In the field of hydraulic cylinder displacement monitoring, especially under stringent flammable and explosive working conditions such as petrochemical and iron & steel metallurgical industries, engineers are often confronted with a challenge: how to achieve high-precision linear measurement at the micron level while guaranteeing absolute safety. What “core configurations” must a genuine explosion-proof magnetostrictive displacement sensor possess to operate reliably within hazardous areas?

As a national-level Specialized, Refined, Unique and Innovative "Little Giant" enterprise, Zheda Jingyi has been engaged in sensor technology for more than 30 years with well-established explosion-proof sensing technology. Taking the FBGB explosion-proof magnetostrictive displacement sensor (hereinafter referred to as FBGB explosion-proof sensor) as an example, we will break down the essential components of a complete explosion-proof displacement monitoring solution, covering core parameters as well as installation design.

Figure 1: FBGB Explosion-proof Magnetostrictive Displacement Sensor

I. Stroke Configuration: 25 mm to 5500 mm, Customizable on Demand

Hydraulic cylinders come in different lengths, and the measuring stroke can be customized. The effective stroke of the FBGB explosion-proof sensor ranges from 25 mm to 5500 mm, with flexible customization available according to the actual cylinder length required by customers. Precise matching specifications can be provided for both compact cylinders and large hydraulic supports, eliminating issues such as excessive installation margin or insufficient measuring range.

II. Interface Configuration: Multiple Output Options Available

The interface of the control system determines the sensor’s communication capability. The FBGB supports various signal outputs including analog, SSI and CANopen.

• Analog (current / voltage): Wide compatibility, suitable for equipment retrofitting or applications without stringent requirements on communication speed.

• SSI: High-speed synchronous serial interface with strong anti-interference performance, ideal for high-precision closed-loop control.

• CANopen: Bus communication enabling multi-node networking, applicable to distributed control systems.

Engineers can select the appropriate variant flexibly according to the model of PLC or controller to achieve plug-and-play operation.

III. Accuracy Configuration: Minimum Resolution of 1 μm

Matched with different output interfaces, the FBGB displacement sensor delivers varying accuracy levels. The maximum resolution of this series reaches 1 μm, enabling precise detection of tiny piston rod displacement and supplying reliable data for precise system control.

IV. Safety Protection: Dual Safeguards of Explosion-proof Performance & Environmental Protection

The FBGB explosion-proof sensor has obtained ExdⅡBT6 flameproof certification.

• ⅡB: Suitable for environments with common gases such as ethylene and propane;

• T6: One of the highest temperature classes. The surface temperature of equipment shall not exceed 85°C, offering greater safety margin for high-temperature flammable applications.

This configuration ensures that if sparks are generated inside the sensor in explosive gas atmospheres, the housing can effectively contain the explosion and prevent ignition of hazardous external gas.

Meanwhile, the FBGB sensor achieves IP67 high ingress protection rating, resisting dust, water and oil. It can operate stably over a long period in humid, dusty and oily conditions, adapting to complex industrial sites.

V. Material Configuration: All-stainless Steel Structure with Corrosion and High-pressure Resistance

The interior of hydraulic cylinders features a harsh environment characterized by high pressure, high temperature and high corrosion. The sensing rod of the FBGB explosion-proof sensor is made of 304 or 316L stainless steel, and the electronic housing adopts 304 stainless steel for robust durability. In particular, 316L material is ideal for corrosive environments containing chloride ions, acids or alkalis. It effectively avoids sensing rod rusting and jamming, and guarantees reliable performance under long-term immersion.

VI. Mounting Configuration: Built-in Cylinder Installation, Straight Cable Outlet & Side Cable Outlet Optional

The FBGB explosion-proof sensor adopts built-in cylinder installation and is embedded directly inside the piston rod. Two cable outlet types (straight outlet and side outlet) are available to fit different cylinder structures. The installation schematic of the product is shown below.

Figure 2: Installation Schematic of FBGB Explosion-proof Sensor

In summary, the core parameters of the FBGB explosion-proof displacement sensor are listed as follows:

A complete set of explosion-proof magnetostrictive displacement sensor configuration is far more than simply combining an explosion-proof housing with displacement detection. Every link including customized measuring stroke, ultra-high precision, explosion-proof certification and corrosion-resistant materials must be precisely implemented.

The FBGB explosion-proof sensor developed by Zheda Jingyi is just such a mature solution with all specifications fully realized. It serves as a reliable choice for hydraulic cylinder displacement measurement in flammable and explosive environments such as petrochemical and metallurgical industries.