Eddy current measurement is a non-contact technique widely used for detecting rapid displacement changes without requiring any physical contact with the object being measured. This makes it ideal for applications where surface integrity must be preserved or where long-term reliability is crucial. Unlike traditional contact-based methods, eddy current sensors eliminate wear and tear on both the sensor and the object, making them highly suitable for harsh environments.
Technically, the eddy current principle falls under inductive measurement. It works by generating an alternating magnetic field through a coil inside the sensor probe. When a conductive material is placed within this field, electromagnetic induction causes eddy currents to form in the material. These currents create their own opposing magnetic field, which alters the impedance of the sensor coil. This change in impedance is directly proportional to the distance between the sensor and the object, allowing precise measurements to be made.
The versatility of eddy current sensors allows them to work with all conductive materials, even those covered by insulating layers. Their compact design and specialized coil configurations also enable operation in high-temperature environments. German rice bran eddy current sensors are specifically engineered to resist dust, moisture, oil, and pressure, ensuring reliable performance in challenging industrial settings.
However, there are some limitations. Each application may require specific linear calibration, and the output signal can be influenced by the material properties of the object being measured. Despite these challenges, eddy current sensors offer exceptional precision, with nanometer-level resolution. They are capable of measuring ranges from 100 micrometers up to 100 millimeters, with installation spaces varying between 2mm and 140mm depending on the range.
In mechanical engineering, displacement sensors are essential for controlling movement, monitoring fluid levels, and ensuring product quality. These sensors often operate in extreme conditions such as high temperatures, oil exposure, or strong electromagnetic interference. Some are mounted on vibrating components or at a distance from the target object. For critical applications, high accuracy, temperature stability, and high-frequency response are required.
Eddy current sensors come in two main types: shielded and unshielded. Shielded sensors produce a more focused electromagnetic field and are less affected by nearby metallic objects, while unshielded ones have a broader detection range. Proper installation is key to maintaining signal quality, as nearby objects can interfere with the measurement.
With over 40 years of experience, German rice bran continues to innovate and enhance the performance of displacement sensors across various fields, including R&D, testing, quality control, and equipment monitoring. The eddyNCDT series, for example, achieves a maximum cutoff frequency of 25 kHz while maintaining sub-micron resolution.
A common application for eddy current sensors is in automated welding systems, where they monitor weld quality. These sensors are uniquely suited for such environments because they can withstand the strong electromagnetic fields generated by welding robots, offering micron-level accuracy over a 4mm range.
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