Smart Pressure Sensor: Types And Applications

An smart pressure sensor is a device that detects pressure signals and converts them into usable electrical output signals according to a defined pattern. Pressure sensors typically consist of a pressure-sensitive element and a signal processing unit. Based on the type of pressure being measured, pressure sensors can be classified into gauge pressure sensors, differential pressure sensors, and absolute pressure sensors.

How Do Smart Pressure Sensor Work?

Smart pressure sensor generally include a pressure-sensitive element and a signal conditioning module. Depending on the type of pressure being measured, smart pressure sensors can be categorized into gauge pressure sensors, differential pressure sensors, and absolute pressure sensors.

Absolute Pressure Sensors

Absolute pressure sensors are a type of vacuum pressure sensor. Their readings are always referenced to absolute zero, and the output is always positive, while other types of sensors may produce positive or negative values.

These sensors are ideal for measuring atmospheric pressure in critical barometric applications such as weather monitoring or altitude detection in navigation. Barometric pressure sensors rely on establishing a reference value from an absolute vacuum to ensure reliable readings.

Differential Pressure Sensors

Differential pressure sensors measure the pressure difference between two points in a system. This is crucial for ensuring proper system performance, such as checking vent valves or monitoring flow.

Specifications vary, but most differential pressure sensors measure pressure on both sides of a single diaphragm. Depending on how the diaphragm deflects, readings on either side may be positive or negative.

Gauge Pressure Sensors

Gauge pressure sensors are a type of relative pressure sensor. They are commonly used to measure the difference between local atmospheric pressure and the pressure at a specific point within another system.

Applications include checking fluid levels in vented tanks, operating blood pressure monitors, or controlling the speed and power of vacuum pumps. In all of these cases, changes in real-time ambient atmospheric pressure will affect the required calculations and readings.

Types of Smart Pressure Sensor

Choosing the right smart pressure sensor requires considering many factors, such as measurement range, accuracy, stability, durability, and installation requirements. Different applications demand different types of sensors to ensure system stability and reliability.

Explosion-proof Pressure Sensors – Intrinsically safe pressure sensors are designed for high-risk environments. We also offer explosion-proof models suitable for extremely hazardous locations.

Hygienic Pressure Sensors – Also known as clamp-type pressure sensors, these combine proven thin-film sensing technology with sanitary isolation seals. They are essential in sanitary processing environments such as food and pharmaceutical applications.

Diaphragm Pressure Sensors – A diaphragm pressure sensor converts pressure changes into electrical signals, allowing pressure variations to be measured through signal output. These sensors are especially suitable for low-pressure measurement applications.

Submersible Pressure Sensors – Also known as level transmitters, these sensors are used to measure pressure in tanks, wells, and similar liquid-level applications.

General-purpose Pressure Sensors – We offer a full range of pressure sensors in various sizes and pressure ranges. You can view all available sensor models on our website.

How to Choose the Right Smart Pressure Sensor

1. Measurement Range and Accuracy Requirements

The measurement range is the primary factor when selecting a sensor. Ensure that the sensor’s range covers the actual operating pressure and includes a safety margin (typically 1.5 times the maximum working pressure). A range that is too small may overload and damage the sensor, while a range that is too large can reduce measurement accuracy.

2. Media Compatibility

Compatibility between the pressure sensor and the measured medium is critical. Consider the following:

• Wetted materials: The materials that come into contact with the medium must resist corrosion. Common materials include stainless steel, Hastelloy, and titanium. Special media (such as strong acids or bases) may require special material selection.

• Sealing method: Different sealing materials (such as Viton or PTFE) are suitable for different media and temperature conditions.

• Cleanliness requirements: Industries like food and pharmaceuticals require sanitary designs that prevent contamination of the media.

3. Environmental Conditions

Industrial environments are often complex and variable. Consider these environmental factors:

• Temperature range: Includes both ambient temperature and media temperature. Exceeding the rated temperature range may affect performance and service life.

• Humidity: High-humidity environments require sensors with high protection ratings to prevent moisture intrusion.

• Vibration and shock: Applications involving heavy machinery or vehicles need models with strong resistance to vibration and shock.

• Explosion-proof requirements: Hazardous areas such as oil and chemical plants require products that meet appropriate explosion-proof ratings.

4. Electrical Characteristics and Interfaces

• Power supply requirements: Different sensors have different power demands (e.g., 12 VDC, 24 VDC) and must match the system.

• Output signal: Choose analog or digital output based on the control system, and make sure the signal type is compatible with the receiving device.

• Electrical connections: Consider connector types, protection ratings, and cable length requirements.

5. Long-term Stability and Reliability

Industrial applications typically require sensors to operate reliably over long periods. Consider the following:

• Long-term stability: Usually expressed as annual drift. High-quality sensors can achieve ±0.1% FS per year.

• Mean Time Between Failures (MTBF): Critical applications should choose products with high reliability.

• Calibration cycle: Determine whether regular calibration is required based on the application, as well as how easy it is to perform calibration.

Applications of Smart Pressure Sensor

Industrial Sector

In industrial environments, smart pressure sensor are widely used in various equipment and systems, such as pressure control systems, fluid transportation systems, and gas cylinder pressure monitoring systems. In these applications, the role of the pressure sensor is to monitor and regulate pressure to ensure proper system operation and to prevent abnormal conditions such as overpressure or underpressure.

Automotive Sector

In the automotive industry, smart pressure sensor are primarily used to monitor intake manifold pressure, fuel pressure, gas cylinder pressure, and tire pressure. These sensors provide real-time pressure data from different parts of the vehicle, giving drivers accurate information and ensuring safe and stable vehicle operation.

Chemical Industry

In the chemical sector, pressure sensors are used to monitor pressure changes during chemical reactions and to measure liquid levels. These sensors help maintain safety and stability in chemical production, preventing accidents caused by overpressure or underpressure.

Agricultural Sector

In agriculture, pressure sensors are commonly used in irrigation systems, aquaculture, and related fields. These sensors can monitor parameters such as soil moisture and tank pressure, providing farmers with accurate information to help them plan irrigation, fertilization, and other agricultural activities—ultimately improving crop yield and quality.

Food Processing Industry

In the food industry, smart pressure sensor are used to monitor pressure changes during food processing and the pressure inside packaging containers. These sensors help ensure the safety and quality of food production and improve the taste and consistency of the final product.

Smart pressure sensors can be defined as devices that convert physical pressure into an electrical signal. They are essential components across many industries, playing a critical role in monitoring and control systems by measuring the pressure of gases or liquids. These devices convert physical pressure into signals that can be interpreted by computers, control systems, or other measuring equipment, making them suitable for a wide range of applications across different fields.