.61 45
434 2.12 63785.72 46
412 2.01 69701.45 50
423 2.07 66666.67 55

Table 1:Parameter Flex Sensor 1

SPEED VS 4 FLEX SENSOR BENDING ANGLE

100
Bending 4 Flex Sensor

50

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
Speed

FLEX SENSOR 1 FLEX SENSOR 2 FLEX SENSOR 2 FLEX SENSOR 4

Figure 6: Comparison bend of 4 Flex Sensor

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 BENDING ANGLE (DEGREE)
TIME (sec) SPEED OF
FAN (rpm) FLEX SENSOR 1 FLEX SENSOR 2 FLEX SENSOR 2 FLEX SENSOR 4
2.09 417 0 0 7 7
3.14 2662 8 2 12 18
4.31 3084 11 9 22 23
5.41 3490 12 10 31 44
6.58 3650 21 14 37 46
7.74 3777 23 22 40 48
8.85 4385 25 23 44 51
10.06 5217 28 26 52 58
11.17 6421 30 28 53 59
12.33 7699 33 29 54 62
13.45 9214 35 30 57 69
14.61 10195 42 40 58 73
15.74 11076 45 64 64 76
16.83 11745 46 71 67 79
18.04 1324 50 77 70 86
19.22 1621 55 90 77 91

Table 2: Data of Bending Angle of 4 Flex Sensor

14000 60

12000 50
10000
40
Speed (rpm)

8000
Angle (degree)

30
6000
20
4000

2000 10

0 0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
time (sec)

speeed of fan (rpm) Time ( sec) FLEX SENSOR 1

Figure 7:Mapping data calibration relationship between speed (rpm) and angle (˚) vs time (sec) for flex sensor 1

The result graphs indicate that a certain range of speed corresponds to a particular angle. This is confirmed by the linear
graph generated by the experimental setup. As a result, this model may be effectively utilised to quantify flow across a
specific range. The range were determined by the bend sensor.

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 RESISTANCE (Ohm)
TIME (sec) SPEED OF
FAN (rpm) FLEX SENSOR 1 FLEX SENSOR 2 FLEX SENSOR 2 FLEX SENSOR 4
2.09 417 37500.88 37204.9 41546.96 41874.3
3.14 2662 42369.88 38858.93 44757.64 48398.8
4.31 3084 44062.5 42871.04 50725.61 51124.48
5.41 3490 44408.75 43377.82 55737.19 63531.02
6.58 3650 49742.45 45820.46 59373.89 64298.61
7.74 3777 52340.91 51325.16 60804.93 65866.2
8.85 4385 50924.64 50527.38 63531.02 67478.57
10.06 5217 53798.75 54651.17 68026.31 71718.52
11.17 6421 55300.01 55082.81 68857.83 72307.69
12.33 7699 57071.42 54223.16 69137.68 74110.83
13.45 9214 58210.07 52546.59 70845.59 78210.94
14.61 10195 62027.21 60804.93 71426.1 80535.81
15.74 11076 64298.61 75343.52 75033 82250.01
16.83 11745 63785.72 79196.84 76601.55 84010.91
18.04 1324 69701.45 82598.38 78537.86 88058.98
19.22 1621 66666.67 90374.28 82948.65 91163.79

Table 3:Resistor data of 4 Flex Sensor

100000 14000
90000 12000
80000
Resistance (ohm)

70000 10000
60000 8000
Speed (rpm)
50000
40000 6000
30000 4000
20000
10000 2000
0 0

Time (sec)

Figure 8:Mapping data calibration relationship between resistance (ohm) and speed (rpm) vs time (sec) for flex sensor 2

As the bending angle of the flex sensor rises, the resistor flex increases linearly. As the resistance rises, this causes in a
linear fluctuation in the voltage. When the sensor is flat without bending, the resistance is minimum and nominal. As
the bending angle rises, the resistance increases linearly. When a flex sensor is bent 45 degrees, the resistance is
doubled compared to when it is flat. Similarly, when the sensor is bent 90 degrees, the resistance is twice that of a 45-
degree curve and four times that of a flat sensor. Thus, if consider the ratio, this resistance is exactly proportional to
the bending angle, which implies that it grows linearly.

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IV. CONCLUSION AND RECOMMENDATION

This study has aided in the accomplishment of the project's aims. The first aim was accomplished by combining
various outputs from the arduino programming into a single data set utilising a combination system of the arduino and
PLX-DAQ software. The second project aim has been accomplished, with the Arduino circuit and flex sensor data
effectively combined to form one entire system. The system integration has been subjected to several testing in order to
ensure that the continuous connection of ADC readings and angle values from four Flex sensors at 0º, 90º, 180º, and
360º angles with a fan acting as a source of wind energy is possible. The architecture of the airflow sensor flap data
system has been modified numerous times to accommodate various parameter output. The project's ultimate aim was
accomplished when the flex sensor angle and speed were successfully analysed using speed over time. While doing the
study, various issues arose throughout the assessment process, including an unsynchronized value of a parameter in the
integration system. To begin, there is friction between two components that obstructs the movement of components such
as the jumper wire and flex sensor. Additionally, breadboards may only be used to connect Arduino components
temporarily, since any disruption can alter the flex sensor bend value and angle in the system. Flex sensors are essentially
variable resistors that respond to bends. When unbent, it measures around 22K; when bent 180º it measures
approximately 40K. Take note that the bend is recognised only in one direction and the readings may be a little wobbly;
it performs best when variations of at least 10º are observed. Additionally, while working on a project, avoid bending
the sensor at the base, since this will not record a change and may damage the leads.

There are suggestions for further study about how to have better data in the integration system. To begin, use
a Clincher connection to prevent the sensor from moving when the connector is clamped down. In comparison to the
other flexible substrates on the flex sensor, the force sensitive resistor will be simpler to clamp down. Following that,
the breadboard may be replaced with a permanent circuit board to ensure that the circuit is not readily interrupted by
minor disturbances.

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