In pneumatic applications, heavy-duty pressure sensors can be used to measure and control the pressure of high-pressure compressed air and gas. The core of pneumatic applications is the air compressor, whose role is to provide compressed air to drive pneumatic equipment or tools.
In pneumatic applications, heavy-duty pressure sensors can be used to measure and control the pressure of high-pressure compressed air and gas. The core of pneumatic applications is the air compressor, whose role is to provide compressed air to drive pneumatic equipment or tools. In air compressors, pressure sensors can convert measured compressed air pressure into digital or analog electronic signals, enabling precise control in manufacturing, construction, chemical, pneumatic tools, oil and gas, food and beverage industries, and medical equipment applications. The pressure measurement range for heavy-duty applications is usually 100 to 1000 PSI. In industrial air compressors, heavy-duty pressure sensors can be used to measure and control inlet and outlet pressures, filter pressure drops, cooling water inlet and outlet pressures, and compressor oil pressure. Sensors play a key role in maintaining compressor performance and efficiency. For example, the Honeywell PX2 pressure sensor can measure the air pressure in the gas tank. (As shown in Figure 1). The air pressure in the gas storage tank is used to control the startup and shutdown of the compressor. The air compressor shown in Figure 1 is suitable for various industrial applications, including the use of compressed air in PET bottles to blow mold plastic bottles, and the operation of pneumatic tools such as air hammers, air nail guns, and jackhammers.
Sensors are usually used for two types of pressure measurement: (1) to determine whether the amount of compressed air output to the equipment used is appropriate; (2) to monitor air pressure leaks for the maintenance of pressure lines. In order to achieve and maintain better compressor performance, the selection of sensors should be based mainly on the two criteria of reliability and barometric pressure measurement accuracy. When selecting a heavy-duty pressure sensor, many key performance technical parameters need to be considered, including total error range (TEB), configurability, and durability. In addition, some other important parameters need to be considered, including calibration, zero output, and wide pressure range. All of the above factors can affect product performance, time to market, and overall customer application costs.
The selection criteria of sensors should meet all the requirements of system consistency and reliability. When selecting a model for pneumatic air compressor applications, design engineers need to consider the following four points:
Accuracy and consistency: When selecting a sensor, the total error range is the most important technical parameter. The total error range includes all possible errors of the sensor, indicating the true accuracy of the device in the compensation temperature range (such as -40 ℃ to 125 ℃). For example, a total error range of ± 2% means that within the operating temperature range, whether the pressure is rising or falling, the sensor error is not greater than 2% of the range. Understanding the total error range is essential to ensure that the sensor can be used accurately within the pressure range and operating temperature range, so as to provide an air pressure reading output with good consistency, reliability, and repeatability. The advantage of this feature is that because the difference in accuracy between the sensors is extremely small, the interchangeability of the sensors is good; the sensors do not need to be tested and calibrated; it helps to ensure the accuracy of the system. The above advantages are critical to the quality control of the end product.
It should be noted that some sensor manufacturers do not provide the total error range in the product data sheets. In many cases, they only provide accuracy errors (pressure nonlinearity, hysteresis, and non-repeatability), and these accuracy errors are only part of the total error range.
Configurability: A product platform that can provide design engineers with a variety of key technical parameter options should be sought. Sensor selection includes key technical parameters such as connectors and cables, pressure interfaces, pressure types and ranges, and output forms. In this way, custom design can be based on existing solutions, configure sensors according to their own application requirements, without having to find different suppliers for supplier qualification and sample testing. Choosing an excellent product platform shows that the design engineer can complete the customized design of the product by choosing standard options. The advantages of this feature: lower equipment costs; reduce overall design, integration and implementation costs; speed up the development of equipment prototypes to quickly market. In addition, as suppliers can reuse mature technologies, designs, and processes, they reduce potential design and procurement risks. Durability: The sensor must have a wide range of harsh media compatibility, a wide operating temperature range (-40 ° C to 125 ° C), and IP69 seal protection. They must also provide EMC protection and meet the CE directive. In addition, sensors based on piezoresistive detection and ASIC (Application Specific Integrated Circuit) signal conditioning technology are compatible with many harsh media. For each material in the sensor that is in direct contact with the medium, careful consideration is required. For example, a sensor with a stainless steel housing can protect more harsh media. The advantage of this feature: the sensor can be used in harsh environments. Supplier quality management and support: Design engineers must also consider supplier quality management processes, global organization distribution, and design support capabilities. Suppliers must adopt Six Sigma quality standards in the manufacturing process to produce high-quality and high-performance sensors. Another factor that needs to be considered is the relevant support that the supplier can provide during the user product design and manufacturing process. Does the supplier have a rich product line, design support, and global branches to support customers' product design and manufacturing requirements? The advantage of this feature: the supplier assures the design engineer that the sensor can be used normally according to the technical specifications throughout the life cycle, and is willing to provide customers with product design, application and manufacturing support. When selecting and designing heavy-duty pressure sensors, the following factors should also be considered:
The sensor must be fully compensated, calibrated, and amplified to provide a plug-and-play solution. The sensor should be calibrated by the user and be able to provide a variety of specified voltage outputs to avoid the expensive cost of changing the design. The wide compensation temperature range makes the sensor applicable to the entire process of system design, and at the same time it can output true pressure measurement readings. The wide pressure range (100 to 1000 psi) allows the sensor to be used in many different parts of the system. Provide multiple connectors and pressure interface options, so that the sensor can meet the special needs of different design engineers around the world. The packaging and compact size make the sensor placement more flexible. Comply with ISO 9001 and other industrial standards.