Pressure Sensor Guide | Working Principles and Industrial Applications

Pressure Sensor Guide | Working Principles and Industrial Applications

Understanding Pressure Sensors: Principles, Types, and Key Applications

May 26, 2023

Pressure Sensor Guide | Working Principles and Industrial Applications

Basic Introduction
Pressure Transducer is a device that senses a pressure signal and converts it into a usable output electrical signal according to specific rules. Pressure sensors are typically composed of a pressure-sensitive component and a signal processing unit. Based on the type of pressure measured, they can be categorized into Gauge Pressure SensorsDifferential Pressure Sensors, and Absolute Pressure Sensors.

Working Principle
Pressure sensors operate on different physical principles, leading to various types suited for specific applications:

  1. Piezoresistive Pressure Sensor
    The strain gauge is a key component. Its operation relies on the piezoresistive effect (or resistance strain effect), where the electrical resistance of the strain gauge changes when it is subjected to mechanical deformation (strain) due to applied pressure.

  2. Ceramic Pressure Sensor
    This type also utilizes the piezoresistive effect. Pressure acts on a ceramic diaphragm, causing minute deformation. Thick-film resistors on the diaphragm form a Wheatstone bridge, whose output voltage is linearly proportional to the applied pressure. Standard outputs are typically 2.0/3.0/3.3 mV/V.
  3. Diffused Silicon Pressure Sensor
    Operating on the piezoresistive effect, pressure deforms a silicon diaphragm. This deformation changes the resistance of piezoresistive elements diffused into the silicon, which is detected by an electronic circuit and converted into a standard output signal.

  4. Sapphire Pressure Sensor
    Using silicon-sapphire semiconductor elements, these sensors offer exceptional stability. They are highly insensitive to temperature changes and possess excellent characteristics even under high-temperature conditions and strong radiation, with minimal PN drift.

  5. Piezoelectric Pressure Sensor
    This type is based on the piezoelectric effect, where certain materials generate an electrical charge when subjected to mechanical stress. Consequently, they are inherently suited for measuring dynamic pressure changes and are not used for static pressure measurement.

Application Areas
Pressure sensors are critical components across a wide range of industries:

  1. Applied to Hydraulic Systems
    Used for closed-loop force control, they must withstand extreme pressure spikes and continuous pressure pulsationsShock-resistant designs, often using strain-gauge technology, are essential for reliability.

  2. Applied to Safety Control Systems
    Commonly used in air compressor management and pipeline monitoring. They provide critical data to control pressure within safe limits, preventing over-pressure situations and ensuring operational safety.

  3. Applied to Injection Molding
    Installed in nozzles, mold cavities, and runner systems, they monitor plastic melt pressure throughout the injection, packing, and cooling stages, which is vital for ensuring product quality and process optimization.

  4. Applied to Mine Pressure Monitoring
    Key for ground pressure monitoring in mining. Types used include vibrating wiresemiconductor piezoresistive, and metal strain gauge sensors, chosen based on the specific harsh environmental conditions underground.

  5. Applied to Sleep Monitoring
    Integrated into smart mattresses or bedding, high-sensitivity sensors detect micromovements from heartbeat and breathing. This data is analyzed to track sleep cycles and quality.

  6. Applied to Compressors & HVAC/R Equipment
    Widely used in air compressors and refrigeration systems for pressure control and protection. Their compact size and often valved pressure port design facilitate easy installation and service.

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