What Is the Function of a Thermal Conductivity Flow Switch? The Most Comprehensive Answer

What Is the Function of a Thermal Conductivity Flow Switch? The Most Comprehensive Answer A thermal conductivity flow switch is a flow monitoring and control device designed based on the principle of heat conduction. Its core function is to **real-time detect the flow state (presence or absence of flow) and flow rate of fluids (liquids or gases)**, and trigger alarms, interlock control, or equipment protection actions according to preset thresholds. It is widely used in industrial automation, HVAC (Heating, Ventilation, and Air Conditioning), water treatment, equipment cooling systems, and other scenarios. Essentially, it provides signal support for the "safe operation" and "precise control" of fluid systems. I. Core Functions: 3 Key Functional Categories The functions of a thermal conductivity flow switch can be broken down into three links: "monitoring - judgment - response", which are specifically implemented as the following three core functions: 1. Flow State Detection: Determining "Flow/No Flow" This is the most basic function. Its principle is as follows: the switch has a built-in heating element (such as a platinum resistor) and a temperature detection element (such as an NTC thermistor). During normal operation, the heating element maintains a constant temperature; when the fluid flows, it takes away the heat of the heating element, causing a change in the temperature difference sensed by the temperature detection element; if the fluid stops flowing (no flow), the heat cannot be dissipated, and the temperature difference increases significantly. Application Scenarios**: Preventing "dry burning/dry running" of equipment. For example, when a water pump or oil pump is in operation, if the fluid supply is interrupted (such as pipeline blockage or low liquid level), the flow switch will detect "no flow" and immediately send a signal to cut off the equipment power supply, preventing the pump body from being burned due to lack of fluid cooling. It can also be used in the compressed air pipeline of an air compressor to detect whether the compressed air is delivered normally. 2. Flow Threshold Control: Enabling "Over-Threshold Alarm/Interlock" In addition to determining "the presence or absence of flow", some thermal conductivity flow switches can be calibrated to set a minimum flow threshold (to prevent reduced system efficiency due to excessively low flow) or a maximum flow threshold (to prevent pipeline overload due to excessively high flow). When the actual flow is lower than or higher than the preset threshold, the switch will output an electrical signal (such as the switching of normally open/normally closed contacts of a relay, or a 4-20mA analog signal). Application Scenarios**: - Cooling Systems**: In the cooling water circuit of machine tools and frequency converters, if the flow rate is too low (resulting in insufficient cooling), the switch will trigger an alarm to remind maintenance personnel to clean the pipeline or inspect the water pump. - HVAC Systems**: In the supply air duct of an air conditioning air cabinet, if the air volume is lower than the threshold (such as filter blockage), the switch will link with the fan to increase the rotation speed or trigger a filter replacement prompt. 3. System Interlock Protection: Ensuring Equipment and Process Safety The signal of the thermal conductivity flow switch can be directly connected to a PLC (Programmable Logic Controller) or a control system to realize the interlock action of "abnormal flow → automatic shutdown/adjustment" without manual intervention, thus avoiding the expansion of accidents. Typical Case**: In a solar water heating system, if the flow rate of the circulating water pump is too low, the water temperature in the collector will become excessively high (causing local overheating damage). After the flow switch detects the abnormality, it will immediately cut off the heating circuit of the collector and start the backup pump at the same time. II. Core Advantages: Why Choose a Thermal Conductivity Flow Switch? The realization of its functions depends on its own technical advantages, which are also the key factors distinguishing it from turbine-type and float-type flow switches: - No Moving Parts**: It only works with heating and temperature-measuring elements, so there is no wear or jamming, and it has a long service life (usually 5-10 years). It is suitable for harsh working conditions such as sewage and fluids containing impurities. - Fast Response Speed**: The detection time for temperature difference changes is usually within 0.1-1 second, which can quickly capture sudden changes in flow rate and avoid equipment damage caused by "response lag". - Easy Installation and Maintenance**: Most of them are installed in an insertion or pipeline type, without the need to cut off the pipeline (some models can be installed online), and no regular calibration is required (some high-precision models need to be calibrated once a year). - Wide Applicability to Media**: It can detect liquids (water, oil, ethylene glycol, etc.) and gases (air, nitrogen, compressed air, etc.), and is not significantly affected by large changes in the viscosity and density of the medium (it is necessary to select the model according to the medium characteristics in advance). III. Typical Application Scenarios (Practical Examples of Function Implementation) | Industry Field       | Specific Application Scenario          | Function of the Thermal Conductivity Flow Switch                                                                 | |----------------------|-----------------------------------------|-------------------------------------------------------------------------------------------------------------------| | Industrial Automation| Machine Tool Cooling Water Circuit      | Detect the cooling water flow rate; shut down the machine when the flow rate is below the threshold to prevent overheating damage to the spindle. | | HVAC                 | Air Supply Duct of Air Conditioning Air Cabinet | Detect the air volume; alarm when the air volume is too low (prompting filter cleaning) and reduce the speed to save energy when the air volume is too high. | | Water Treatment      | Water Supply Pipe of Reverse Osmosis System | Detect the inlet water flow rate; cut off the high-pressure pump when there is no flow to prevent dry grinding of membrane elements. | | New Energy (Photovoltaic) | Cooling Oil Circuit of Photovoltaic Inverter | Detect the cooling oil flow rate; trigger the cooling fan when the flow rate is too low to prevent inverter overload. | | Medical Equipment    | Steam Pipeline of Medical Sterilizer    | Detect the steam flow rate to ensure continuous steam supply during the sterilization process and avoid sterilization failure. | In conclusion, the core value of a thermal conductivity flow switch is to provide dual guarantees of "real-time monitoring + safety protection + precise control" for fluid systems. Through a simple and reliable principle, it solves the core problem of "equipment damage and process failure caused by abnormal flow" in industrial and civil scenarios.