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Allied sensors are devices or units that detect pressure signals and convert them into usable output electrical signals according to a defined pattern. Pressure sensors typically consist of a pressure-sensitive element and a signal processing unit. Depending on the type of pressure measured, pressure sensors can be classified as gauge pressure sensors, differential pressure sensors, and absolute pressure sensors. Pressure sensors are among the most commonly used sensors in industrial practice, widely applied in various industrial automation environments, involving water conservancy and hydropower, railway transportation, smart buildings, production process control, aerospace, military industry, petrochemicals, oil wells, electric power, ships, machine tools, pipelines, and many other industries.

Allied sensor classification

The basic principle of multi-sensor information fusion technology is similar to the human brain's comprehensive information processing: it performs multi-level, multi-spatial complementary and optimized combination processing of data from various sensors, ultimately producing a consistent interpretation of the observed environment. This process requires full utilization and rational management of multi-source data. The ultimate goal of information fusion is to derive more useful information by combining information from multiple levels and aspects based on the separate observations obtained from each sensor. This not only leverages the advantages of collaborative operation among multiple sensors but also comprehensively processes data from other information sources to enhance the intelligence of the entire sensor system. Pressure sensors are the most widely used type of sensor. Traditional pressure sensors were primarily mechanical structures that indicated pressure through the deformation of elastic elements, but these structures were large in size, heavy in weight, and could not provide electrical output. With the development of semiconductor technology, semiconductor pressure sensors have emerged. They are characterized by small size, light weight, high accuracy, and good temperature characteristics. Especially with the development of MEMS technology, semiconductor sensors are trending toward miniaturization, featuring low power consumption and high reliability.

Allied sensor installation precautions

1) Correct installation method: Using appropriate instruments, verify the frequency response value of the pressure sensor under normal atmospheric pressure and standard temperature conditions. Verify the correctness of the pressure sensor code against the corresponding frequency response signal. 2) Determine specific installation location: To determine the numbering and specific installation location of the pressure sensors, consider each inflation section of the pneumatic network. Pressure sensors must be installed along the cable, preferably at cable joints. Install no fewer than 4 pressure sensors per cable. The two pressure sensors closest to the telephone exchange shall be no more than 200m apart. Install 1 at each end of every cable. Install 1 at each branch point of the cable; if two branch points are close together (less than 100 m), only 1 needs to be installed. Install 1 where the cable laying method (overhead, underground) changes. For cables without branches, since the cable specification is consistent, the installation spacing of pressure sensors shall not exceed 500m, and the total number shall be no less than 4. To facilitate identification of pressure sensor fault locations, in addition to installing a pressure sensor at the starting point, install another 1 at a distance of 150~200m from the starting point. Of course, economic and technical factors must be considered in the design; pressure sensors need not be installed where they are not required.

Allied sensor applications

Pressure sensors are mainly applied in: booster cylinders, boosters, gas-liquid booster cylinders, gas-liquid boosters, presses, compressors, air conditioning and refrigeration equipment, and other fields. 1) Application in hydraulic systems: In hydraulic systems, pressure sensors are primarily used to achieve closed-loop force control. When the control valve spool moves suddenly, a peak pressure several times higher than the system operating pressure forms within a very short time. In typical mobile machinery and industrial hydraulics, if such extreme conditions are not considered during design, any pressure sensor will be damaged quickly. Shock-resistant pressure sensors are required. There are mainly 2 methods for achieving shock resistance in pressure sensors: one is changing the strain gauge chip, and the other is using an external capillary tube. The first method is generally adopted in hydraulic systems, mainly due to ease of installation. Another reason is that the pressure sensor must withstand continuous pressure pulsations from the hydraulic pump. 2) Application in safety control systems: Pressure sensors are frequently used in safety control systems, primarily targeting the safety management systems of air compressors themselves. Many sensors are used in the field of safety control. As a very common sensor, the application of pressure sensors in safety control systems is not surprising. Applications in safety control are generally considered from the perspectives of performance, price, and operational safety and convenience. Practical evidence shows that the effect of selecting pressure sensors is very good. Pressure sensors use mechanical processing technology to mount components and signal conditioners onto a small chip. Therefore, small size is one of its advantages; additionally, low price is another major advantage. To some extent, it can improve the accuracy of system testing. In safety control systems, installing pressure sensors in the pipeline equipment at the air outlet helps control the pressure generated by the compressor to some extent, serving as a protective measure and a highly effective control system. After the compressor starts normally, if the pressure value has not reached the upper limit, the controller will open the intake port and adjust to bring the equipment to maximum power. 3) Application in injection molds: Pressure sensors play an important role in injection molds. Pressure sensors can be installed in the nozzle of the injection molding machine, hot runner systems, cold runner systems, and within the mold cavity. They can measure the plastic pressure at certain points between the injection molding machine nozzle and the mold cavity during the processes of injection, filling, holding pressure, and cooling. 4) Application in mine pressure monitoring: Sensor technology is one of the key technologies for mine pressure monitoring. On one hand, we should correctly apply existing various sensors to serve the mining industry; on the other hand, sensor manufacturers must research and develop new types of pressure sensors to adapt to more mining industry applications. There are various types of pressure sensors. Due to the special environment of mine pressure monitoring, mine-used pressure sensors mainly include: vibrating wire pressure sensors, semiconductor piezoresistive pressure sensors, metal strain gauge pressure sensors, and differential transformer pressure sensors. These sensors have wide applications in the mineral industry; the specific choice of sensor depends on the particular mining environment. 5) Application in compressors and air conditioning/refrigeration equipment: Pressure sensors are commonly used in air compressors and air conditioning/refrigeration equipment. These sensor products have a compact form factor, are easy to install, and typically use specialized valve-needle-style pressure ports.

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