Mass sensor

Types of mass sensors

Mass sensors come in various types, each suited for specific applications and measurement ranges. The choice of mass sensor depends on the intended use, such as industrial processes, scientific research, or environmental monitoring. Below, we describe the most common types of mass sensors.

Mechanical balance mass sensors

One of the oldest and most straightforward mass sensors is the mechanical balance. These mass sensors utilize a beam and counterweights to measure mass. The balance deflection is converted to mass by weighing it. Although they are not used in mass flow measurement, mechanical balances are used extensively in laboratories.

Strain gauge load cells

This is one of the most popular mass sensors used today. Load cells utilize the resistance change of strain gauges to measure mass. In this case, the structure is deformed by the load, and the strain gauges change in resistance. They are very popular because of their accuracy and ability to perform in the long term.

Capacitive mass sensors

Capacitive mass sensors use variations in the capacitor to measure mass. A mass change results in a distance change between capacitor plates. The resulting capacitance variation is then converted to mass. These mass sensors are applied in microbalances and industrial scales.

Pressure-based mass sensors

Mass sensors use pressure transducers to infer mass. These sensors are mainly applied in fluid systems. Changes in mass result in pressure variations, which can then be measured. These sensors are commonly used in industries and scientific experiments.

Piezoelectric mass sensors

Piezosensors utilize piezoelectric material to measure mass. Any mass change produces pressure in the material, resulting in a charge. This charge can be measured to determine mass. This sensor is typically applied in dynamic mass measurements like force measurements.

Industrial applications of mass sensors

Mass sensors are essential for many industries, helping not only measure mass and flow but also optimize processes and maintain safety. Below are the mass sensor industrial applications.

Food and Beverage Industry

This industry uses mass sensors to measure solids and liquids during processing, mixing, and packaging. It also does mass monitoring for quality control and consistency during the manufacturing process. In this industry, load cells and capacitive sensors are mainly used because of their accuracy and ability to work in food-processing environments.

Pharmaceutical Industry

The pharmaceutical industry requires precise mass measurements in drug production, formulation, and packaging. Here, strain gauge load cells and piezoelectric sensors are preferred due to their high accuracy and quick response in mass measurements. These sensors ensure organization and compliance during the manufacturing process.

Chemical Industry

Mass sensors are used in mass monitoring, raw material mixing, and product measurement in the chemical industry. They help to mass tracking of chemical reactions and enable real-time adjustments to ensure product consistency and quality. Mass sensors also offer safety by detecting unusual mass changes in storage tanks or pipelines.

Agriculture Industry

Mass sensors are applied in agriculture for mass monitoring in soil sampling and crop mass estimation. They enable the tracking of mass changes in fertilizers and compare the data to optimal growth conditions. These sensors help farmers make informed decisions about water and fertilizer applications.

Mining Industry

In the mining industry, mass sensors are used for ore mass estimation, tailing monitoring, and equipment load monitoring in real time. Example pressure-based sensors are used in this industry to monitor the mass of fluids in pipelines, enhancing safety and efficiency in mining operations.

Environmental Monitoring

Mass sensors monitor mass-based environmental parameters such as pollutant mass in air and water, mass in waste analysis, and mass of particulates in a given time. They provide essential data for environmental impact assessments and regulatory compliance. Mass sensors also track changes in mass within ecosystems, contributing to ecological studies.

Product specifications and features of mass sensors

Key features

• Sensitivity:Higher sensitivity enables the detection of small mass changes. This is important, especially in the pharmaceutical industry, where they must be precise when measuring drug ingredients. In such industries, they use sensors like strain gauges or piezoelectric sensors sensitive enough to measure small increments.
• Linearity:Linearity is important for accurate mass measurements. Linear sensors maintain proportionality for the entire measurement range. This prevents mass reading errors across varying masses. Environmental and load cell factors may cause a nonlinear response on the mass sensor. This can be eliminated through mechanical balancing or software calibration.
• Temperature compensation:Usually, temperature affects the mass sensor materials and readings. It also affects the readout electronics. Many sensors offer temperature compensation to mitigate this effect. This helps maintain accuracy in temperature-varying environments. Metal load cells, for instance, use a compensation network of resistors to counter the effect of temperature changes.
• Installation:Most mass sensors are designed to be easy to install in existing setups. For example, load cells can be mounted on an existing industrial scale without major alterations. This makes it easy to integrate new sensors into an ongoing industrial process.
• Durability:Mass sensors, especially those used in industry, are designed with high durability and robust construction. These keep them effective, especially in harsh environments. Most strain gauge load cells have water and dust protection ratings for such applications.

How to install

• Preparation: The first step in installing a mass sensor is preparing the installation site. In industrial applications, this involves assessing existing infrastructure. It also involves determining the best place to install the sensor without interfering with ongoing operations.
• Mechanical Installation: Most mass sensors have mechanical components, such as load cells, that require secure mounting. For example, load cells are usually mounted into existing frameworks and industrial scales. It is recommended to avoid excessive vibration and movement.
• Electrical connections:Mass sensors have electrical components for signal transmission. This makes it necessary to connect them to power supply or data acquisition systems. Appropriate wiring ensures optimal sensor performance. Also, during this stage, shielding may be added to reduce electrical interference. It is particularly important for sensors in high-noise environments.
• Calibration:After the mass sensor is mechanically and electrically installed, it is then calibrated. Calibration is the process of ensuring accuracy when the sensor reads. Calibration involves applying known masses to the sensor or using reference standards. The data is then adjusted to ensure precision at the intended mass range.
• Testing:Once the sensor has been installed and calibrated, the final step is to test the system. This helps assess performance and accuracy. Often, initial tests involve subjecting the sensor to various loads or conditions within the normal operating range.

