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Flush-Mount Pressure Switches—And Transducers Too

Food, pharmaceutical and chemical processes often use tubular equipment to mix, transport or store materials. In these applications, it’s a good idea to keep any internal switches or sensors from protruding too far into the tube—where they can create a toehold for material buildup or impede flow. That’s where our newest pressure switch design comes into play.

This custom switch’s sensing element has been designed and manufactured to match the interior curvature of a specific food processing machine. The only part that protrudes into the flow within the machine is a low-profile, seamless seal that provides no place for materials to hang up during production.

While this particular flush-mount switch was designed for a specific use, the same approach can be applied to a wide variety of processing machines. We can alter the design of the switch for tubular structures with internal diameters as small as three inches.

We’ve also created a similar design for flush-mount pressure transducers.

Click here to learn more about our custom pressure switch capabilities.

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Blog Custom Pressure Switches Pressure Switches

Thermal Lockout for Hermetic Pressure Switches

In hydraulic systems, cold start-ups often cause pressure switching errors that disappear once the system reaches its normal operating temperature. The culprit behind these false high pressure signals is increased fluid viscosity, which temporarily increases the differential pressure across the diaphragm or pressure sensing device. A thermal lockout mechanism based on a snap-acting, temperature-sensitive bimetallic disc can prevent this problem.

Check out our infographic to see how it works.

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Blog Custom Pressure Switches Pressure Switches

Off-Road Vehicle Sees Success In Pressure Switch Signal Delay

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If your hydraulic systems suffer from pressure spikes, your pressure switches may not work as expected. The spikes can trigger the switch prematurely, even though continuous pressures remain below the set point. The result is a hard-to-control hydraulic system plagued by false switching signals.

Fortunately, there’s a simple solution to these spike-induced switching errors: Just add a time delay to the switch. That’s exactly what we did in a recent application.

Off-Road Vehicle Experiences Pressure Transients. In an off-road vehicle, a pressure switch was used as part of a hydraulic monitoring system, which was designed to trigger a warning light in the cabin if it experienced sustained excess pressure. But driving over rough terrain was causing unintended pressure spikes, causing the annunciator light in the crew compartment to constantly switch on and off.

Our engineers incorporated a PC board into the pressure switch that was programmed to delay signal output based on certain adjustable parameters, including the amount of time—down to the millisecond—and whether the signal occurred on the rising or falling pressure. In this case, engineers set the time delay at 3.2 seconds. As a result, the warning light remained off unless a pressure change lasted longer than that.

Pressure Switches For Tough Environments. In addition to integrating time delays, these pressure switches had to be ruggedized for use in an off-road application and are designed to withstand pressure spikes, leaks, temperature extremes, moisture, chemical exposure, vibration and shock loads. These ruggedized features include:

  • Proof pressures up to 12,000 psig
  • Maximum operating pressures up to 7,500 psig
  • Wide temperature range of -40 to 250°F
  • High overpressure capability
  • High shock and vibration survivability
  • Snap-action electrical switch tested to 1 million cycles
  • IP67 compliance

To learn more about pressure switch design, download our latest white paper.