Industrial process monitoring scenarios vary widely, and standard sensors often cannot fully meet all requirements. Tianjin Youyi Technology provides custom sensor design services. This document details the key parameters required for custom sensor design, for customers to fill in during the early project stage so our engineering team can quickly assess feasibility and propose optimal design solutions.
Custom Sensor Design Specification
Industrial process monitoring scenarios vary widely, and standard sensors often cannot fully meet all requirements. Tianjin Youyi Technology provides custom sensor design services. Based on your specific process conditions, measurement objectives, and on-site environment, we create tailored process tomography sensor systems. This document details the key parameters required for custom sensor design, for customers to fill in during the early project stage so our engineering team can quickly assess feasibility and propose optimal design solutions.
I. Necessity of Custom Design
Why do you need a custom sensor?
Limitations of standard sensors:
- Pipe size mismatch (standard products typically cover DN15–DN200; beyond this range requires customization)
- Temperature/pressure rating insufficient (standard sensors typically tolerate ≤80°C, pressure ≤2 MPa)
- Media compatibility issues (standard materials may be incompatible with corrosive media)
- Installation space constraints (on-site space is tight, standard form factor cannot be installed)
- Special measurement accuracy requirements (e.g., ultra-high spatial resolution, extremely fast acquisition speed)
Advantages of custom design:
- Fully adapted to on-site conditions: pipe size, flange standard, installation method — one-to-one correspondence
- Meet extreme operating conditions: high temperature, high pressure, strong corrosion, strong radiation, and other special environments
- Optimize measurement performance: adjust electrode/coil parameters based on media characteristics to improve imaging quality
- Integrate with existing equipment: seamless connection with your existing pipelines, reactors, and production lines
- Optimal cost-effectiveness: avoid over-design; invest only where it matters
II. Basic Parameter Table (Required)
| Parameter | Description/Options | Your Entry |
|---|
| Application scenario | Pneumatic conveying/fluidized bed/stirred tank/pipeline conveying/reactor/separator/other | _______________ |
| Medium under test | Name, physical state (gas/liquid/solid), and ratio of continuous and dispersed phases | _______________ |
| Medium conductivity | Conductivity range of continuous phase (e.g., 0.1–10 S/m) | _______________ S/m |
| Medium permittivity | Relative permittivity of continuous and dispersed phases (e.g., air εr≈1, water εr≈80) | _______________ |
| Medium temperature | Normal operating temperature range (e.g., 20–80°C) | _______________ °C |
| Medium pressure | Normal operating pressure range (e.g., 0.1–0.5 MPa) | _______________ MPa |
| Medium corrosivity | Whether it contains acid/alkali/solvent or other corrosive components | _______________ |
| Medium viscosity | Dynamic viscosity range (e.g., 1–100 mPa·s) | _______________ mPa·s |
| Particle size | Particle size distribution of solids (e.g., 10–500 μm) | _______________ μm |
| Flow velocity range | Flow velocity of medium in pipeline/reactor (e.g., 0.5–5 m/s) | _______________ m/s |
2.2 Pipeline/Container Geometric Parameters
| Parameter | Description/Options | Your Entry |
|---|
| Pipe inner diameter | Inner diameter of circular pipe (e.g., DN50 is Φ50mm) | _______________ mm |
| Pipe outer diameter | Used to determine wall thickness and assess sensor installation space | _______________ mm |
| Pipe material | Carbon steel/stainless steel/PVC/acrylic/glass/other | _______________ |
| Pipe orientation | Horizontal/vertical/inclined (inclination angle) | _______________ |
| Cross-section shape | Circular/square/rectangular/annular | _______________ |
| Number of measurement cross-sections | Number of cross-sections to be monitored (1/2/multiple) | _______________ |
| Cross-section spacing | For multiple cross-sections, distance between each cross-section | _______________ mm |
| Straight pipe length | Straight pipe length upstream and downstream of sensor installation location | Upstream ______ mm / Downstream ______ mm |
2.3 Installation and Environmental Parameters