Maintenance and repair tips

• Regular inspections:The first and most important aspect of mass sensor maintenance is regular inspection. When they are examined regularly, signs of wear, damage, or misalignment can be identified and rectified before they create bigger problems. In this case, check for physical damage like cracks or corrosion on external parts.
• Calibration checks:A mass sensor's accuracy is purely dependent on calibration. Often, mass sensors drift over time as they continuously operate. This means that periodic recalibration is non-negotiable. Refer to the manufacturer’s specifications for the calibration frequency and procedures.
• Protect against environmental factors:The performance of mass sensors is affected by mass exposure to environmental elements like dust, humidity, and temperature extremes. Installing protective housings or shields minimizes such exposure and prolongs mass sensor lifespan.
• Lubrication:The internals of some mass sensors, especially those with mechanical moving components, require regular lubrication. They ensure smooth operation and prevent wear. The type of lubricant to be used and the lubrication intervals are often recommended by the manufacturers.
• Software updates:The performance of some modern mass sensors is highly dependent on the associated software. Updating the software helps incorporate improvements and fixes that will optimize mass sensor performance.
• Use of genuine replacement parts:If one has to replace a part, ensure it is the same specified by the manufacturer. For instance, if a strain gauge wears out, use an identical one. Remember that use of non-original parts will only lead to more problems and possibly void the warranty if there is one.

Mass sensors' shipping considerations and conditions

The shipping of mass sensors comes with various considerations to ensure safe and timely delivery as well as cost-effectiveness. Below are these shipping considerations for mass sensors.

• Packaging

  Proper packaging, including cushioning and protective materials, is crucial for fragile sensors such as piezoelectric ones. Such instruments are vulnerable to damage from shock or vibration during transport, hence the need for proper packaging. Use anti-static bubble wrap, sturdy cardboard boxes, and foam inserts to minimize the impact on mass sensors during transport. For sensors that may be affected by changes in temperature, humidity, or environment, the best option to consider is a weatherproof package.

• Shipping method

  The choice of shipping method for bulk mass flow controllers depends on how long the items will take to get to their destination and cost. If the shipment is large, then freight services are inarguably the best option. For smaller shipments, express courier services are fast but more expensive. Other than these two options, standard postal services and economy courier services offer cheaper alternatives that take longer to deliver.

• Customs documentation

  International shipments of mass sensors usually need customs clearance. Proper preparation of customs documentation is a must for compliance. In this case, customs forms to include are commercial invoices and export declaration forms. These documents detail the shipment content and value and ensure proper assessment for duties and taxes. Lack of or inaccurate documents causes delays, seizures, or additional fines.

• Insurance

  Cost of shipping electronic items such as mass sensors comes with some risk. Shipping insurance covers the items against loss or damage during transport. This gives one peace of mind, especially when shipping valuable or delicate sensors. Choose an insurance policy that protects against the replacement or repair of the equipment at current market value.

• Tracking

  Most carriers offer tracking services for shipments. This enables real-time monitoring of the shipment status using a tracking number. Real-time tracking of mass sensors helps manage delivery expectations and promptly address potential delays or issues with transport.

• Reputation of carrier

  Always choose a reliable carrier for shipments. It doesn't really matter whether the shipments are domestic or international. Select carriers like DHL, UPS, FedEx, or the US Postal Service, which offer electronic tracking and have experience transporting fragile items.

Q&A

Q1. What is the function of a mass flow sensor?

A1. A mass flow sensor measures fluid mass through a conduit. It gives precise mass flow rates of liquids and gases. Industrial process control, biomedical applications, and HVAC systems widely use it to provide accurate flow measurements for efficiency, safety, and performance.

Q2. What industries use mass sensors?

A2. Diverse industries commonly use mass sensors. Pharmaceutical manufacturing employs them for precise chemical mass measurements in drug production. The agricultural sector utilizes them to monitor soil conditions and fertilization. Furthermore, the mining and chemical industries use mass sensors for substance mass measurement and flow rate control.

Q3. How are mass sensors shipped?

A3. Mass sensors are shipped in protective packaging using appropriate shipping methods for cost-effectiveness and timely delivery. The choice of carrier depends on the destination and delivery time. Insurance, tracking, and adherence to customs regulations ensure the safe and compliant delivery of mass sensors.

Q4. What should one consider when buying mass sensors for several businesses?

A4. First, one must think about how many mass flow sensors one needs to buy and whether they can ensure they are all bought from the same source. Then, after considering scale, think about buying only what is essential. Focus on a few reliable brands that cover all the important features and specifications that will benefit the target clients.

Q5. What is the difference between mass sensors and volume sensors?

A5. Mass sensors measure the mass of fluids moving through a pipe. On the other hand, volume flow sensors measure how much liquid or gas fills a pipe. The former offers more accurate data, while the latter is more commonly found in industrial settings.