When selecting the right in-cylinder linear position sensor for hydraulic cylinders in mobile applications, understanding the various sensor technologies available can be crucial. At Aggressive Hydraulics, we work with advanced sensor manufactures to ensure precision, durability, and performance in the field. This guide will provide an overview of the most common types of position sensors used in mobile hydraulic cylinders: Magnetostrictive Technology and Hall Effect Technology.

Magnetostrictive Technology

Magnetostrictive sensors offer high accuracy by using magnetic fields and torsional straining to measure position within a hydraulic cylinder.

How it works:

A magnetic pulse travels along a rod, and the sensor measures the time it takes for the pulse to travel. This allows the system to determine the exact position of the magnet.

Advantages:

  • Wear-free operation
  • Stable signals across a wide temperature range
  • Resistant to shock and vibration
  • Can be mounted internally or externally, providing flexibility for various designs.

Magnetostrictive sensors are a reliable option for applications requiring precise and long-lasting performance in demanding environments.

Hall Effect Technology

Hall Effect sensors measure the piston’s position by detecting changes in magnetic strength as a movable magnet passes over the sensor chips.

How it works:

The sensor’s microprocessor interprets voltage drops created by the moving magnet and translates them into proportional digital or analog outputs such as voltage, current, PWM, or CANBus signals.

Advantages:

  • Ideal for small cylinder packages
  • Rugged design suitable for harsh environments
  • Capable of providing digital and analog outputs
  • Hall Effect technology is commonly used in mobile hydraulic systems and is well-suited for applications where space is limited but durability is critical.

Embedded vs External Sensors

When deciding between embedded and external sensors, there are important factors to consider:

Embedded Sensors (Internal):

  • Protected from physical damage
  • Compatible with rear cylinder mounts (cross tube, clevis, or spherical bearing)
  • More common in mobile applications
  • Less expensive sensor, but the machining of the end cap is generally more costly

External Sensors:

  • Exposed to potential damage
  • Better suited for flange, trunnion, or foot mount cylinders
  • More common in industrial applications
  • More expensive sensor, but the machining of the end cap is typically less expensive

Markets and Applications for In-Cylinder Linear Position Sensors

In-cylinder linear position sensors are vital for ensuring precise control and reliability in a variety of demanding applications. The following are common markets where these sensors are used:

  • Railway Maintenance: Ensuring the accurate positioning of hydraulic cylinders in equipment such as track maintenance machines, tampers, and ballast regulators.
  • Industrial Equipment: Used in manufacturing equipment, material handling systems, and automated machinery where precision and durability are critical.
  • Aerial Devices: Providing safe and accurate positioning for hydraulic systems in aerial lifts, bucket trucks, and other equipment where people are elevated and safety is paramount.

These advanced sensors play an essential role in maintaining optimal performance across these industries, ensuring reliability and safety in even the most challenging environments.

Conclusion

Each sensor technology offers distinct advantages depending on the application, cylinder design, and operating environment. At Aggressive Hydraulics, we help guide you through the selection process to ensure your hydraulic systems are equipped with the most suitable sensor for precise and reliable operation. Contact our team today. Whether you need high accuracy in mobile equipment or robust performance in industrial environments, our comprehensive sensor solutions can meet the demands of any application.

By understanding the strengths of each sensor type, you can make informed decisions that optimize the performance and longevity of your hydraulic systems.