Tips for selecting heavy-duty pressure sensors for pneumatic applications

In pneumatic systems, heavy-duty pressure sensors play a crucial role in monitoring and controlling the pressure of high-pressure air and gas. These sensors are essential components in air compressors, which supply compressed air to power various pneumatic tools and equipment. Within an air compressor, pressure sensors convert the measured compressed air pressure into digital or analog signals, enabling precise control across industries such as manufacturing, construction, chemical processing, oil and gas, food and beverage, and medical devices. The typical operating range for heavy-duty pressure measurements in industrial applications is between 100 and 1000 PSI. These sensors are used to monitor inlet and outlet pressures, filter pressure drops, cooling water pressure, and compressor oil pressure, all of which are vital for maintaining the efficiency and performance of the system. For example, the Honeywell PX2 sensor measures the pressure inside an air reservoir, helping to control when the compressor starts and stops. As shown in Figure 1, this type of compressor is widely used in industrial settings, such as blow molding plastic bottles in PET production and powering pneumatic tools like air hammers, nail guns, and drills.

Tips for selecting heavy-duty pressure sensors for pneumatic applications

Figure 1 heading: Compressed air is used in industrial systems where the air compressor automatically starts when the tank pressure falls below a set level, and continues running until the desired pressure is reached. This ensures continuous and reliable operation of pneumatic equipment.

Pressure sensors in pneumatic applications are typically used for two main purposes: (1) ensuring that the amount of compressed air delivered to the equipment is sufficient, and (2) detecting pressure leaks for timely maintenance of the system. To achieve optimal compressor performance, the selection of sensors should focus on reliability, accuracy, and long-term stability. When choosing a heavy-duty pressure sensor, engineers must consider key specifications such as total error band (TEB), configurability, durability, calibration options, zero output, and a wide pressure range. These factors directly impact the sensor’s performance, time-to-market, and overall cost for the end-user.

When selecting a pressure sensor for a pneumatic air compressor application, design engineers should prioritize the following four criteria:

**Accuracy and Consistency:** The total error band is the most critical parameter when evaluating a pressure sensor. It represents the maximum deviation from the true value over the entire operating temperature range, such as -40°C to 125°C. A sensor with a total error band of ±2% means that its readings will not deviate by more than 2% of the full scale, regardless of whether the pressure is increasing or decreasing. Understanding this metric is essential for ensuring consistent and reliable pressure readings. This feature also enhances sensor interchangeability, reduces the need for frequent calibration, and supports better system accuracy, which is crucial for product quality control.

**Important Note:** Some manufacturers do not clearly specify the total error band on their data sheets. Instead, they may only list individual errors like nonlinearity, hysteresis, and repeatability—components of the total error band. This lack of transparency makes it difficult to compare different sensors effectively. As shown in Figure 2, understanding the full error margin is essential for making informed decisions when selecting a sensor for critical applications.

Tips for selecting heavy-duty pressure sensors for pneumatic applications

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