The connection between the liquid level sensor cable and the sensor is a weak point in the entire liquid level measurement system, highly susceptible to liquid infiltration. Once liquid seeps in, it can damage the sensor's internal precision electronic components, affecting measurement accuracy and stability, and may even cause short circuits and other safety hazards. Therefore, ensuring the sealing of this connection is crucial.
From a connection structure design perspective, a reasonable design is fundamental to ensuring a tight seal. Common connection structures include threaded connections and compression fittings. Threaded connections use the engagement of the threads to create a tight fit between the cable and the sensor. In thread design, it's essential to ensure precise parameters such as thread profile and pitch to generate sufficient preload during tightening, ensuring a tight seal and preventing liquid infiltration. Compression fittings utilize the elastic deformation of the ferrule to firmly hold the cable at the sensor interface. The ferrule material must possess good elasticity and corrosion resistance. During installation, proper procedures and force application must be followed to ensure even force distribution on the ferrule and achieve a reliable seal.
The selection of sealing materials is a critical factor. The sealing material used at the connection between the liquid level sensor cable and the sensor needs to possess several properties. First, it must have excellent sealing performance to effectively prevent liquid penetration. Rubber-based sealing materials are commonly used, such as silicone rubber, which not only has excellent sealing performance but also resistance to high and low temperatures and corrosion, making it suitable for various working environments. Second, the sealing material must be compatible with the materials of the cable and sensor to avoid affecting the sealing effect due to chemical reactions between materials. For example, in some special chemical environments, chemically resistant sealing materials, such as fluororubber, should be selected, as they can resist the erosion of various chemicals and ensure long-term stable sealing performance.
Proper installation procedures directly affect the sealing performance. When installing the liquid level sensor cable and sensor, the operating procedures must be strictly followed. Before connection, ensure that the connection surfaces of the cable and sensor are clean and free of dust, oil, and other impurities, as these impurities will affect the adhesion of the sealing material and reduce sealing performance. When applying the sealing material, it should be even and appropriate; too much or too little will affect the sealing quality. For connection methods requiring a sealing ring, the sealing ring must be installed correctly, ensuring its accurate positioning and absence of twisting. After installation, tighten the connections appropriately, but be careful not to overtighten, which could damage the sealing material or deform the connecting parts.
Regular inspection and maintenance are essential to ensure long-term effective sealing. During use, the connection between the liquid level sensor cable and the sensor is subject to various factors such as vibration and temperature changes, which may lead to a decrease in sealing performance. Therefore, the connection should be inspected regularly for signs of aging or cracking in the sealing material, and for loose connections. If problems are found, repair or replace the sealing material promptly. For example, rubber sealing materials may harden over time, requiring timely replacement to maintain sealing performance.
Environmental factors also need to be fully considered. Different working environments have different requirements for the sealing performance of the connections. In humid environments, choose sealing materials and connection structures with better waterproof performance; in environments with corrosive liquids, ensure that the sealing materials and connecting parts are resistant to corrosion. Furthermore, temperature variations also affect the performance of sealing materials. High temperatures may soften the material, while low temperatures may harden and make it brittle. Therefore, it is crucial to select a suitable sealing material based on the operating environment temperature.
The testing process is essential for ensuring a tight seal. During production, rigorous sealing tests must be performed on the connection between the liquid level sensor cable and the sensor. Methods such as immersion tests and pressure tests can be used, immersing the connected product in a specific liquid or applying pressure to observe for any liquid seepage. Only products that pass these tests can enter the market, ensuring excellent sealing performance in actual use.
