Water tank level detection sensors face multiple challenges during long-term operation, including liquid corrosion, temperature fluctuations, and mechanical vibration. Their corrosion resistance directly impacts equipment lifespan and data accuracy. Achieving this requires a comprehensive approach encompassing five aspects: material selection, structural design, protective processes, environmental control, and maintenance strategies, forming a systematic protection plan.
Material selection is fundamental to corrosion resistance. Components of the water tank level detection sensor that come into direct contact with the liquid should prioritize corrosion-resistant materials, such as stainless steel, titanium alloys, or engineering plastics. Stainless steel is commonly used in general industrial water tanks due to its moderate cost and strong corrosion resistance; titanium alloys are suitable for extreme environments such as strong acids and alkalis, but are more expensive; engineering plastics such as polytetrafluoroethylene (PTFE) are ideal for corrosive liquids due to their chemical inertness. Surface treatment technologies can further enhance corrosion resistance, such as electroplating, spraying ceramic or polyester coatings to form a dense protective layer that isolates the liquid from direct contact with the substrate.
Structural design must balance functionality and protection. Water tank level detection sensors typically employ a fully sealed housing, using laser welding or ultrasonic welding to ensure a seamless seal and prevent liquid penetration. For sensors that need to be immersed in liquid, a double-layer housing design can be used: an inner layer for the detection unit and an outer protective layer, with thermally conductive silicone grease filling the space between, enhancing protection and optimizing heat dissipation. Installation methods are equally crucial; for example, flange connections or threaded locking should be used to prevent loosening due to vibration. For mobile water tanks, quick-connect fittings can be used for easy assembly and disassembly while reducing the risk of leakage.
Protective processes are key to extending lifespan. The surface coating of the water tank level detection sensor must be customized according to the liquid properties. For example, a ceramic coating is used in salt spray environments due to its high hardness and wear resistance; a polyester coating is chosen for organic solvent environments due to its excellent chemical stability. Coating application requires strict control of thickness and uniformity to prevent corrosion penetration caused by excessively thin areas. Furthermore, the internal circuitry of the water tank level detection sensor requires tri-proof treatment (moisture-proof, mildew-proof, and salt spray-proof), achieved by potting with silicone or epoxy resin to isolate electronic components from the external environment and improve shock resistance.
Environmental control can significantly reduce the risk of corrosion. During storage, water tank level detection sensors should be placed in a dry, well-ventilated warehouse, avoiding contact with corrosive gases or liquids. Before use, the packaging integrity should be checked to prevent damage to the protective layer during transportation. During operation, temperature and concentration should be controlled according to the liquid properties. For example, high-temperature liquids require temperature-resistant water tank level detection sensors, and high-concentration corrosive liquids require shorter maintenance cycles. For open water tanks, a liquid level protection sleeve can be installed to isolate the water tank level detection sensor from the liquid, detecting the water level only through capillary action or pressure conduction, reducing the direct contact area.
Maintenance strategies are crucial for ensuring long-term stability. Regularly clean the surface of the water tank level detection sensor to remove dirt and deposits. Use a neutral detergent and a soft brush, avoiding the use of hard objects such as steel wool to scratch the protective layer. For water tank level detection sensors that have already shown slight corrosion, an anti-corrosion grease can be applied to form a temporary protective film. Establish a maintenance record, recording the water tank level detection sensor's operating time, environmental parameters, and maintenance records to facilitate predicting replacement cycles. For example, water tank level detection sensors operating in corrosive liquids should undergo a comprehensive inspection every six months, including coating thickness, sealing performance, and circuit insulation resistance, to ensure that all indicators meet requirements.
The corrosion resistance stability of water tank level detection sensors requires synergistic optimization of materials, structure, processes, environment, and maintenance. From targeted design during the selection phase to proactive protection during operation and precise intervention during maintenance, each step must adhere to the principle of "prevention first, combined with control" to ensure the long-term stable operation of water tank level detection sensors under complex conditions and provide reliable data support for water tank level monitoring.