| Parameter | Description/Options | Your Entry |
|---|
| Installation method | Flange connection/clamp connection/welding/clamp-on/insertion | _______________ |
| Flange standard | GB/HG/ANSI/DIN, etc. (e.g., HG/T 20592-2009) | _______________ |
| Flange pressure rating | PN10/PN16/PN25/PN40/Class150/300, etc. | _______________ |
| Explosion-proof requirement | Whether explosion-proof certification is required (e.g., Ex d IIC T4) | _______________ |
| Protection rating | IP54/IP65/IP67, etc. | _______________ |
| Ambient temperature | Air temperature range of sensor installation environment | _______________ °C |
| Ambient humidity | Relative humidity range (e.g., 20%–80% RH) | _______________ % RH |
| EMI | Whether there are high-power motors, frequency converters, electric welding, or other interference sources nearby | _______________ |
| Vibration | Whether the pipeline/equipment has significant vibration | _______________ |
| Installation space | Axial/radial available space constraints for sensor | Axial ______ mm / Radial ______ mm |
2.4 Measurement Requirements
| Parameter | Description/Options | Your Entry |
|---|
| Measurement objective | Phase fraction/flow pattern identification/velocity measurement/interface detection/concentration distribution/other | _______________ |
| Expected accuracy | E.g., phase fraction accuracy ±5%, ±2%, etc. | _______________ |
| Temporal resolution | Required acquisition speed (e.g., 100 fps) | _______________ fps |
| Spatial resolution | Expected imaging resolution (e.g., 5% of pipe diameter) | _______________ % of pipe diameter |
| Data output | Need 4-20mA/Modbus TCP/EtherNet/IP/USB, etc. | _______________ |
| Display method | Local touch screen/remote host PC/web browser | _______________ |
| Alarm function | Whether threshold alarm/trend warning is needed | _______________ |
| Data storage | Whether historical data storage is needed (e.g., 30 days) | _______________ |
III. Technical Selection Parameters (Fill after consultation)
3.1 Modality Selection (ECT / ERT / EMT)
| Modality | Suitable Scenarios | Unsuitable Scenarios |
|---|
| ECT Capacitance Tomography | Gas-solid/gas-liquid two-phase, continuous phase is low-permittivity substance (gas, oil) | High water content media, enclosed metal pipes |
| ERT Resistance Tomography | Water-oil/water-solid/water-gas two-phase, continuous phase is conductive medium (water-based, electrolyte) | Non-conductive media (pure oil, pure gas) |
| EMT Electromagnetic Tomography | Metal-containing/liquid metal/magnetic media | Non-conductive and non-magnetic media |
| ECT/ERT Dual-modality | Complex media electrical properties, need multi-parameter complementarity | Cost-sensitive scenarios |
Quick decision reference:
Is the measured medium conductive?
├─ Yes → Contains metal?
│ ├─ Yes → EMT
│ └─ No → ERT
└─ No → ECT
3.2 Electrode/Coil Parameters
ECT Sensor
| Parameter | Standard Range | Custom Options |
|---|
| Number of electrodes | 8 / 12 / 16 | Customizable 6–24 |
| Electrode material | Copper/brass/stainless steel | Customizable gold-plated, platinum, etc. |
| Electrode shape | Rectangular/concave/annular | Customizable special shapes |
| Electrode size | Axial length 10–50 mm | Customizable |
| Electrode arrangement | Single cross-section/dual cross-section/spiral | Customizable |
| Shielding method | Grounded shielding/radial shielding | Customizable |
ERT Sensor
| Parameter | Standard Range | Custom Options |
|---|
| Number of electrodes | 8 / 12 / 16 | Customizable 4–32 |
| Electrode material | Stainless steel 316L/titanium alloy/Hastelloy | Customizable corrosion-resistant materials |
| Electrode form | Point electrode/annular electrode/surface patch | Customizable |
| Insulating liner | PTFE/ceramic/rubber | Customizable |
| Sealing method | O-ring/metal seal | Customizable |
EMT Sensor
| Parameter | Standard Range | Custom Options |
|---|
| Number of coils | 4 / 8 | Customizable |
| Number of turns | 10–100 turns | Customizable |
| Coil material | Enameled wire/Litz wire | Customizable high-temperature wire |
| Core material | No core/manganese-zinc ferrite | Customizable |
| Excitation frequency | 10 kHz – 10 MHz | Customizable range |
3.3 Electronic System Parameters
| Parameter | Standard Value | Custom Options |
|---|
| Acquisition speed | 100–1000 fps | Customizable higher speed |
| Excitation frequency | ECT: 100 kHz–1 MHz
ERT: 1 kHz–100 kHz
EMT: 10 kHz–10 MHz | Customizable |
