Flat-head vs. Protruding-head Inductive Sensors

The choice between flat-head and protruding-head inductive sensors depends on the application and the type of object to be detected. Each type offers clear benefits, but also specific limitations that must be considered during design and installation.

Flat-head inductive sensors are used when precise detection of small metal parts is required. They only sense objects directly in front of the face, which increases accuracy. They are also preferred when the sensor needs to be flush mounted with the surface, ensuring compact and protected installation.

Protruding-head inductive sensors provide a wider sensing field and can detect objects at different angles and heights. This makes them more flexible in situations where the target is irregularly shaped or not perfectly aligned. They are often selected where some mounting distance is necessary or where tolerance for misalignment is important.

In summary: use flat-head sensors when you need precise detection and flush mounting. Choose protruding-head sensors when you need wider coverage and versatility.

Flat-head Inductive Sensors

Advantages:
+ Accurate sensing due to direct alignment with the target
+ Less sensitive to unwanted side objects
+ Suitable for flush mounting in metal panels

Disadvantages:
+ Detects only objects in front
+ May lose accuracy in high vibration environments

Protruding-head Inductive Sensors

Advantages:
+ Wider sensing angle thanks to extended face
+ More versatile for different shapes and positions
+ Can perform better under vibration or mechanical stress

Disadvantages:
+ Less precise due to larger sensing zone
+ More prone to detect unwanted side objects
+ Not ideal for applications requiring high accuracy

Field Experience Notes

+ In heavy machinery areas, flat-head sensors are more reliable since they resist both side interference and mechanical impact.

+ Protruding-head sensors are commonly used in conveyor systems, where product height or alignment is inconsistent. Their wide field reduces the risk of missed detection.

+ When installing multiple sensors close together, flat-head types allow tighter spacing. Protruding-head models need a free-zone to avoid false triggers.

+ Sensor performance depends on target material. Non-ferrous metals like aluminum or stainless steel reduce sensing distance, which is more noticeable on protruding-head models.

+ For long-term durability, mount flush sensors in panels and use protective housings. Protruding-head models may require guards or covers in harsh environments.