A 2D calorimetric flow transducer is used to study distortions of the flow velocity field induced by small surface discontinuities around the chip. The transducer is incorporated into a matching recess of a PCB enabling wire-bonded interconnections to the transducer. The chip mount forms one wall of a rectangular duct. Two shallow recesses at opposite edges of the transducer chip are required for wired interconnections. They distort the flow velocity field inside the duct and deteriorate the flow setting precision. In-depth 3D-FEM analyses of the setup revealed that both the local flow direction as well as the surface-near distribution of the flow velocity magnitude deviate significantly from the ideal guided flow case. With a temporary leveling of the indentations, the impact of the surface imperfections could be largely suppressed. Including a yaw setting uncertainty of about ±0.5°, a peak-to-peak deviation of 3.8° of the transducer output from the intended flow direction was achieved with a mean flow velocity of 5 m/s in the duct corresponding to a shear rate of 2.4·104 s-1 at the chip surface. In view of the practical compromises, the measured deviation compares well with the peak-to-peak value of 1.74° predicted by previous simulations.
Keywords: FEM (Finite Element Method); Wheatstone bridge configuration; flow measurement; thermal wind sensor.