AUTOMOTIVE
FlowNodes – Miniature Wireless Gas Flow Velocimeters .
HARDWARE | FIRMWARE
Project Overview
FlowNodes bring wind tunnel testing into real-world conditions using ultra-compact, wireless flow sensing nodes. These devices measure aerodynamic surface pressures in live flight and road tests, enabling accurate aerodynamic performance analysis outside controlled environments.
Client Requirement & Objectives
Miniature Sensor Design: Develop a wireless node with a maximum diameter of 15mm and a total height of 5mm, including battery and enclosure.
High Sensor Density: Each node must integrate 15 MEMS pressure sensors and a Wi-Fi module for wireless data retrieval after tests.
Onboard Storage: The system needed flash memory capable of storing over 1 million records, with pressure readings sampled every 100 milliseconds.
Post-Test Data Transfer: All stored test data had to be reliably transferred to a laptop via Wi-Fi for further aerodynamic performance analysis.
System Design & Build
Compact PCB Layout: Designed a complex 6-layer PCB with a 15mm diameter and 2mm height, fitting all 15 MEMS sensors on one side and all other components—including microcontroller, flash, and Wi-Fi—on the reverse.
Ultra-Low-Power Components: Selected the world’s smallest Wi-Fi module and microcontroller at the time, optimized for space and minimal power consumption.
Precision Data Logging: Engineered firmware to sample and log 15 sensor readings every 100ms, ensuring consistent recording during hour-long tests.
Seamless Wireless Transfer: Integrated a Wi-Fi data offloading mechanism that initiates post-test, transferring approximately 4MB of data per session for offline analysis.
Project Tech Stack
Key Challenges & Solutions
Miniaturization Constraints: Fitting all components within a 15mm x 2mm volume was a major design hurdle. We overcame this with meticulous 6-layer PCB routing and custom placement strategy separating sensor and processing elements.
Thermal & Power Optimization: Operating 15 sensors and a Wi-Fi module within such a small form factor posed heat and battery life challenges. We used power-efficient firmware scheduling and deep-sleep states to manage heat and extend runtime.
High-Speed Logging Reliability: Achieving consistent logging every 100ms without data loss required optimized memory access and sensor polling routines. Flash storage was fine-tuned with buffer caching and efficient write cycles.
Post-Test Data Handling: Transferring high-volume data wirelessly after tests demanded a robust file transfer system. We implemented a Wi-Fi-enabled bootloader to reliably stream data in batches without overwhelming the device or network. .
Client
FlowNodes specializes in the development of ultra-compact, wireless aerodynamic sensor nodes designed for high-precision wind tunnel testing and flow diagnostics in aerospace and automotive applications.
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