Why are Pressure Sensors Important to Original Equipment Manufacturers?
In the vast landscape of industrial operations, precise measurement and control of pressure is paramount for ensuring efficiency, safety, and quality. Original Equipment Manufacturers (OEMs) play a critical role in providing tailored solutions that meet the unique requirements of various industries, from automotive to aerospace through to manufacturing. Among the key components in these solutions are industrial pressure sensors, which have seen significant advancements in recent years, offering enhanced accuracy, reliability, and flexibility.
Evolution of Industrial Pressure Sensor Technology
Industrial pressure sensors have evolved considerably from their early iterations, thanks to advancements in materials, sensing technologies, and signal processing techniques. Traditional sensors, such as strain gauge-based devices, have been augmented by more sophisticated technologies like piezoelectric, capacitive, and microelectromechanical systems (MEMS) sensors.
Piezoelectric sensors, for instance, rely on the piezoelectric effect to generate an electrical charge proportional to the applied pressure. These sensors offer high sensitivity and fast response times, making them suitable for dynamic pressure measurements in applications like automotive engine control and hydraulic systems.
On the other hand, capacitive sensors utilise changes in capacitance to detect pressure variations. They excel in low-pressure measurements and are often used in applications where accuracy and stability are critical, such as medical devices and environmental monitoring systems.
MEMS-based pressure sensors represent another significant advancement, leveraging microfabrication techniques to produce miniature sensors with high accuracy and reliability. These sensors find widespread use in consumer electronics, industrial automation, and aerospace applications, owing to their compact size, low power consumption, and compatibility with integrated circuits.
What sensors do Druck manufacture?...
Druck manufactures piezoresistive pressure transmitters and transducers based on an advanced design of a diffused silicon strain gauge, this gives an electrical output when subjected to pressure.
Druck has perfected their design and manufacture of silicon strain gauge wafers for over 50 years, the sensing elements are micro machined using techniques specifically designed to optimise pressure sensor performance.
The silicon element is bonded and mounted into a glass to metal seam (GMS). Gold leads are bonded on to contact areas, creating a one piece module which greatly enhances the long term stability.
Piezoresistive pressure sensors are often considered superior to piezoelectric pressure sensors for certain applications due to several key advantages:
- Sensitivity: Piezoresistive pressure sensors typically exhibit higher sensitivity compared to piezoelectric sensors. This means they can detect smaller changes in pressure more accurately, making them suitable for OEM applications requiring precise pressure measurements.
- Linearity: Piezoresistive sensors tend to have better linearity over a wider pressure range compared to piezoelectric sensors. This ensures that the sensor's output signal accurately reflects the applied pressure, simplifying future calibration and data interpretation.
- Stability: Piezoresistive sensors offer excellent long-term stability and repeatability, meaning their performance remains consistent over time and across repeated pressure cycles. This reliability is crucial for OEM applications requiring consistent and accurate pressure monitoring over extended periods. This also ensure long term functional use.
- OEM Size and Form Factor: Piezoresistive sensors are typically smaller and more compact than piezoelectric sensors, making them easier to integrate into space-constrained environments or portable devices. Their smaller size also enables greater flexibility in design and installation.
- Cost: Piezoresistive sensors are often more cost-effective than piezoelectric sensors, particularly for large-scale production or applications where multiple sensors are required. Their simpler construction and manufacturing process contribute to lower overall lifetime costs.
While piezoresistive pressure sensors offer many advantages, it's important to note that the choice between piezoresistive and piezoelectric sensors ultimately depends on the specific requirements of the OEM application, including factors such as pressure range, temperature sensitivity, environmental conditions, and budget constraints. Each sensor type has its strengths and limitations, and selecting the most appropriate sensor requires careful consideration of these factors to ensure optimal performance and reliability.
Druck also manufacture Resonate Pressure Sensors
Resonant pressure sensors (resonating silicon) which measures the changes in resonate frequency in a sensing mechanism caused by applied pressure.
A resonating silicon sensor’s performance is inherently more accurate and stable than the piezo resistive device, and many other common sensor technologies. It takes full advantage of the mechanical properties of the single crystalline structure, silicon... and frequency can be measured with greater precision than any other parameter.
The external pressure deflects the resonator and the resonator is pushed apart, changing its frequency.
Key Features and Considerations for OEMs
For OEMs tasked with integrating pressure measurement solutions into their products, several key features and considerations come into play:
Accuracy and Precision: Industries such as aerospace, automotive, and pharmaceuticals demand high levels of accuracy and precision in pressure measurements to ensure product quality and safety. OEMs must select sensors with the appropriate accuracy specifications to meet these stringent requirements. Druck’s pressure sensor range offers one of the most accurate, reliable and stable range of products – Druck’s proprietary TERPS (Trench Etched Resonant Pressure Sensor) technology offers high precision +/-0.01% FS over compensated temperature range with high stability +/-100ppm FS/year.
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Range and Compatibility: Industrial applications encompass a wide range of pressure levels, from vacuum to ultra-high pressures. OEMs must choose sensors that cover the desired pressure range while ensuring compatibility with the fluids and environments encountered in their specific applications. Druck offers a configurable pressure sensors that can be customised for your application.
