The magnetostrictive displacement sensor can achieve an accuracy of the micrometer level. With this advantage, it plays a crucial role in monitoring fields such as industrial automation and precision manufacturing. The displacement values of equipment in many scenarios, including chemical workshops, port terminals, and tunnel construction, all rely on its precise measurement. However, the corrosive factors such as moisture, salt spray and chemical gases in these scenarios are like "invisible killers", seriously threatening the performance and service life of magnetostrictive displacement sensors. How does the magnetostrictive displacement sensor arm itself and handle corrosive and harsh working conditions with ease?
The first line of defense: Material selection
The first step in anti-corrosion is to select the right material from the source. Currently, for the shells and measuring rods of mainstream sensors, stainless steel is preferred. Under extremely harsh working conditions of strong acids and strong alkalis, highly corrosion-resistant materials such as Hastelloy, PTE, and PFA would be more ideal choices.
304 stainless steel: Suitable for general damp workshop environments without strong corrosive chemical media.
316L stainless steel: Compared with 304 stainless steel, 316L stainless steel contains 2% to 3% molybdenum (Mo) and also reduces the carbon content. It has particularly strong resistance to chloride ion corrosion and pitting corrosion, and can withstand salt spray-filled ports and acid and alkali splashing chemical workshops.
Special alloys and engineering plastics: In extreme environments such as strong acids and strong alkalis, engineering plastic casings with extremely strong corrosion resistance, such as Hastelloy, PTE, and PFA, may be used. Don't think that plastic is not strong. These special materials are even more durable than metals in certain chemical environments. For instance, PFA hardly reacts with any organic solvents, strong acids or strong alkalis. The ESC magnetostrictive displacement sensor developed and designed by Zheda Lean is made of this material and is specifically designed for strong acid and alkali corrosive environments.
The second line of defense: Sealed protection
The gaps and joints of sensors are the places where corrosive media are most likely to get in. Sealing design is the key to "plugging the loopholes". This includes using sealing rings for tight sealing at cable interfaces, adjusting screws, etc. The shell is sealed with high-grade IP protection to ensure dust-proof, water-proof and other features. For instance, IP67 (resistant to short-term immersion), IP68 (resistant to continuous immersion), and IP69K (resistant to high-temperature and high-pressure water erosion). This directly represents the sealing strength of the shell. In environments with flushing, dust and humidity, the IP rating is a hard indicator.
The third line of defense: Actively avoid sources of corrosion
No matter how good the protection is, it cannot withstand brute force and negligence. Proactively avoiding risks is the key to anti-corrosion that we can take the lead in. Attention can be paid to the installation process.
Installation location: Avoid direct splashing of liquids, condensation and dripping of steam, and directly above the outlet of corrosive gases as much as possible.
Installing protective gear: In workstations with severe splashing, simple splash-proof baffles or sleeves can be installed on the sensors. This is cost-effective and highly effective.
Standard wiring: Ensure that the cable sealing heads are tightened and that exposed wire ends are properly treated with insulating sealant. Pay attention to protecting the sealing surface. Do not scratch the coating and sealing ring with tools.
The fourth line of defense: Regular maintenance
The fourth line of defense against corrosion is regular maintenance.
Daily visual inspection: During shift handover, take a look at the sensor housing to check for any abnormal dirt, crystals, or coating peeling. Wipe the surface contaminants with a clean soft cloth to prevent them from adhering and corroding for a long time.
In summary, the anti-corrosion of high-precision magnetostrictive displacement sensors is a four-layer protection system of "material selection + sealing + avoidance + maintenance". From the inside out, it is strictly controlled layer by layer, which can not only withstand the erosion of harsh working conditions but also ensure stable measurement accuracy. With more attention paid to maintenance during use, the sensor can be used for a longer time and be more reliable.