Level measurement Magnetostrictive

Magnetostrictive level measurement combined with temperature output 4-20mA

In today's highly technological world, level and temperature measurement in industrial plants, tanks, and containers are becoming increasingly crucial. Level and temperature measurement is a fundamental process in the industry and significantly influences the efficiency and safety of operations. Analog magnetostrictive level measurement, in combination with a temperature sensor like the PT100 or PT1000, has proven to be a top performer in this field. It enables continuous and precise monitoring of liquid levels and, additionally, temperature measurement.

Operating Principle

The magnetostrictive measurement principle is based on the properties of certain materials that change under the influence of a magnetic field. One such material is the magnetostrictive wire, composed of an alloy that responds magnetically when exposed to an external magnetic field. In the case of level measurement using a float, the float is placed in the liquid whose level needs to be measured. The float rises or falls according to the liquid level. Inside the float is a magnet. A tube surrounding the float contains a coil through which a short electrical pulse is sent to create a magnetic field. This magnetic field propagates along the tube and reaches the magnet within the float. When the magnetic field pulse reaches the magnet, it causes a magnetic alignment of the wire, resulting in mechanical expansion or contraction of the wire. This expansion or contraction generates an elastic wave that travels along the wire. Simultaneously, the coil serves as a receiver, capturing the elastic wave as it returns to the starting point and converting it into an electrical signal. The time between sending the pulse and receiving the signal is measured. Since the speed at which the elastic wave propagates in the wire is known, the liquid's fill height can be calculated. Thus, the magnetostrictive float allows for precise measurement of liquid levels. The measured values can then be evaluated and displayed accordingly or integrated into a control system to, for example, realize level indication or automatic control of the filling process.

Analog temperature measurement is performed using highly accurate temperature sensors such as PT100 or PT1000. These sensors operate on the principle of the change in electrical resistance of a metal depending on temperature. A PT100 sensor consists of a platinum resistor that changes its resistance value as temperature rises. Similarly, a PT1000 sensor operates, but its resistance is 1000 times greater than that of a PT100. PT sensors are capable of delivering very precise and accurate resistance values directly related to the temperature of the liquid or medium in contact. These analog resistance values are then converted into temperature values and displayed through an appropriate measuring device or evaluation circuit. Temperature values can also be transmitted to control and regulation systems to monitor the temperature in the facility and potentially control and regulate the process.

Advantages

• Precise Measurements: The combination of level and temperature sensors allows for real-time precise and reliable measurements. This enables the capture of accurate data to optimize processes and achieve high-quality results.
• Efficient Process Control: Continuous measurements allow for efficient control of processes and equipment. Operators can monitor process parameters in real-time and make adjustments as needed to optimize operations and reduce energy and material costs.
• Early Problem Detection: Sensors enable the early detection of deviations or malfunctions in operations. Timely intervention can prevent costly downtime or damage and extend the lifespan of equipment.
• Enhanced Safety: Accurate measurement of liquid level and temperature contributes to process safety. Potential hazards such as overfilling, leaks, or overheating can be detected early, and appropriate safety measures can be taken.
• Easy Integration: Modern sensors often come equipped with digital interfaces that facilitate seamless integration into existing control and automation systems.
• Versatile Applications: Such sensors find applications across various industries and environments, from industrial settings to medical technology, making them suitable for diverse tasks and conditions.
• Long-term Cost Savings: By avoiding overfilling, leaks, or unexpected failures, long-term cost savings can be achieved by preventing costly repairs or production interruptions.
• Environmental Friendliness: Efficient process control often leads to a reduced environmental impact as the use of raw materials and energy is optimized.

Applications and Industries

Hydraulic Systems
In hydraulic systems and machinery, these sensors enable precise measurement of hydraulic oil levels and temperature. This allows for efficient operation and prevents failures due to leaks or overheating.

Cooling Systems
In cooling systems of machinery and equipment, these sensors are used to monitor coolant levels and temperature, ensuring effective cooling and preventing damage from overheating.

Lubrication Systems
In lubrication systems, the sensors are used to measure lubricant levels and temperature, enabling efficient lubrication of machine parts and preventing wear and damage.

Pressure Vessels and Tanks
In pressure vessels and tanks, these sensors enable accurate capture of liquid level and temperature data, crucial for safe handling and compliance with safety standards.

Steam Generators and Boiler Systems
In steam generators and boiler systems, these sensors are employed to monitor water levels and temperature, optimizing steam generation efficiency and minimizing safety risks.

Textile Machinery
In the textile industry, these sensors accurately measure the liquid level and temperature of chemicals and dyes in textile machines, ensuring precise processing and coloration of textiles.

Food Processing Machinery
In the food industry, these sensors are used in various processing machines to monitor real-time liquid levels and temperature, ensuring product quality and safety.

Environmental Protection Applications
In environmental protection systems, these sensors are used to monitor liquid level and temperature in wastewater treatment tanks and containers, contributing to efficient wastewater treatment and compliance with environmental regulations.