The difference between explosion-proof weighing sensors and ordinary weighing sensors

The difference between explosion-proof weighing sensors and ordinary weighing sensors

1. Explosion-Proof Structural Design
    
   Adopt intrinsically safe (Ex i) or flameproof (Ex d) core design: Intrinsically safe type ensures there is no spark or heat sufficient to ignite flammable media in case of failure by limiting circuit voltage, current, and power; flameproof type uses a high-strength shell to encapsulate hazardous components, preventing flame from leaking out even if there is an internal explosion. Some products are also equipped with a sealing structure to prevent flammable and explosive gases and dust from invading the internal circuit.
2. Stringent Material and Protection
    
   The shell is mostly made of explosion-proof materials such as stainless steel and high-quality alloy steel, and the surface is nickel-plated or anti-corrosion treated to resist corrosion. The protection grade generally reaches IP68, which can completely isolate dust and accumulated water. The internal circuit is protected by nitrogen filling, and combined with lightning surge design, it further improves stability in extreme environments.
3. Intelligent Safety Compensation and Diagnosis
    
   Integrate functions such as temperature compensation and linearity calibration, and be equipped with a self-diagnosis system, which can monitor circuit faults in real time and automatically cut off dangerous circuits. Digital explosion-proof sensors also prevent signal tampering through encrypted communication protocols, with both anti-cheating and safety protection capabilities.
4. Mandatory Certification Standards
    
   Must pass authoritative explosion-proof certification. The certification mark must clearly indicate the explosion-proof grade (such as ExdBT4Gb), applicable hazardous areas (Zone 0/1/2 for gas environments, Zone 20/21/22 for dust environments), and other key information.

1. Structure and Material
    
   No explosion-proof shell, mostly made of aluminum alloy or ordinary steel. The protection grade is usually IP65 or below, which can only resist a small amount of dust and splashing water.
2. Performance Focus
    
   The core is to optimize the balance between accuracy and cost. Some products are equipped with basic temperature compensation, but lack special designs for corrosion resistance and extreme temperature resistance. The signals of analog sensors are easily affected by electromagnetic interference, and the transmission distance is limited (usually no more than 50 meters).
3. Certification and Testing
    
   Only need to pass general industrial accuracy tests (such as OIML Class Ⅲ), no explosion-proof performance testing is required, and the production process is more simplified.

1. Chemical Industry
    
   Used for silo metering of flammable and explosive chemicals (such as ethylene, methanol, ammonia) and batching weighing of reaction kettles, which need to withstand corrosive media and high-temperature environments. For example, in pesticide production, explosion-proof sensors are used to achieve precise proportioning of highly toxic raw materials, while avoiding explosions caused by circuit sparks.
2. Oil and Gas Industry
    
   Suitable for scenarios such as oilfield drilling fluid weighing, oil depot storage tank metering, and liquefied petroleum gas loading and unloading. The flameproof design can resist the explosive environment formed by oil and gas leakage. Intrinsically safe sensors are commonly used on offshore drilling platforms to prevent seawater corrosion and the risk of explosion caused by oil-gas mixtures.
3. Dust Explosion Risk Areas
    
   Including automated loading and unloading systems in grain warehouses (flour, starch dust), coal weighing in mines (coal dust), and metering in metal powder processing, etc. The sealed structure can prevent dust from entering the interior of the sensor.
4. Pharmaceutical and Food Processing
    
   Used in links such as weighing of flammable and explosive APIs (such as nitrocellulose) and metering of alcohol fermentation tanks, taking into account safety and hygiene standards.

1. Commercial and Civil Scenarios
    
   Supermarket electronic scales, express weighing platforms, household body scales, etc., focus on low cost and basic accuracy (error ±0.1g to ±1g).
2. General Industrial Scenarios
    
   Ordinary material conveying belt scales, workshop component weighing, packaging assembly line inspection, etc., where there is no explosion risk and working conditions are stable.
3. Laboratory and Scientific Research
    
   Used for conventional sample weighing, instrument calibration, etc., relying on accuracy but without explosion-proof design. For example, laboratory electronic balances mostly use ordinary sensors.