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Float Level Sensors

Float level sensors are widely used in industrial and commercial applications, primarily in the monitoring of liquid levels. They are commonly deployed in the production and processing of food and beverages, petroleum production, chemical manufacturing, cooling systems and scientific research. Float level sensors have become an indispensable tool for many industrial settings, offering a reliable, non-contact sensing solution that is easier to install and maintain than conventional gauging devices.

Working Principle

Float level sensors deploy a float and switch assembly which operates on the displacement of density principle. The float is a solid cylinder or sphere made from a light material such as plastic, hardwood or aluminum which is able to float on a liquid’s surface. The float is attached to a long stem, which extends down into a sensor chamber. A switch is attached to the bottom of the stem and is triggered when the float reaches the top and bottom checkpoints of the chamber.

The float works by changing the buoyancy of the switch assembly as the liquid in the chamber rises or lowers. This is known as the displacement of density principle, in which objects with lower density than the liquid they are in will float up and objects with higher density than the liquid they are in will sink down. As the liquid rises or falls the float stem will extend further upwards or downwards and the switch will either be triggered or cut off. This allows the sensor to detect the rise and fall of the liquid.

The float level sensor will generally feature an adjustable overwire which allows the user to select the specific point of termination. This is done by manipulating the stem of the stem and the float, while the liquid\'s surface is observed at the other end. The switch is then set to trigger at various levels until the optimal water level is reached.

Types

Float level sensors are available in a variety of different sizes and configurations to suit a variety of applications. Common types include free-floating mechanical switches, optical switches, contact-type electrical devices and hermetically sealed switches with a magnetically active float.

Free-floating mechanical switches are the most common variety. They work by employing a reed switch which is triggered by the float as it moves up and down the stem. As the liquid level rises and falls the float causes the switch to open and close, providing the user with an accurate indication of the liquid\'s current level. This type of switch is often the most cost-effective option but it will wear over time as the metals in the reed switch corrode.

Optical switches use a light-emitting diode (LED) and a photosensitive cell to measure the position of the float. This type of device will only be triggered when the float is aligned within a certain distance of the photosensitive cell. Optical switches are generally more accurate than mechanical switches and have less likelihood of experiencing corrosion.

Contact-type electrical devices make use of a mercury switch, which is a sealed stoppered container filled with a quantity of mercury. The switch is triggered when the mercury rises to a certain level and contacts are made between the two electrodes, offering the user an accurate level reading. Unlike mechanical switches, mercury switches are generally unaffected by corrosion but can be more expensive.

Hermatically sealed switches employ a magnetically active float which rises and falls inside a chamber as the liquid level rises and falls. The switch is triggered by the magnet which is housed inside the float. This type of switch is sealed against any outside influences and is ideal for hazardous environments.

Advantages

Float level sensors are incredibly reliable and highly accurate even in the most extreme conditions. Their robust construction also makes them highly resistant to damage and corrosion, meaning they require minimal maintenance and are much easier to install than other types of level monitoring systems.

Furthermore, float level sensors can operate in a wide range of temperatures and are also capable of measuring extreme pressure variances. This makes them invaluable for monitoring gases and hazardous chemicals, as well as many other applications.

Finally, some varieties of float level sensors come with additional features such as temperature and pressure compensation. This allows the sensor to accurately measure levels in fluids that may be fluctuating in temperature or pressure, and it can help to minimize the effects of external factors on the accuracy of the sensor.

Conclusion

Float level sensors are an invaluable tool for a wide range of industries and applications. Their reliability, accuracy and robust construction make them an ideal choice for many applications and they offer a cost-effective and easy to install solution for liquid level monitoring.

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