If the pressure sensor is exposed to a manufacturing environment that exceeds the limits specified by the supplier during storage or assembly, the sensor will have problems. The following six factors are worth noting.
Temperature
Excessive temperature is one of the common causes of many problems with pressure sensors, because many components of pressure sensors can only work normally within the specified temperature range. During assembly, if the sensor is exposed to an environment that exceeds these temperature ranges, it may be adversely affected.
For example, if the pressure sensor is installed near a steam line that generates steam, the dynamic performance will be affected. The correct and simple solution is to move the sensor to a location far away from the steam line.
2. Voltage spikes
Voltage spikes refer to short-term voltage transients. Although this high-energy surge voltage lasts only a few milliseconds, it can still cause damage to the sensor. Unless the source of the voltage spike is very obvious, such as from lightning, it is extremely difficult to find. OEM engineers must pay attention to the potential failure risk of the entire manufacturing environment and its surroundings. Communicating with us in a timely manner helps to identify and eliminate such problems.
3. Fluorescent lighting
Fluorescent lamps require high voltage to generate an arc to break down argon and mercury when they are started, thereby heating mercury into a gaseous state. This start-up voltage spike may pose a potential danger to the pressure sensor. In addition, the magnetic field generated by fluorescent lighting may also induce voltage to act on the sensor wires, so that the control system may mistake it as the actual output signal. Therefore, the sensor must not be placed under or near fluorescent lighting.
4. EMI / RFI
Pressure sensors are used to convert pressure into electrical signals and are therefore susceptible to electromagnetic radiation or electrical interference. Although sensor manufacturers have tried their best to ensure that the sensors are protected from the adverse effects of external interference, some specific sensor designs should reduce or avoid the effects of EMI / RFI (electromagnetic interference / radio frequency interference).
Other sources of EMI / RFI to avoid include contactors, power cords, computers, walkie-talkies, cell phones, and large machines that generate varying magnetic fields. The most common methods to reduce EMI / RFI interference are shielding, filtering and suppression. You can consult us for the correct precautions.
5. Shock and vibration
Shock and vibration can cause a variety of problems, such as recessed casings, broken wires, broken circuit boards, signal errors, intermittent failures, and shortened life. In order to avoid shock and vibration during assembly, OEM manufacturers must first consider this potential problem in the designer, and then take measures to eliminate it.
The easiest way is to install the sensor as far as possible from obvious sources of shock and vibration. Another possible solution is to use vibration-impulse isolators, depending on the installation method.
6. Overpressure
Whether at your own manufacturing site or at the end user, once the OEM completes the machine assembly, care should be taken to avoid overpressure issues. There are many reasons for overvoltage, including water hammer effect, unexpected heating of the system, and voltage regulator failure.
If the pressure value occasionally reaches the upper limit of the pressure resistance, the pressure sensor can still withstand and will restore the original state. However, when the pressure value reaches the rupture pressure, this will cause the sensor diaphragm or housing to rupture, causing leakage. A pressure value between the upper limit of the withstand pressure and the rupture pressure may cause permanent deformation of the diaphragm, thereby causing output drift.
To avoid overvoltage, OEM engineers must understand the dynamic performance of the system and the limits of the sensors. When designing, they need to grasp the interrelationships between pumps, control valves, balance valves, check valves, pressure switches, motors, compressors, storage tanks and other system components.