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Ready to ShipMagnetostrictive liquid level sensors are available in several types. Each of these sensors is suitable for a particular application.
This is because each specific application has unique operational requirements. The categorization can be through the configuration of the sensor or the measurement principle.
The common types of these sensors are listed below.
This magnetostrictive liquid level sensor measures a solitary liquid level point. It uses a float with a magnet to offer a simple, reliable solution for level measurement.
The resultant output is typically used in such applications as inventory monitoring or high-low level alert systems. It is also effective in tanks or vessels requiring only basic level measurement.
Continuous magnetostrictive liquid level sensors provide real-time, precise liquid level readings. Unlike single-point sensors, these can measure the entire level range in a tank or vessel.
This ability makes them ideal for dynamic processes requiring constant monitoring. Their accuracy and ability to cater to full-level ranges make them suitable for critical applications.
Multi-point magnetostrictive liquid level sensors measure liquid levels at several predetermined points. These points are spaced along the sensor's length. These sensors integrate the functions of single-point sensors into one system.
This makes them effective for applications requiring periodic level checks. However, they lack the continuous measurement capability of a full-range sensor.
A submersible fuel level magnetostrictive sensor is designed to operate directly in liquid. This makes it suitable for applications where space limitations require the sensor to be positioned beneath the liquid surface.
The sensors can be installed in areas where the top of the storage tank or vessel is inaccessible. This makes them ideal for underground tanks or wells.
This kind of sensor integrates other measurements. For instance, it may measure temperature or pressure in addition to liquid level. This reduces the need for multiple devices.
Its versatility makes it ideal for complex industrial systems where several parameters need monitoring from a single point. However, they can be more expensive than basic level sensors.
Magnetostrictive liquid level sensors use different materials. Each of these materials caters to specific environments. They must also ensure durability.
They also need to maintain accuracy and reliability. Thus, the materials used are critical to the sensor's performance.
Some of the prominent materials include:
Stainless steel is the most commonly used material for the components of magnetostrictive liquid level sensors. It is used especially in industrial applications.
This is due to its corrosion resistance. Common grades used include 304 and 316 stainless steel. 316 is preferred in environments with high salt content or acidic conditions due to its superior resistance.
Brass is another material used in these sensors. It is often used for sensor floats or other internal components.
The material is highly durable and corrosion-resistant. These properties make it ideal for use in such basic to moderately aggressive liquid environments as water or oil.
Glass-filled nylon is commonly used in point level sensors. The nylon's flexibility allows for lightweight design, while glass reinforcement provides rigidity and strength. This makes it suitable for sensors requiring quick, easy installation.
Hastelloy is a type of superalloy commonly found in high-end applications. These include those exposed to extreme temperatures and pressures. Users value the material for its exceptional resistance to chemical corrosion.
Magnetostrictive sensors sometimes use Copper Beryllium alloys for their working rods. The material offers high fatigue resistance, excellent electrical conductivity, and good corrosion resistance. These properties make it ideal for sensitive measurement applications.
Magnetostrictive liquid level sensors offer precise measurements of liquid level. They operate based on the principle of magnetostrictive technology. Below is the basic process of how these sensors function.
The working principle involves sending a pulse of torque along a stainless steel sensor wire. This wire is typically located along the length of the sensor tube. The sensor tube is immersed in the liquid to be measured.
The components include a float with a permanent magnet. As the float rises or falls with the liquid level, the magnet generates a magnetic field.
This field interacts with the torque pulse to create a magnetostrictive wave. The achieved wave then travels back along the wire to the sensor.
Some functional features that enable these sensors work include:
Return Time
The time taken for the magnetostrictive wave to return to its source after interaction with the magnetic field is called return time. It is proportional to the liquid level. The higher the liquid level, the longer the return time and vice versa.
Wave Interference
When the torque pulse and the magnetostrictive wave meet, they interfere with each other. This interference is what the sensor reads as a change in level.
Precision and Output
These sensors are designed to offer high accuracy. They can even detect changes as small as a millimeter. The resulting level data is immediately converted into an electrical signal. Users can thus achieve real-time monitoring of liquid levels.
Magnetostrictive liquid level sensors are widely deployed across industries. These sensors offer reliable and precise measurements under harsh conditions to users.
