In the field of industrial automation, magnetostrictive displacement sensors are often referred to as "precision rulers for position measurement", featuring micrometer-level accuracy and extremely long service life. For instance, an early model of magnetostrictive displacement sensor manufactured by Zheda Jingyi has been in service since 2011 and was only decommissioned in 2025, achieving an ultra-long service life of 14 years.

Nevertheless, many users frequently encounter problems such as signal jitter, data drift and even premature failure of the sensors. Where lies the root cause? In fact, most faults are induced by improper installation.

Proper installation enables the sensor to deliver its full performance potential; poor installation will compromise the performance even of high-quality equipment. Below are several key guidelines for installation to help you avoid common pitfalls.

Figure 1: Test Site of Zheda Jingyi Magnetostrictive Displacement Sensor

Pre-installation: Thorough Preparation Avoids Unnecessary Troubles

Many operators rush to mount the sensor immediately upon receipt. However, experienced technicians understand that proper installation begins with preparation.

First, assess the environment: Select a dry, clean location free of corrosive gases. Keep the sensor away from equipment generating strong magnetic fields such as motors and transformers. If intense vibration is unavoidable on site, install vibration damping brackets in advance — far more efficient than troubleshooting afterwards. For externally mounted sensors, ensure the mounting surface is flat without unevenness.

Second, prepare tools and inspect goods: Get mounting brackets, screwdrivers and other tools ready. After unpacking, check whether all components including the sensor body, magnetic ring and cables are complete. Inspect for collision damage and address defects promptly.

Last but not least, prioritize safety: Confirm the equipment is powered off before operation. This protects personal safety as well as the precision internal components of the sensor.

Installation: Precise Operation with Focus on Core Requirements

This stage determines whether the sensor can operate accurately, with the key points being alignment and stable fastening.

Mounting the Sensor Body

The mounting surface must be flat. Level calibration with a spirit level is recommended to keep the sensor axis parallel to the measured motion path — generally, the angular deviation shall not exceed 0.5°. Tighten bolts incrementally following a diagonal sequence for uniform clamping force. If the sensor stroke exceeds 1 meter, add intermediate supports to prevent bending deformation after long-term operation.

Mounting the Magnetic Ring

The magnetic ring acts as the "signal trigger" of the sensor. Its installation quality directly affects measurement accuracy.

Correct orientation: The magnetic ring is normally fitted with a magnetic isolation shim. When the piston rod is made of magnetically conductive material, ensure the shim is installed in the correct position (refer to the manual for details).

Figure 2: Installation Instructions for Zheda Jingyi RH Pressure-resistant Tubular Displacement Sensor

Maintain Concentricity: The inner bore of the magnetic ring must be concentric and coaxial with the sensor measuring rod to minimize eccentricity. Ideally, the magnetic ring shall slide smoothly along the measuring rod without jamming or stalling.

Secure Fastening: Firmly mount the magnetic ring on the measured object. No looseness or gaps are allowed at the connection to guarantee that every tiny movement of the object is accurately transmitted.

Electrical Connection

Electrical connections serve as the "channel" for signal transmission. A clean channel ensures stable signals. Special shielded cables must be adopted, and the shielding layer shall be reliably grounded, which forms the primary defense against interference. During wiring, signal cables shall be kept away from power cables and parallel routing should be avoided — this is the golden rule for anti-interference.

Refer to the wiring diagram to correctly connect power supply, output signal wires and ground wires. Tighten terminals to prevent loosening. In addition, effective waterproof and dustproof sealing shall be implemented at the cable entry. This enables the sensor to operate stably for a long time even under harsh industrial conditions.

Post-installation: Calibration and Maintenance

After installation and power-on, a system calibration is recommended to verify normal operation.

• Static Test: Slowly move the magnetic ring through the full stroke and check whether the output signal changes continuously and smoothly without signal jumping or interruption.

• Limit Position Verification: Move the magnetic ring to both ends of the stroke respectively, and confirm that the sensor output values match the actual mechanical positions.

• Dynamic Trial Run: Operate the equipment at low speed to observe output stability and response timeliness, and check for abnormal noise from the sensor.

Regular Maintenance to Extend Service Life

Regular maintenance is essential for long-term stable operation of the sensor. A comprehensive inspection is recommended every six months to check for loose screws, unreliable wiring and smooth sliding of the magnetic ring. Professional calibration is suggested every one to two years. Keep routine records and establish equipment files to facilitate traceability and analysis in the future.

Please note that the above are general core installation guidelines. Different sensor models may have special requirements. Make sure to read the operation manual before installation. For complicated conditions, contact the manufacturer’s technical support to achieve proper installation at one time and secure long-term trouble-free operation.