Flow Sensors: Types, Applications and Working Principles

A flow sensor is a type of instrument used to detect and measure the flow parameters of medium

such as liquids and gases, and convert them into other forms of signals for output. Flow sensors are

diverse and widely used. This article will provide you with a detailed introduction to the advantages

and disadvantages of flow sensors, their application scenarios, and the working principles of different

types of flow sensors.

What is Flow Sensor?

A flow sensor, often referred to as a flow meter, is an electronic device designed to measure or

regulate the flow rate of liquids and gases within pipes and tubes. It functions by leveraging both

mechanical and electrical subsystems to detect changes in a fluid's physical properties and then

calculates its flow rate accordingly. These sensors are typically linked to gauges for a visual

representation of their measurements, but they can also be connected to digital interfaces for

advanced monitoring and control.

come in direct contact with the fluid and are ideal for applications where there is no risk of clogging.

Non-contact flow sensors do not have any direct interaction with the fluid, making them suitable for

scenarios where the fluid (commonly in food products) might be contaminated or physically altered

by contact with moving parts. These sensors are indispensable components heavily utilized across

various sectors, including HVAC systems, medical devices, chemical industries, and numerous other

manufacturing systems.

Working principle of flow sensor

Flow sensors work by employing various principles to measure the quality of a fluid or gas passing

through them. The particular principle used depends on the type of flow sensor. Here are a few

commonly used flow sensor types and their working principles:

Differential Pressure Flow Sensors

These sensors are part of a class of flow meters known as Pressure-Based Flow meters. The basic

principle involved is that the pressure drop across the meter is proportional to the square of the flow

rate. By measuring the differential pressure produced by orifice plate restriction, the flow rate can be

calculated. The pressure difference (high pressure before the orifice, low pressure after) is often

measured with a diaphragm differential pressure sensor. It is a robust technology often used for

water, wastewater, HVAC, and power generation industry applications.

Thermal Flow Sensors

Hot wire anemometers or thermal flow sensors use the cooling effect of a flow to determine the mass

flow, or the actual volumetric flow. Based on the amount of heat loss from the sensor, which
increases with higher flow rate, they can accurately calculate the flow rate of gases. These are often

used in HVAC and clinical applications.

Magnetic Flow Sensors (Magmeters)

Flowing conductive liquid through a magnetic field induces a voltage according to Faraday's law.

This voltage is proportional to the flow rate, making it possible to derive speed and thus flow.

They’re commonly used in wastewater treatment, food and drink, and industrial process applications.

They require the liquid to be conductive.

Ultrasonic Flow Sensors

This technology uses sound waves that are sent through the medium and are affected by the

movement of the fluid. By measuring the transmitted time of the ultrasonic signal both downstream

and upstream, the sensor can calculate the velocity and thereby the flow rate of the fluid. These are

commonly used for water flow measurement and flow measurement of natural gas.
Turbine Flow Sensors

As the fluid moves through the meter, it causes a rotor to turn at a speed that is proportional to the

flow rate. The rotations are typically detected by a hall effect sensor or a coil. These are known for

their accuracy and are often used in hydraulic, pharmaceutical, and energy industries.

Vortex Flow Sensors

Flow passing a bluff in a storm will generate vortices downstream from the bluff. By detecting these

vortices, the sensor can calculate flow rate as the frequency of vortex shedding is proportional to

flow velocity. Vortex flow sensors are used in numerous applications, including Steam Flow,

Chemical Injection, and HVAC. Their operation is largely unaffected by changes in process

conditions.
 Application of Flow Sensor

Flow sensors are used in different industries. Their main function is to monitor, regulate or measure

fluid flow. Below we will introduce its application scenarios in detail.

 Healthcare and Biotechnology: In the healthcare sector, flow sensors play a pivotal role. For

instance, they are deployed in medical ventilators to regulate the flow of air and other gases,

providing critically ill patients with the life-saving oxygen they need. They are also used in dialysis

machines to ensure the fluid transfer rate is correctly managed. Moreover, in biotechnological

applications, flow sensors measure the rate of nutrient delivery to biological reactors or bioreactors.

 Heating, Ventilation, and Air Conditioning (HVAC): Maintaining comfort levels in buildings

requires efficient monitoring and control of air flow, and it's here that flow sensors come into play.

They help control the volume of air flowing into different parts of the building, maintaining a balance

in temperature and air quality.

 Automotive Industry: Car engines are complex systems, requiring a fine balance of air and fuel to

operate effectively. Flow sensors, such as mass air flow (MAF) sensors, measure the amount of air
 entering the engine, ensuring the correct air-fuel mixture for optimal engine performance and fuel

efficiency.

 Industrial Processes and Manufacturing: Flow sensors are vital for controlling process variables in

various industries. They analyze flow rates in pipelines, ensuring the correct volume of fluid or gas is

delivered at the right time. This ranges from managing the flow of ingredients at a beverage

production line to controlling the heavy oils flow at a petroleum processing plant.

 Environment and Water Management: Monitoring water usage and controlling wastewater

treatment is vital for efficient water resources management. Flow sensors in these situations help

track water usage, detect leaks, and manage the treatment of wastewater, enabling more sustainable

water practices.

 Agricultural Practices: Modern farming practices have turned to sophisticated irrigation methods

for better crop yields. Flow sensors are used to monitor and control water flow in these irrigation

systems, enabling efficient water usage and less waste.

Advantages of Flow Sensors

Flow sensors offer advantages such as precision and accuracy in measuring fluid or gas flow rates,

empowering industries to increase efficiency and resource management. Their versatility allows

application across a plethora of sectors, such as industrial, environmental, medical, and HVAC

settings. The real-time data they provide supports automated control of operations, minimizing

manual interventions and encouraging constant output. Moreover, by efficiently monitoring and

controlling the consumption of fluids and gases, these sensors can reduce waste and contribute to

more sustainable business practices.

Disadvantages of Flow Sensors

impacted by their placement, with improper installation leading to inaccuracies and potential

inefficiencies. Depending on the types of media they monitor, they may require regular maintenance

or cleaning, and certain substances could lead to erosion or contamination over time. Some flow

sensors can be expensive, creating barriers for smaller businesses or operations on a tight budget.

Furthermore, while designed to withstand a variety of conditions, their performance and reliability

can degrade when exposed to continuous extreme temperatures, pressures, or corrosive fluids.