weFlux² fluid sensors are the new generation of high-performance sensors that integrate two measuring functions—alongside an analysis module—in a single device.
They use a patented measuring method that simultaneously determines the flow velocity as well as the temperature of the liquid/gas media as per the calorimetric principle. The 2 in 1 feature is owed to Wenglor’s engineers who successfully managed to integrate a temperature element into a pressure measuring cell.
weFlux² Fluid Sensors: Features
Wenglor’s fluid sensor technology covers a range of more than 900 products, including pressure, temperature and flow sensors that come in different ranges, process connections, and outputs. However, our focus in this article will be on the new weFlux² series, which are manufactured using top-quality components that make them shock and vibration resistant and give them the ability to withstand high-pressure levels.
These sensors are distinguished by their stainless steel housing and are based on a modular platform that makes it possible to adapt process connections, probe length, housing, and sensor outputs that meet specific customer requirements.
Let’s look at each one of them in detail.
weFlux² Pressure Sensors
weFlux² pressure sensors measure relative pressure from −1 to +400 bar and temperature from −40 to +125° C. Besides having the latest IO-Link version 1.1 and two analogue outputs (pressure/temperature), weFlux² Pressure Sensors are able to measure both temperature and pressure in any medium because they have an innovative measuring cell with an integrated temperature element.
These pressure sensors are excellent for liquid and gaseous media and come with a pressure measuring accuracy of ±0.5% and a temperature measuring accuracy of ±1° C. They make it possible to implement continuous fill-level measurement for dynamic applications primarily because they measure the hydrostatic pressure of the liquid and are; therefore, able to measure the actual fill-level when the sensor is placed at the bottom of the liquid-filled tank (remember, the hydrostatic pressure of a liquid is proportional to the fill-level).
Image Courtesy of Wikimedia Commons.
Depending on individual needs, sensor parameters, the measured values (PSI, bar), and the filter and output functions can be flexibly adjusted. Thanks to the setting options available with the weFlux² pressure sensors that make flexibility possible.
weFlux² Temperature Sensors
weFlux² Temperature sensors are equipped with the latest IO-Link version 1.1 or a PT100/PT1000 resistance value. The IO-Link versions have a measuring range from -50 to +150° C while the PT100/PT1000 versions have a measuring range from -50 to +200° C. Both variants are accurate to ±0.5°C.
Their broad measuring range prevents machines and systems from overheating and their super short response time ensures processes remain stable. Using the modern interface, it’s possible to configure these temperature sensors in a decentralised way and to query diagnosis at any given time. The sensors—via IO-Link 1.1—forward data to a controller in real-time, which makes it easier to notice any slight temperature fluctuations and to make the necessary adjustments.
The sensors also have IP68/IP69K protection and short response time. They are meant for liquid and gaseous media, and they stand out owing to their large measuring ranges, compact design, and high levels of accuracy.
weFlux² Flow Sensors
weFlux² flow sensors have the capability of measuring high flow velocities of up to 400 cm/s (with a velocity measuring accuracy of ±2%) while simultaneously acquiring the temperature of the medium within −25 to +150° C (with a temperature measuring accuracy of ±1° C).
These wear-free and maintenance-free flow sensors are housed in high-quality, rugged V4A stainless steel housing that ensures they remain reliable in their processes. They utilise a unique calorimetric measuring principle where the measuring probe gets heated, and the flow rate is measured based on the amount of heat carried by the flowing medium—Wenglor provides a flow calculator (for free) that you can use to calculate flow rates.
This method is advantageous because the recorded values can also be used to determine temperature. This leads to economic efficiency in terms of reducing costs and the mounting space that would otherwise be required for temperature sensors.
weFlux² Flow Sensors don’t need to be aligned to the direction of flow, which can sometimes be a source of installation errors and production downtimes for other types of sensors. In addition, these sensors can be mounted in any position, meaning they can be installed inside pipes regardless of position without having to align the measuring probe with the direction of the flow. Thanks to the unique and patented measuring method, which makes it easier to integrate them into most machines and systems.
Flow sensors have IP68/IP69K protection, two analogue outputs (flow/temperature) and the latest IO-Link version 1.1. The FXFF005 is a perfect example of a weFlux² flow sensor. It measures both velocity and temperature, and its laser-welded V4A stainless steel housing protects it against chemical and mechanical influences.
