Everything You Need To Know About Sensor Housing

Sensors play a crucial role in collecting critical data in the world of scientific measurement and industrial monitoring systems. However, a sensor’s reliability and lifespan depend on its protective housing. 

From testing water quality in municipal water treatment facilities to environmental monitoring on construction sites, selecting appropriate sensor housing determines whether data is reliable and reduces equipment failure. In this article, we will look at the materials and design considerations for sensors and which sensor housing is best for your testing applications.

Why Sensor Housing Is Important

Sensor housing is essential for protecting the sensor elements. In harsh environments, sensors face exposure from extreme temperatures and corrosive chemicals which can impact the physical parts of the sensor and cause electromagnetic interference. Without proper sensor housing protection, even the most advanced sensor can fail early or produce inaccurate readings that can compromise the entire operation. 

For example, a pH sensor is deployed for water quality monitoring without a proper sensor housing may work fine in a laboratory setting, but if it is exposed in industrial environments where there are temperature swings, mechanical stress, and chemical use, the need for adequate housing is non-negotiable.

How Are Sensor Housings Engineered?

Most modern sensor housings are engineered with specific industries and applications in mind. For example, the Atlas Scientific EZO Embedded Humidity Probe is weather resistant. This sensor housing offers more than protection – it is carefully engineered to allow the sensor to interact with the environment while preventing damage from physical impact, moisture, and dust. 

The housing material itself plays a key role in the sensor performance. A photosensitive resin body may be ideal for measuring indoor humidity, offering durability while maintaining the accuracy that laboratory-grade sensors offer. But that same sensor was to be used outdoors, you would need a more robust material, like stainless steel housing. 

This is why understanding the specific requirements for the application is critical. At Atlas Scientific, the Industrial ORP probe demonstrated this beautifully. The probe covers all the sensing capabilities of our lab-grade probe while using a virtually indestructible housing engineered for harsh industrial environments. At Atlas Scientific, we tell our customers, “It is built to last!”.

Selecting The Right Sensor Housing Material 

As mentioned, the sensor housing typically determines the success or failure of a monitoring system. The most common material for industrial applications is stainless steel, as it offers corrosion resistance, exceptional strength, and the ability to work in extreme temperatures. So, if you’re working with aggressive chemicals or high-pressure environments, stainless steel is a great choice. 

However, stainless steel is not suited for all industries. Aluminum is an excellent alternative with superior thermal conductivity and strength-to-weight ratio. This is why this sensor housing is used in aerospace and automotive applications. 

For applications that require chemical resistance without the cost of metal and weight, advanced plastic materials such as polyetheretherketone (PEEK) offer outstanding performance. It can tackle both aggressive chemicals and high temperatures while remaining stable. These are most commonly used in applications where traditional sensor housing materials could fail.

The Atlas Scientific EZO-RGB-S sensor shows how material choice directly impacts performance. The sensor housing is weather-resistant, made from stainless steel, providing different mounting options while protecting the sensitive color detection components and illuminator LEDs. With this type of sensor housing, the color sensor can therefore reliably detect colors in changing environments where a plastic sensor housing could be an issue and fail. 

Matching Sensor Housing Types To Applications

Different testing environments demand different sensor protection. Waterproof housing with IP67 & IP68 ratings allows sensors to fully operate even when submerged or exposed in high-pressure water environments. Pay attention to the housing ratings as they represent testing standards that guarantee safety and levels of protection. 

Explosion-proof sensor housings are used in hazardous environments where flammable gas or dust is present, ensuring the safety against fires and explosions. The most common sensor housing materials for these environments typically involve stainless steel or specialized alloys designed to withstand potential explosions within the sensor housing. These sensor housings also prevent internal sparks and meet strict ATEX or IECEx standards.

High-temperature applications such as energy production, aerospace, automotive, and food and beverage industries require sensor housings that will maintain structural integrity and sensor accuracy under extreme thermal stress. 

In the oil and gas industries, corrosion-resistant sensor housing protects against acids, aggressive chemicals, and other volatile and corrosive substances that can rapidly destroy unprotected sensors. These sensors often have specialized coatings or are made from corrosion-resistant materials such as chemically resistant plastics or titanium. 