| Data interface | Ethernet / USB / RS485 / 4-20mA | Customizable |
| Explosion-proof rating | Standard type / Ex d IIC T4 | Customizable |
| Power supply | 24V DC / 220V AC | Customizable |
| Protection rating | IP65 | Customizable IP67, etc. |
IV. Special Operating Condition Design Parameters
4.1 High-Temperature Scenarios (>80°C)
| Temperature Range | Recommended Solution | Notes |
|---|
| 80–150°C | High-temperature electrode encapsulation + high-temperature cable | Cable must be high-temperature resistant; electronic system must be away from heat source |
| 150–300°C | Ceramic insulation + water/air cooling jacket | Requires cooperation with cooling system |
| >300°C | Special high-temperature materials (e.g., Inconel) | Requires special assessment; recommends laboratory pilot test |
4.2 High-Pressure Scenarios (>2 MPa)
| Pressure Range | Recommended Solution | Notes |
|---|
| 2–6 MPa | Thickened insulation layer + high-pressure flange | ECT electrode pressure-resistant design |
| 6–20 MPa | Metal pipe + contact electrode (ERT) | Or EMT non-contact solution |
| >20 MPa | Special design; recommends pilot verification | |
4.3 Strong Corrosion Scenarios
| Medium Type | Recommended Material | Notes |
|---|
| Acidic media | Titanium alloy/Hastelloy/PTFE liner | Select material based on acid type and concentration |
| Alkaline media | Stainless steel 316L/Nickel alloy | |
| Saltwater/Seawater | Duplex stainless steel 2205/Titanium alloy | Watch for crevice corrosion |
| Organic solvents | PTFE/PFA perfluoro materials | Swelling needs assessment |
4.4 Hygienic/Food-Grade Scenarios
| Requirement | Recommended Solution | Standard |
|---|
| Surface roughness | Ra ≤ 0.8 μm | Polished |
| Dead-space-free design | Rounded corners | Compliant with 3A / EHEDG |
| Cleaning/Sanitization | Supports CIP/SIP | Resistant to high-temperature steam |
V. Customization Process
5.1 Standard Process
Requirements Communication → Parameter Confirmation → Design → Contract Signing → Manufacturing → Factory Test → On-site Installation → Acceptance Delivery
↓ ↓ ↓ ↓ ↓ ↓ ↓ ↓
1 day 2-3 days 1-2 weeks 1 week 4-8 weeks 1 week 1-2 weeks 1 week
Total cycle: Standard customization takes approximately 8–12 weeks (from requirements confirmation to acceptance delivery)
5.2 Expedited Process
For urgent projects, expedited service is available:
- Small batch expedited: 10–20 working days (for small sizes, standard materials)
- Medium batch expedited: 4–6 weeks (for medium complexity)
- Assessment required: For new structures/new materials/extreme conditions, pilot verification is needed first
5.3 Pilot Test Service
For scenarios with high uncertainty, laboratory pilot verification is recommended:
- We provide: Standard sensor + test system + laboratory facility
- Customer provides: Real medium or simulated medium
- Verification content: Measurement feasibility, accuracy assessment, long-term stability
- Deliverables: Test report + sensor design proposal
VI. Case References
Case 1: DN300 Large-Diameter Pneumatic Conveying ECT Sensor
| Item | Parameters |
|---|
| Application scenario | Power plant pulverized coal pneumatic conveying |
| Pipe size | DN300 (Φ300mm) |
| Medium | Air + pulverized coal (solid fraction 1–10%) |
| Temperature/Pressure | 50°C / 0.3 MPa |
| Customization highlights | 16 electrodes, concave design, enhanced edge sensitivity |
| Delivery cycle | 8 weeks |
Case 2: DN15 High-Temperature High-Pressure ERT Sensor
| Item | Parameters |
|---|
| Application scenario | Oil-water separator internal monitoring |
| Pipe size | DN15 (Φ15mm) |
| Medium | Crude oil + oily wastewater |
| Temperature/Pressure | 120°C / 6 MPa |
| Customization highlights | 8 electrodes, titanium alloy material, metal pipe + PTFE insulating liner |
| Delivery cycle | 10 weeks |
| Item | Parameters |
|---|
| Application scenario | Flow field monitoring in steel continuous casting mold |
| Vessel size | 200×200mm square cross-section |
| Medium | Molten steel (approximately 1500°C) |
| Customization highlights | Non-contact coil arrangement, water cooling protection, high-temperature resistant materials |
| Delivery cycle | 12 weeks + pilot verification |
If you have custom sensor requirements, please fill in the “Basic Parameter Table” section of this specification and contact us via:
This document is provided by Tianjin Youyi Technology (iptomo.com). Content updates are made without prior notice.