The FXFFOO5 is ideally meant for hygienically sensitive environments and can fit into almost any system. Its compact design makes it versatile, and despite lacking a display, it communicates with an intelligent IO-Link interface; making it well-equipped for industry 4.0 applications. The hygienically designed stainless steel housing is corrosion resistant and FDA compliant.
Depending on your sensor requirements, flow sensors have different process connections designed as per EHEDG (European Hygienic Engineering and Design Group) guidelines.
To achieve fluid intelligence, Wenglor uses digital communication on the weFlux² series to ensure processes are more transparent and to identify potential areas for optimisation and innovation. Most of the weFlux²sensors use the latest IO-Link version to generate and send diagnostic information and status data for condition monitoring, which translates to reduced maintenance costs, increased system availability, accelerated initial start-up, and simplified operation.
The free wTeach2 software allows one to set up the weFlux² sensors with IO-Link easily, and the same software can be used to analyse transmitted data for requirements-oriented maintenance and to avoid downtime.
The wTeach2 software makes it possible to create a digital platform for smart machines by enabling the fluid sensors to configure themselves automatically and where the collected data can be visualised and evaluated in real time.
Using wTeach2 enables the user to set sensor parameters using a controller, analyse diagnosis data easily, export measurement data for data analysis, adjust switching points in diagrams, and store data (the stored parameters can be transmitted to a replacement sensor).
The sensors communicate via the IO-Link with all common control systems and can be easily added into existing networks. Whenever a sensor is replaced, the stored settings are automatically transferred to the new sensor, making replacement possible without the need for programming. The sensors are plug and play-based, and it is possible to store their configuration on controllers and to transfer the information to other applications with a simple click, regardless of where one is located. This makes the initial start-up quick.
This entire intelligent process monitoring ensures machines are utilised to the fullest and systems are not easily damaged.
weFlux² Fluid Sensors: Application
Having two measuring functions on a single sensor immensely reduces the number of measuring points in closed systems by half and ultimately cuts the costs and effort needed with process monitoring by 50%.
Consider, after all, that when you need no additional temperature sensors, because your flow sensor has that capability, you will end up with fewer sensors, which is also beneficial for compact systems and machines with minimal mounting space.
weFlux² Fluid Sensors are designed for maintenance-free operation and are recommended whenever liquids need to be monitored, controlled, or regulated.
weFlux² temperature sensors, for example, could be used to:
- Monitor inlet and return temperature for solar-thermal energy conversion
- Measure temperature in tempering ovens
- Monitor temperature in the brewing process
- Measure temperature in cheese production
weFlux² flow sensors mainly ascertain the speed of liquid media (besides temperature), and could be used:
- In the automotive industry for monitoring cooling water or the robots used in welding. This is owing to their compact design and the fact that they have a rugged stainless steel housing
- To monitor flow rate in filling machines
- In the metalworking industry to monitor cooling water systems for blast furnaces. This is mainly because they can be mounted in any desired position, and they offer great flexibility. Since they combine two measuring functions, they will guarantee efficient process monitoring by reducing the number of measuring points within a system
- To prevent pumps from running dry
- In the textile industry to monitor the flow velocity of the water that is used to clean and rinse the thread
- To control coolant water and to monitor coolant water in electric power generators
- In the beverages industry to scrutinise the flow velocity of the cleaning water that is normally used in bottle washing systems. They are EHEDG certified, and using them ensures proper hygiene.
The rugged and laser welded V4A stainless steel housing is supplied deliberately without a display because these sensors are meant to be used in hygienically sensitive environments. The laser welding makes them resistant to corrosion, cleaning agents, and aggressive chemicals
weFlux² pressure sensors are highly suitable for pneumatics, hydraulics, and process engineering. They can be used for the following uses:
- Monitoring compressed air systems
- Fill level monitoring in tank/silo systems
- Monitoring filters
- Regulating pressure
- Monitoring compressed
- Monitoring pressure in filling systems
By introducing the first sensor that simultaneously acquires relative pressure and the temperature of liquids and gases, Wenglor is enabling process monitoring of smart machines for the digital age. The sensors are ready for industry 4.0, and adapting them for any processes involving liquid/gaseous will not only give accurate process values, but will also reduce service, installation, and inventory costs.