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18

2025

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06

Introduction to the Principle and Characteristics of Flow Sensors

A flow sensor is an instrumentation device used to detect the flow parameters of media such as liquids and gases, converting these measurements into signals that can be output in alternative forms. It boasts several advantages, including compact size, lightweight design, intuitive and clear readings, high reliability, and zero pressure loss. As a result, it has been widely adopted across various fields—such as environmental monitoring, safety protection, healthcare, and commercial billing.

Introduction to the Principle and Characteristics of Flow Sensors:

A flow sensor is an instrumentation device used to detect the flow parameters of media such as liquids and gases, converting these measurements into signals that can be output in alternative forms. It boasts several advantages, including compact size, lightweight design, intuitive and clear readings, high reliability, and zero pressure loss. As a result, it has been widely adopted across various fields—such as environmental monitoring, safety protection, healthcare, and commercial billing.

Flow sensors come in a variety of designs, and the working principles behind different types of sensors can vary significantly. For instance, ultrasonic sensors may operate either based on the Doppler method—where the reflection of sound waves off a medium causes a shift in frequency, resulting in a frequency difference when there’s relative motion between the sound source and the medium receiving the waves—or on the time-of-flight method, in which the speed of sound is combined with the velocity of the fluid flow. If the ultrasonic wave travels against the direction of the water flow, the transit time is shorter; if it moves in the same direction as the flow, the transit time is longer. The flow velocity can then be calculated precisely from the difference in transit times. On the other hand, vortex shedding sensors rely on the vortex frequency method (based on the Karman vortex street principle), where a bluff body placed in a flowing fluid generates alternating vortices known as a Karman vortex street. Under conditions of steady flow, these vortices form regularly on either side of the obstruction. Lastly, differential pressure sensors function according to Bernoulli’s principle: they measure flow by detecting the pressure drop that occurs when fluid passes through a constricted section of a pipe. Since the flow rate remains constant at any point within the pipeline system, this pressure difference can be directly linked to the flow rate, allowing for accurate calculations using Bernoulli’s equation.

 

 

Flow rate is a critical parameter in industrial processes. During industrial manufacturing, many raw materials, semi-finished products, and waste materials exist in fluid form. As a result, fluid flow rate becomes the key factor determining product composition and quality—and it also serves as an essential basis for calculating production costs and optimizing energy usage. Moreover, to ensure reliable detection and accurate measurement results in manufacturing, many processes require consistent control of the inflow and outflow rates of liquid or gas media. In automated production systems, measuring flow rate is just as vital as monitoring pressure and temperature. Therefore, flow measurement and control are integral components of process automation. A flow sensor is a device that detects fluid flow and converts it into a usable output signal. By placing the sensor directly in the fluid’s path, changes in flow can be precisely measured through the interaction between the fluid and the sensor, or vice versa. According to the definition of flow rate, these sensors are primarily used for detecting both gaseous and liquid flows.


Keywords:

Industrial Control

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