Application of Flexible Magnetostrictive Linear Position Sensors in Industrial Automation

In the process of industrial automation, the accuracy and adaptability of displacement measurement are directly related to the smooth operation of equipment and the optimization of production efficiency. Nexisense flexible magnetostrictive linear position sensors, with their innovative flexible structure and stable performance, stand out in fields such as metallurgy, wind energy, construction machinery, and new energy, providing reliable support for displacement monitoring under complex working conditions. This article explores in depth their measurement principles, structural design, advantages and features, application scenarios, technical parameters, and maintenance methods, aiming to provide practical references for industry professionals.

.Overview of Flexible Magnetostrictive Linear Position Sensors

Flexible magnetostrictive linear position sensors are non-contact measurement devices based on the magnetostrictive effect, specifically designed for industrial automation. The Nexisense series breaks through the limitations of traditional rigid sensors by introducing flexible measuring rods, enabling more flexible installation and application. These sensors play a key role in displacement monitoring, especially in space-constrained or curved-path scenarios, where they demonstrate unique value.

With the advancement of Industry 4.0, displacement sensors are required to cope with extreme environments such as high temperature, high pressure, and heavy dust. Nexisense sensors ensure continuity and reliability of measurement data through advanced materials and electronic processing technologies, and have accumulated successful cases across multiple industries.

Detailed Explanation of Measurement Method

The measurement of flexible magnetostrictive linear position sensors is based on the magnetostrictive principle: when the magnetic ring moves along the flexible measuring rod, it creates a magnetic field intersection point, triggering a torsional wave in the magnetostrictive wire inside the rod. This wave propagates to the sensor head at a fixed speed, and the electronic module calculates the time difference and converts it into a displacement value.

The specific process includes: the magnetic ring is fixed to the moving component, and the flexible measuring rod is inserted along the path; an excitation pulse generates the initial magnetic field; when the torsional wave returns, the sensor detects it and calculates the distance. Absolute output ensures that no zero-point reset is required after power-off, supporting linear or curved measurements and adapting to complex trajectories.

Compared with contact-type sensors, this non-contact method avoids wear and improves accuracy. Nexisense products integrate digital filtering to reduce noise interference, ensuring stable output in vibration environments.

.Structural Analysis

The core of the Nexisense flexible magnetostrictive linear position sensor lies in the flexible measuring rod, which is typically made of high-strength composite materials. It can be bent to adapt to curved installations, avoiding transportation and space challenges associated with traditional rigid rods. The sensor head integrates electronic modules, including signal processors and interface circuits.

The magnetic ring features a non-contact design, surrounding the measuring rod without physical friction. The housing is made of corrosion-resistant alloy, with an IP67 protection rating, and is equipped with an M12 connector for convenient on-site wiring. The overall structure is compact, with a small rod diameter, making it suitable for narrow spaces. Laser welding technology ensures sealing performance and prevents media ingress.

This structure not only reduces installation difficulty but also enhances durability, delivering stable performance in high-pressure or dusty environments.

Advantage Analysis

Nexisense flexible magnetostrictive linear position sensors demonstrate multiple advantages in industrial applications. First is high flexibility: the flexible measuring rod solves curved displacement measurement challenges, requires minimal installation space, and reduces transportation risks. Second, the non-contact design eliminates wear and noise, significantly extending service life.

Strong environmental resistance: oil-resistant and contamination-resistant, capable of stable operation across a wide temperature range from -40°C to +85°C, unaffected by vibration or high pressure. Excellent accuracy, with non-linearity as low as 0.05%FS and temperature drift less than 0.007%FS/°C. Low power consumption reduces energy usage.

Multiple output options: supports 4-20mA, 0-10V DC, and other signals. Absolute measurement mode ensures data continuity. Easy maintenance and IP67 protection reduce failure rates and overall operating costs. These features enable reliable operation under dynamic conditions and promote automation upgrades.

Application Scenario Analysis

Flexible magnetostrictive linear position sensors are widely used in industrial automation.

In metallurgical equipment, they are used for displacement monitoring of rolling mills and continuous casting machines. The flexible design adapts to high-temperature and high-vibration environments, ensuring precise control.

In the wind power generation sector, they are installed on blades or towers to monitor deformation and displacement, supporting remote maintenance and improving power generation efficiency.

In construction machinery such as excavators and cranes, curved measurement capabilities track boom movement and prevent overload conditions.

In injection molding machines, they accurately monitor mold opening and closing, optimizing the molding process and improving product quality.

In the new energy sector, such as solar tracking systems and battery production lines, they adapt to flexible paths and provide real-time feedback.

Measurement ranges from 0-50mm to 2000mm are customizable to meet diverse requirements. These scenarios demonstrate the adaptability and reliability of the sensors.

.Detailed Technical Parameters

Typical parameters of Nexisense flexible magnetostrictive linear position sensors include a measurement range of 50-2000mm, non-linearity ≤0.05%FS, and resolution ≤0.01mm. Output signals include 4-20mA, 0-10V DC, or RS485. Supply voltage is 9-36VDC, with power consumption <1W.

Operating temperature ranges from -40°C to +85°C, protection rating IP67, and pressure resistance up to 10MPa depending on the model. Temperature coefficient <0.007%FS/°C, response time <1ms. Magnetic ring gap of 0.5-2mm ensures stable non-contact operation.

During selection, factors such as path curvature, medium type, and interface requirements should be considered. Nexisense provides customization options to ensure parameter matching with application needs.

Installation and Maintenance Guide

During installation, ensure an appropriate bending radius for the measuring rod and avoid excessive twisting. Secure the magnetic ring firmly and ensure connector sealing against dust. Commissioning includes zero-point setting and range calibration, adjusted using dedicated software.

For maintenance, inspect the measuring rod and connections quarterly, and clean contaminants with neutral agents. Calibrate accuracy annually and monitor output stability. In humid environments, add protective sleeves. Nexisense sensors are highly durable, with service life reaching millions of cycles under normal use, reducing replacement frequency.

FAQ

What is the difference between flexible magnetostrictive sensors and rigid types?
Flexible types support curved measurement and offer more flexible installation, making them suitable for space-constrained scenarios, while rigid types are limited to linear paths.

How should high-temperature environments be handled?
The sensors withstand temperatures up to 85°C. For higher temperatures, heat dissipation or isolation measures can be added.

Which systems are the output signals compatible with?
They support standard signals such as 4-20mA, making integration with PLC or SCADA systems easy.

Can the measurement range be extended?
The standard range is up to 2000mm. Longer ranges can be customized depending on the application.

Conclusion

The application of flexible magnetostrictive linear position sensors in industrial automation marks the evolution of measurement technology toward intelligence and adaptability. Nexisense products inject vitality into industries such as metallurgy and wind energy through innovative structures and stable performance. From measurement methods to technical parameters, every aspect reflects professional standards. Proper selection and maintenance can maximize potential and enhance production efficiency. Looking ahead, these sensors will further integrate with the Internet of Things, supporting industrial transformation and upgrading.