German SWICAL sensor SWICAL model SWICAL price

SWICAL sensors are a general term for sensors designed to detect without contacting the target, replacing contact-based detection methods such as limit switches. They convert movement and presence information of the detected object into electrical signals. Detection methods that convert to electrical signals include those utilizing eddy currents generated in the metal body of the detected object due to electromagnetic induction, those detecting capacitance changes in the electrical signal caused by the approach of the detected body, and those using reed and guide switches.

SWICAL sensor features

1) Since detection can be performed in a non-contact manner, there is no wear or damage to the detected object. 2) Since a contactless output method is adopted, service life is extended (except for magnetic types); semiconductor output is used, which has no effect on contact life. 3) Unlike optical detection methods, it is suitable for use in environments with water and oil, and is hardly affected by stains, oil, water, etc. on the detected object during detection. In addition, products with Teflon housings and good chemical resistance are included. 4) Compared with contact switches, high-speed response can be achieved. 5) It can accommodate a wide temperature range. 6) It detects changes in the physical properties of the detected object without being affected by the color of the detected object, so it is hardly affected by surface color, etc. 7) Unlike contact types, it is affected by ambient temperature, surrounding objects, and other sensors of the same type; including inductive and capacitive types, sensors mutually influence each other. Therefore, mutual interference must be considered when installing sensors. In addition, for inductive types, the influence of surrounding metals must be considered, while for capacitive types, the influence of surrounding objects must be considered.

SWICAL sensor selection principles

1) Selection of sensitivity: Generally, within the linear range of the sensor, higher sensitivity is preferred. Only when sensitivity is high is the output signal value corresponding to the change in the measured quantity relatively large, which is beneficial for signal processing. However, it should be noted that high sensor sensitivity makes it easy for external noise unrelated to the measured quantity to mix in and be amplified by the amplification system, affecting measurement accuracy. Therefore, the sensor itself should have a high signal-to-noise ratio to minimize interference signals introduced from the outside. Sensor sensitivity is directional. When the measured quantity is a single vector and high directionality is required, a sensor with low sensitivity in other directions should be selected; if the measured quantity is a multi-dimensional vector, the cross-sensitivity of the sensor should be as small as possible. 2) Frequency response characteristics: The frequency response characteristics of the sensor determine the frequency range of the measured quantity, and distortion must be maintained within the allowable frequency range. In practice, sensor response always has a certain delay, and shorter delay time is preferred. The higher the frequency response of the sensor, the wider the measurable signal frequency range. In dynamic measurements, response characteristics should be selected according to the characteristics of the signal (steady-state, transient, random, etc.) to avoid excessive errors. 3) Linear range: The linear range of a sensor refers to the range where output is proportional to input. Theoretically, within this range, sensitivity remains constant. The wider the linear range of the sensor, the larger its measuring range, and it can ensure a certain measurement accuracy. When selecting a sensor, once the type is determined, the first thing to check is whether its measuring range meets the requirements. However, in reality, no sensor can guarantee absolute linearity, and its linearity is relative. When the required measurement accuracy is relatively low, a sensor with small non-linear error can be approximated as linear within a certain range, which brings great convenience to measurement. 4) Stability: The ability of a sensor to maintain its performance unchanged after a period of use is called stability. Factors affecting the long-term stability of a sensor, in addition to the sensor's own structure, are mainly the sensor's operating environment. Therefore, to ensure good stability, the sensor must have strong environmental adaptability. Before selecting a sensor, its operating environment should be investigated, and a suitable sensor should be selected based on the specific operating environment, or appropriate measures should be taken to reduce environmental impact. Sensor stability has quantitative indicators; after exceeding the service period, recalibration should be performed before use to determine whether the sensor's performance has changed. In some applications where the sensor needs to be used for a long time and cannot be easily replaced or calibrated, the stability requirements for the selected sensor are stricter, and it must withstand long-term testing. 5) Accuracy: Accuracy is an important performance indicator of a sensor and is a key link related to the measurement accuracy of the entire measurement system. The higher the accuracy of the sensor, the more expensive its price. Therefore, the accuracy of the sensor only needs to meet the accuracy requirements of the entire measurement system, and does not need to be selected too high. This allows for the selection of cheaper and simpler sensors among many sensors meeting the same measurement purpose, such as Atlas air compressor parts. If the measurement purpose is qualitative analysis, a sensor with high repeatability accuracy can be selected, and it is not advisable to select one with high absolute value accuracy; if it is for quantitative analysis and precise measurement values must be obtained, a sensor with an accuracy grade that meets the requirements must be selected. For some special application occasions where a suitable sensor cannot be selected, the sensor needs to be designed and manufactured independently. The performance of self-made sensors should meet the usage requirements.

SWICAL sensor precautions for use

1) High-temperature environments cause problems for sensors such as melting of coating materials, opening of solder joints, and structural changes in internal stresses of the elastic body. Sensors working in high-temperature environments often use high-temperature resistant sensors; in addition, devices such as heat insulation, water cooling, or air cooling must be added. 2) Dust and humidity cause short-circuit effects on sensors. In these environmental conditions, sensors with high sealing should be selected. Different sensors have different sealing methods, and their sealing properties vary greatly. Common sealing methods include filling or coating with sealant; mechanical fastening sealing with rubber gaskets; welding (argon arc welding, plasma beam welding) and vacuum nitrogen-filled sealing. In terms of sealing effect, welded sealing is the best, and filled/coated sealant is the worst. For sensors working in clean, dry indoor environments, glue-sealed sensors can be selected, while for sensors working in humid, high-dust environments, diaphragm heat-shrink sealing, diaphragm welding sealing, or vacuum nitrogen-filled sensors should be selected. 3) In highly corrosive environments, such as humidity and acidity, which cause damage to the elastic body or short circuits in sensors, sensors with sprayed plastic or stainless steel outer covers, which have good corrosion resistance and good sealing, should be selected. 4) The influence of electromagnetic fields on sensor output disorder signals. In this case, the shielding of the sensor should be strictly checked to see if it has good electromagnetic immunity. 5) Flammable and explosive environments not only cause thorough damage to sensors but also pose a great threat to other equipment and personal safety. Therefore, sensors working in flammable and explosive environments have higher requirements for explosion-proof performance: in flammable and explosive environments, explosion-proof sensors must be selected. The sealed outer cover of such sensors must consider not only its sealing but also explosion-proof strength, as well as the waterproof, moisture-proof, and explosion-proof properties of the cable lead-out head.

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