Monitoring Multi-Parameters In Applications

Most industrial applications monitor multiple parameters at the same time. This is where systems like the Atlas Scientific Industrial Sensor Interface System come in handy. This multi-parameter process monitor is capable of reading eight sensors at a time, displaying real-time values on an LCD (display). 

The interface system’s modular design enables you to add different sensors:

• ORP
• Dissolved Oxygen 
• pH
• Conductivity
• Temperature
• CO2
• Pressure
• Humidity

Each sensor can benefit from the system’s IP67 housing, providing industrial-grade protection while maintaining super easy access for maintenance and calibration needs. 

What operators love is the integrated protection. They say rather than worrying about individual sensor housing, they can plug in different sensors and know they’re protected within a single, robust area. This not only simplifies installation and maintenance, but also ensures consistent protection standards across all monitoring parameters. 

The sensor interface system supports both serial RS232 data communication and 4-20mA analog output, making it compatible with any existing industrial control systems. We have also engineered an on-board calibration and temperature compensation to ensure measurement accuracy. Additionally the SD card data recording with timestamps gives you comprehensive data logging capabilities that makes your life easier!

Applications & Performance

If you’re still considering which sensor housing is best, giving you some actual applications may help illustrate their importance. Here’s a quick summary of what we have discussed:

Environmental Monitoring Stations

These rely on weather-resistant housings to protect sensors from snow, rain, UV radiation, and other temperature extremes. These sensors need to continuously operate through different seasons, commonly in remote locations where maintenance and calibration access may be limited. 

Industrial Processes

Industrial applications are known for presenting different challenges. Chemical plants expose sensors to harsh substances that can quickly degrade sensor housing materials. Plus, pressure and temperature variations in industrial processes add additional stress, all while precise control is needed for accurate measurements.

In industrial processes, investment in proper sensor housing with high-class materials and designs pays dividends in reducing maintenance costs and improving reliability. 

Saltwater Applications

Because of the corrosive nature of saltwater, marine environments can push sensor housings to their limits. While currents and the mechanical stress of waves are challenging when monitoring marine applications, the dissolved salts (like sodium chloride) found in saltwater accelerate oxidation process, which means materials, especially metals, degrade faster. 

In saltwater applications, sensors usually require titanium or heavily alloyed stainless steel housing to maintain long-term stability and reliability. 

Selecting The Best Sensor Housing For You

When selecting the best sensor housing, you should understand your specific environment and testing requirements. Consider the types of chemicals your sensor will be exposed to, the temperature range likely encounter, and any mechanical stress. You may also want to consider the available mounting space, integration with existing testing systems, and accessibility for sensor maintenance. 

Budget may also be on your mind. We always recommend investing in a high-quality sensor with long-term performance. While stainless steel or titanium have higher initial costs,  they provide better value in terms of lifespan and lower maintenance needs. If you work in applications where sensor failure could cause safety issues or process downtime, investing in a robust sensor housing is even more justified.

Never overlook the importance of professional installation and maintenance access. Even the best sensor housing in the world won’t protect sensors if they cannot be properly maintained or installed. When selecting a sensor housing, ensure the design provides secure mounting options and reasonable access so you can easily service and calibrate your sensor. 

Advances In Sensor Housing

As sensor technology advances, sensor housing will evolve to meet new testing challenges. Smart sensors that have integrated processing capabilities must have the correct protection for the complex electronic components and sensing elements.

Smart wireless sensor networks have introduced new housing designs. Factors like antenna placement, wireless transmission signal, and battery access have influenced the type of sensor housing required. The housing must offer protection, but also be comprehensive enough to allow reliable operation while not interfering with the sensor communication. As environmental regulations change, there is an increasing demand for engineering sensor housing that ensures safety, accuracy, and durability in changing environments.

Summing Up, Sensor Housing & Sensor Application Needs

Sensor housing is one of the most important yet overlooked aspects of successful sensor monitoring systems. The correct sensor housing protects the sensor from harsh chemicals and extreme environments while ensuring data is reliable. From weather-resistant housing for humidity sensors to industrial-grade housing for harsher environments, Atlas Scientific sensors offer probes with versatile sensor housing for reliable performance.

If you would like to learn more about the wide variety of sensors we have to offer, or are unsure which sensor housing is best for your application, contact the world-class team at Atlas Scientific.