Some of the prominent industries deploying these sensors include:
In this space, magnetostrictive fuel level sensors measure liquid levels in tanks and pipelines. They ensure accuracy in a critical safety-related operation by providing reliable data even under extreme temperatures and pressures.
This ability to function under adverse conditions makes them ideal in this space. The sensors help optimize operations, reduce costs from overfill or downtime, and improve overall efficiency in this industry.
These sensors monitor water levels in treatment plants, reservoirs, and distribution systems. Their durability and accuracy make them well-suited for tracking levels in corrosive environments.
Water and wastewater management spaces use the sensors for real-time monitoring. They help the plants ensure compliance with environmental regulations and avoid overflow situations.
The chemical processing industry frequently exposes its equipment to highly corrosive liquids. That is why they commonly use these magnetostrictive sensors made from durable materials like stainless steel and Hastelloy.
These types of level sensors provide accurate measurements of liquid levels. They do this even in the most extreme operating conditions. These sensors help improve process control, increase safety, and minimize downtime in this industry.
These industries utilize these sensors to measure fuel levels in tank systems. The sensors' precision ensures accurate fuel readings for better vehicle performance and customer satisfaction.
Moreover, the automotive space increasingly deploys magnetostrictive sensors for battery monitoring. It gives real-time data on electric vehicle system levels and health.
Pharmaceutical companies have to maintain stringent levels of accuracy and reliability in their processes. That is why these industries prefer using magnetostrictive sensors to measure liquid levels in tanks, pipelines, and reactors.
The durable materials of these sensors help maintain the integrity of the pharmaceuticals by withstanding corrosive chemicals. The sensors' precision helps ensure product quality and regulatory compliance.
When selecting these sensors for resale, buyers must first consider certain factors. Doing so ensures they get the right sensors for their intended use.
Below are those key factors:
Level sensor buyers must first assess the operating conditions where the sensor will be deployed. Things such as temperature, pressure, and the type of liquid can significantly affect a sensor's performance.
It is especially critical to consider the liquors' corrosive nature in industries like the oil and gas or chemical processing spaces. For these industries, opt for magnetostrictive sensors made from stainless steel, hastelloy, or brass.
Buyers should also ensure the sensors' measurement range is appropriate for the tanks or vessels their customers will use the sensors in.
Generally, continuous magnetostrictive sensors are suitable for real-time measurement across the entire range. Customers who only need periodic measurements will be fine with multi-point or single-point sensors.
The accuracy and resolution depend on the customers' specifications. So, buyers must consider these two aspects to ensure they satisfy their customers' needs.
If customers require highly accurate sensors, they will prefer those that can measure even millimeter changes. On the other hand, customers who use these sensors for bulk liquid measurements can settle for lower resolutions.
Manufacturing standards in the pharmaceutical and water treatment spaces are very high. So, buyers must get magnetostrictive sensors with the proper certifications.
For example, in the pharmaceutical space, look for sensors that adhere to FDA regulations. Also, ensure the sensor has ATEX or IECEx certification. This ensures the sensor can function effectively in explosive environments.
Yes, there are submersible magnetostrictive sensors for vacuum environments. These sensors have durable materials that will not deform under high vacuum pressures.
So, as long the sensor features these materials, it will work perfectly in vacuum environments.
Although these sensors are very durable, they occasionally require maintenance. Routine checks help identify any wear or damage after extended exposure to harsh environments.
Moreover, regular sensor calibrations will ensure it continues to deliver accurate measurements. Note that cleaning the sensor will also help prevent any interference with its magnetic functionality.
Magnetostrictive sensors are highly precise. They also offer a robust design for reliable operation in strenuous environments. In addition, they provide real-time continuous level measurement. This makes them a preferred choice in various industries over other sensors like capacitive or ultrasonic ones.
Yes, these sensors are suitable for high-temperature applications. Users primarily make them from stainless steel and hastelloy. These materials have very high melting points and are, therefore, very suitable for high-temperature applications.
Fortunately, there are magnetostrictive sensors with wireless technologies. They then transmit the measured liquid level data in real time. This feature eliminates the need for wired connections. It thus offers more flexibility in sensor deployment.
