Area of application - Pneumatics

Pressure sensors play a crucial role in both pneumatic and hydraulic systems, where they help monitor and control the pressure within these systems to ensure safety, efficiency, and reliability.

Pneumatic systems

Vehicle tyres: Pressure sensors monitor the air pressure in tyres, ensuring they are within the correct range to prevent blowouts, improve fuel efficiency, and ensure optimal vehicle handling.

Air brakes: In buses, trucks, and trains, pressure sensors in air brakes monitor the air pressure to ensure the brakes are functioning correctly. If the pressure is too low, the brakes might fail; if too high, they could engage too forcefully.
Air compressors: Pressure sensors in air compressors monitor the air pressure to maintain it within a specified range. This ensures that the compressed air provided to tools or machinery is at the correct pressure, preventing damage to the equipment or inefficient operation.
Compressed-Air engines and vacuum umps: These systems rely on pressure sensors to regulate the pressure of air or vacuum being used, ensuring the engine or pump operates effectively without causing damage or inefficiency.

Hydraulic systems

Vehicle braking systems: Hydraulic brakes in vehicles use pressure sensors to monitor the hydraulic fluid pressure. This ensures that the braking force is correctly applied, preventing brake failure or uneven braking.

Power steering systems: Pressure sensors in hydraulic power steering systems help maintain the correct fluid pressure, ensuring smooth and responsive steering.
Shock absorbers: In hydraulic shock absorbers, pressure sensors help monitor and adjust the damping force, providing a comfortable ride and improving vehicle handling.
Utility vehicles: These machines rely on hydraulics for movement and lifting. Pressure sensors ensure the hydraulic system operates within safe limits, preventing accidents due to hydraulic failure.
Lifts: Hydraulic lifts use pressure sensors to maintain the correct pressure in the hydraulic fluid, ensuring smooth and safe operation.
Industrial machinery: In industrial applications, hydraulic presses use pressure sensors to control the force applied during pressing operations, ensuring consistency and safety.

Safety and Control

In both pneumatic and hydraulic systems, pressure sensors are often integrated with pressure regulators or automatic valves to control the system’s pressure. The sensors provide real-time feedback to the regulator, which adjusts the flow to maintain the desired pressure level. This is particularly crucial in hydraulic systems, where the fluid may be volatile or flammable, and high pressures can be dangerous.

Regulators

Monitoring: Continuously checking the pressure to ensure it stays within safe and operational limits.
Regulating: Adjusting the flow to maintain a constant pressure despite changes in system demand.
Safety: Triggering alarms or safety shutdowns if the pressure exceeds or drops below safe levels.

By integrating pressure sensors into these systems, engineers can ensure that machinery operates safely, efficiently, and reliably, preventing accidents and extending the lifespan of the equipment.

Pressure sensors in pneumatic and hydraulic systems have various measurement options depending on the application’s requirements. The primary types of pressure measurement include differential pressure and absolute pressure. These measurement methods are essential for ensuring accurate control and monitoring in pressure regulators and other components.

Benefits

Precision and reliability: The use of advanced materials like silicon and precise mechanisms such as LVDTs allows for highly accurate and reliable pressure measurements. This precision is vital in applications like power steering, where even minor deviations can impact system performance.
Adaptability: With the advent of standalone sensors, installation and system design have become simpler and more streamlined. However, the availability of embedded sensors ensures that even in the most demanding environments, accurate pressure sensing is possible.
Enhanced durability: The careful design of pressure sensors, including features like silicon-only contact and flexible tube monitoring, ensures that they can withstand harsh conditions, making them suitable for a wide range of industrial applications

Technology

Pressure sensors used in pneumatic and hydraulic systems are critical components that translate physical pressure into electrical signals. This conversion enables real-time monitoring and control via electronic devices. Here’s an overview of the technology behind these sensors and how they are adapted to various applications.

The technology behind pneumatic and hydraulic pressure sensors has evolved to meet the demands of modern, high-performance systems. From diaphragm-based sensors providing accurate and direct pressure measurements to embedded systems that function in extreme environments, these sensors are essential for ensuring the safety, efficiency, and reliability of various mechanical systems.