Reliability and Durability: Industrial environments can be harsh, subjecting sensors to extremes of temperature, pressure, vibration, and chemical exposure. OEMs should prioritise sensors with robust construction and sealing to ensure long-term reliability and durability in challenging operating conditions. OEMs rely on Druck pressure sensors due to their reliability – perfect for remote/hazardous operations that require infrequent calibrations.
Size and Form Factor: Space constraints are a common consideration in OEM design, particularly in applications where miniaturisation is essential. MEMS-based sensors offer compact form factors that enable integration into tight spaces without sacrificing performance.
Signal Conditioning and Interface: The output signal of pressure sensors may require conditioning and amplification before integration with the OEM's control or monitoring systems. Sensors with built-in signal conditioning circuits or standardised interfaces simplify integration and reduce development time for OEMs. Take a look at the Druck DPS5000 with is high-level specifications and accuracy with a choice of digital signal: i2c, SDI-12 (350mbar – 70 bar) or CANBUS (-40 – 80 deg c).
Applications Across Industries
The versatility of industrial pressure sensors makes them indispensable across a broad spectrum of industries:
Automotive: In automotive applications, pressure sensors are used for monitoring tyre pressure, engine performance, fuel injection systems, and exhaust gas recirculation (EGR) systems, contributing to improved fuel efficiency, emissions control, and vehicle safety. Druck work closely with an number of automotive manufacturers where the sensors and test and calibration products are used to develop new products in test cells as well as refine systems before production.
Manufacturing and Process Control: Industrial automation relies heavily on pressure sensors for monitoring and controlling pneumatic and hydraulic systems, ensuring precise positioning, force control, and leak detection in manufacturing processes. Druck prides itself on stable and reliable sensors – repeatability is important for manufacturing and process control and Druck sensors prove themselves time after time.
Aerospace and Defense: Aerospace applications demand pressure sensors capable of withstanding extreme conditions encountered in aircraft engines, hydraulic systems, and cabin pressure control systems. These sensors contribute to the safety, performance, and reliability of aerospace platforms. Safety is paramount for aerospace and defence. Many aircraft platforms specify Druck sensors (approximately 80% of passenger planes in use incorporate Druck sensors) for a number of different applications from cabin pressure management, engine systems, fuel and hydraulic pressures to name a few… Druck has just recently launched its NG3000 configurable flight approved pressure sensors that can be used in general aviation to commercial to drones.
Environmental Monitoring: Pressure sensors are integral to environmental monitoring systems for measuring atmospheric pressure, water depth, and soil compaction, aiding in weather forecasting, flood monitoring, and precision agriculture. Druck manufacturers its highly accurate RPS8100-Meteo barometric pressure sensors as well as its PACE1000B barometric pressure indicator. These are ideal for weather stations for OEM or stand alone. To complement these, Druck manufacture a range of depth and level sensors that can be used to monitor water levels in urban and remote areas.
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Take a look at the below Original Equipment Manufacturer brochure and get in touch with Acutest to discuss your requirements.
OEM SENSORS BROCHURE
Other Druck Products:
The Druck process calibration range gives you reliable, accurate and easy to use calibration tools and instruments at every level.
Elite Modular multifunction communication and calibration
The Elite range gives you state-of-the art calibration, communication and data integration on the move. Modular design gives you the capability of a full calibration lab, anywhere in the field.
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| Druck GENII Multifunction Calibrator |
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This advanced modular calibration system combines an advanced multi-function and HART/Foundation Fieldbus communicator with world-class pressure measurement and generation, complete with TASK menu enabling single touch configuration for common devices.
- Multi-function capabilities: electrical, frequency, temperature and pressure
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Expert High performance, high accuracy calibration
The Expert range provides incredible calibration capability built around Druck’s benchmark reliability, accuracy and ease-of-use.
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| Druck DPI 611 Hand-Held Pressure Calibrator |
| A simple selector lets you convert from vacuum to pressure and with a few stokes of the pump, you will generate the required pressure! |
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This fully self-contained pressure test and calibration system combines pressure generation, signal measurement and loop power to provide convenience and ease of use.
- Generate: from 95% vacuum to 20 bar/300 psi pneumatic pressure.
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| Druck DPI 612 Flexible Pressure Calibrator |
| Models provide dependable, high performance pressure systems provide quick and easy generation with great accuracy! |
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A fully self-contained pressure test and calibration systems with interchangeable pressure modules to enable flexible ranging.
- 3 models permit: 20 bar/300 psi in 30 seconds; 100 bar/1500 psi without gas bottles and regulators; 1000 bar/15000 psi hydraulic pressure.
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Essential Core function test and calibration
The Essential range are test and calibration tools you can rely on. Druck have designed these day-to-day tools to be tough, reliable, accurate and easy to use.
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| Druck DPI 705 E Pressure, Temperature Indicator (Commercial) |
| A high accuracy pressure and temperature indicator comes complete with plug and play remote sensors! |
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A handheld pressure and optional temperature indicator built with essential features for accurate and reliable measurements.
- Perfect for: routine maintenance and system troubleshooting (intrinsically safe version also available).
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| Druck DPI104 Pressure Gauge |
| A digital unit combining precision and functionality in a compact, robust and simple-to-use package! |
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A microprocessor-controlled digital pressure gauge that combines precision and functionality in a compact, robust and simple-to-use package.
- Designed perfectly to do the job well: this unit matches advanced silicon sensor technology with several convenient design features, resulting in an accurate, versatile yet affordable pressure gauge.
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