Introduction

Inductive sensors are widely used in automation to detect metal objects without contact. They are essential in systems where reliability and precision matter.

Two common installation types are flush (Built-in) and non-flush (Non Built-in) mounting. While both serve the same purpose, they differ in how they work, where they’re used, and how they’re installed.

This blog explains the key differences to help you choose the right type for your application.

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Common Mounting Styles

Flush mounting means the sensor is installed so its sensing face is level with the mounting surface. This design shields the sensor and focuses the magnetic field forward, making it ideal for applications where space is tight or where the sensor needs protection from damage.

Non-flush mounting means the sensor extends beyond the mounting surface. Without shielding, the electromagnetic field radiates from the front and sides, allowing for a longer sensing distance. However, the sensor is more exposed and requires a metal-free zone around it to avoid interference.

Understanding these differences is key to making the right choice for your machinery or automation setup.

Inductive Sensor Flush vs Non Flush: 8 Key Differences

Operating Principle

Flush sensors focus the magnetic field forward. Non-flush sensors allow it to spread wider from the front and sides.

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Sensor Structure

Flush types include a built-in shield to block side fields. Non-flush types are unshielded, allowing for a broader detection zone.

Electromagnetic Field

Flush sensors have a narrow, controlled field. Non-flush sensors cover a wider area but need more space.

Mounting Style

Flush sensors can be embedded in metal. Non-flush sensors require a metal-free space around them.

Sensing Distance

Flush sensors offer shorter but more precise sensing. Non-flush sensors can detect from farther away.

Environmental Suitability

Flush sensors are more protected and better in dusty or rugged environments. Non-flush sensors are better for clean, open setups.

False Trigger Risk

Flush types are less likely to be triggered by surrounding metal. Non-flush types need careful placement to avoid errors.

Maintenance and Cost

Flush sensors are more durable and need less maintenance. Non-flush sensors may wear faster if exposed to damage

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Conclusion

If your application involves tight spaces or exposure to metal, flush sensors are the safer bet. If you need a longer sensing range and have space, non-flush sensors are ideal.

Knowing these 8 differences will help you pick the right sensor for stable, efficient operation.

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