Ultrasonic Flow Sensor Types and Selection for OEM Buyers

Why Ultrasonic Flow Sensors?

Traditional mechanical flow meters suffer from moving parts, pressure loss, and contamination risk. Ultrasonic flow sensors address these limitations through non-invasive measurement—no contact with the fluid, no moving parts, and minimal maintenance. For OEM applications where sterility, accuracy, and reliability are paramount, ultrasonic technology has become the preferred choice.

XY-TEK’s Ultrasonic Flow Sensor Portfolio

XY-TEK, established in 2018 and based in Shanghai, designs and manufactures a comprehensive range of ultrasonic flow sensors and meters. The company employs approximately 50 staff and operates a 5,000 square meter facility with an annual production capacity exceeding 8,000 units. Their R&D team of over 30 engineers focuses on innovation for small tubing and low flow applications. Below are the core product families, each built for specific measurement scenarios.

Clamp-On Sensors (Non-Invasive)

• CG Series – General-purpose clamp-on ultrasonic flow sensor. Range: 0.02–20 L/min, accuracy ±1%. Features air bubble detection and bi-directional flow. Material: ABS housing, stainless steel sensor components. Outputs: analog, pulse, RS485. Used in industrial automation, biopharmaceutical, medical devices.
• CM Series – OEM clamp-on flow meter. Range: 0.05–30 L/min, accuracy ±3%. Compact design with RS485 output, designed for easy OEM integration. Applications: medical devices, fluid control systems, lab equipment.
• CPD Series – Clamp-on sensor with built-in LED display. Range: 0.1–50 L/min, accuracy ±2%. Non-invasive, no pipe cutting, air bubble monitoring. Suitable for semiconductor, water treatment, food & beverage, industrial automation.
• CS Series – Non-invasive industrial flow sensor. Range: 0.1–50 L/min, compact integrated design with digital output. Intended for semiconductor, water treatment, food & beverage, industrial automation.

Inline Sensors (In-Line)

• TPD Series – Industrial inline flow meter. Range: 0.5–100 L/min, accuracy ±2%. No moving parts, low maintenance, real-time monitoring. Made of stainless steel and engineering plastics. Used in industrial automation, battery manufacturing, chemical processing, liquid cooling.
• TPK Series – Inline ultrasonic flow sensor similar to TPD, with same range 0.5–100 L/min, accuracy ±2%, integrated structure. Applications identical.

Specialized Sensors

• SU Series – Single-use ultrasonic flow sensor. Range: 0.05–10 L/min, made of biocompatible polymer materials, supports sterile applications. Intended for biopharma, single-use systems, medical manufacturing, bioprocess.
• TH Series – Pulsatile flow sensor (hemodynamic). Range: 0.01–15 L/min, accuracy ±2%. Designed for cardiovascular flow testing, made of medical-grade polymer. Used in cardiovascular research, hemodynamic testing, medical laboratories.
• BG Series – Ultrasonic bubble detector. Non-contact gas-liquid state detection, customizable detection range and response time. Suitable for medical devices, bioprocess, food & beverage dosing, industrial.

Step-by-Step Selection Process for OEM Buyers

1. Define Fluid and Pipe – Determine fluid type (water, chemicals, blood, etc.), tubing material (soft like PVC/silicone or rigid like PFA/PTFE), and outer/inner diameter. Clamp-on sensors work best on flexible tubing; inline sensors suit rigid pipes.
2. Identify Flow Range – Match the expected minimum and maximum flow rate to the sensor’s measurement scope. For micro-flows (mL/min), consider TGU (not listed here but in corpus) or TPK/TPD at higher end.
3. Check Accuracy Requirement – XY-TEK offers ±1% (CG), ±2% (many models), ±3% (CM, CG standard). Higher accuracy is available for critical medical/bioprocess applications.
4. Evaluate Installation Constraints – Clamp-on sensors require no pipe cutting and are ideal for retrofits. Inline sensors require integration into existing piping but provide direct measurement.
5. Consider Environmental Conditions – Fluid temperature up to 60°C for most models, 90°C for CPD and CS series. Indoor industrial or medical environments with potential dust and humidity are standard.
6. Select Output and Connectivity – Analog, pulse, or RS485 (CM, CG, CP series). Confirm compatibility with your control system.

Key Use Cases

Industrial Automation

In micro-flow precision measurement for spraying, dispensing, and cleaning systems, XY-TEK clamp-on sensors monitor pulsating and micro-flow liquids, detect bubbles or blockages, and support closed-loop control with resolution down to 0.05 mL/min. Typical equipment includes dispensing machines, coating machines, and industrial control systems.

Medical Devices

For dialysis, ECMO, and artificial heart systems, non-invasive clamp-on sensors (CG, CM, TH) provide real-time blood flow monitoring and air bubble detection to improve patient safety. The sensors meet strict hygiene and biocompatibility requirements and operate in indoor medical environments.

Biopharmaceutical Processing

In cleanroom environments, clamp-on sensors monitor purified water, buffer solutions, and culture media through bioreactors and peristaltic pumps. They detect bubbles, prevent overflow, and maintain sterility with contamination-free measurement. Applications include perfusion, tangential flow filtration, and chromatography.

Comparison of Key XY-TEK Ultrasonic Flow Sensor Series

Frequently Asked Questions