Application of Construction Machinery Pressure Sensors in Industrial Equipment

In modern construction machinery and heavy industry, hydraulic systems act as the "nerves and blood vessels" of equipment, and pressure sensors are the most critical sensory organs. They capture real-time oil and air pressure changes, providing precise data to control systems, directly impacting operational efficiency, safety, and equipment lifespan.

With the increasing demands of large infrastructure, mining, and port logistics projects for reliability and intelligence, traditional pressure sensors face limitations under extreme conditions: vibration shocks, rapid temperature changes, oil contamination, electromagnetic interference… these factors can cause inaccurate monitoring or sensor failure.

The Nexisense 800-4002 is specifically designed for these harsh conditions. Using glass microfusion integrated technology combined with intelligent temperature compensation and multiple anti-interference designs, it demonstrates exceptional stability and adaptability in excavators, cranes, loaders, pile drivers, concrete pump trucks, and other construction equipment. It has become a trusted choice for many OEMs and construction projects.

Strict Requirements for Pressure Sensors in Construction Machinery

A medium-to-large excavator can experience hydraulic system pressure jumps from a few MPa to 30–40 MPa within milliseconds, while enduring strong mechanical vibrations (10–2000Hz) and impacts. Cranes experience frequent oil cylinder pressure fluctuations with high-temperature oil shocks. In cold regions, equipment can quickly rise from -30℃ at night to over +40℃ during the day. These are common conditions.

Traditional separated or ordinary welded sensors often encounter:

• O-ring aging and weld fatigue causing oil leaks or pressure loss

• Strong vibration loosening or breaking internal connections

• Rapid temperature changes causing zero-point and range drift

• Electromagnetic interference from high-power motors or welding equipment distorting signals

Such failures can reduce operational efficiency or even lead to equipment shutdowns, hydraulic leaks, and safety hazards. Therefore, the construction machinery industry requires sensors that are "reliably operational under extreme conditions," beyond mere measurement accuracy.

Core Technology and Structural Advantages of 800-4002

The Nexisense 800-4002 uses advanced glass microfusion technology, fusing stainless steel elastomer with the sensing element at over 500℃ in a single process, forming a true weld-free integrated structure. This completely eliminates traditional O-ring seals and welding seams, fundamentally solving leakage and fatigue failure issues.

Key performance parameters:

• Range: 0–6MPa to 0–60MPa (customizable higher)

• Accuracy: 0.5%FS / 1%FS

• Medium temperature: -40℃ to +105℃ (some models up to +125℃)

• Long-term stability: ≤±0.2%FS/year

• Vibration resistance: 10–2000Hz, 20g

• Shock resistance: 100g, 11ms

• Protection rating: IP67/IP68 (optional)

• Output: 4–20mA, 0.5–4.5V, CAN, RS485, etc.

The sensor also includes a high-precision digital temperature compensation circuit, maintaining minimal temperature drift even under rapid changes from -40℃ to +105℃, ensuring consistent measurements year-round under different climates.

Application Value in Typical Construction Machinery and Industrial Equipment

1. Excavators and Loaders

Monitors pump outlet pressure, boom/arm/bucket cylinder pressure, and travel motor pressure. 800-4002’s fast response (<2ms) and high vibration resistance ensure millisecond-level coordination between operator input and hydraulic actuator, improving multi-motion smoothness.

2. Cranes and Aerial Work Platforms

Real-time monitoring of leg cylinders, boom cylinders, and telescopic cylinders prevents overload and tilt. The leak-free integrated structure is ideal for long-term high-altitude, high-pressure, high-vibration operations.

3. Concrete Pump and Mixer Trucks

High-pressure pump outlet monitoring is a critical safety parameter. 800-4002 maintains excellent stability and durability even at 70MPa, reducing risks of clogging or pipe bursts.

4. Compressors, Gas Dispensers, and Refrigeration Equipment

In CNG/LNG stations, industrial air compressors, and cold chain refrigeration units, the 800-4002 ensures long-term stable operation under extreme outdoor climates thanks to wide temperature range and anti-interference design.

5. Industrial Automation and Pump Stations

Supports multiple bus outputs, facilitating integration with PLC or central control systems for remote pressure monitoring and fault warning.

Project Feedback and Value Demonstration

OEM feedback after batch application of 800-4002:

• Hydraulic system leakage complaints reduced by ~70%

• Sensor replacement cycle extended from 1.2 years to over 3 years

• Consistent pressure monitoring in extreme cold and high-temperature regions

• Reduced after-sales pressure and improved customer satisfaction

These results demonstrate the sensor’s robust performance under real-world, high-intensity conditions.

FAQ

What is the main difference between 800-4002 and ordinary sensors?

It uses glass microfusion integrated technology with no welds and no O-rings, solving leakage and fatigue issues, and has superior vibration and shock resistance compared to traditional sensors.

Can it be used with particulate or corrosive media?

Recommended for clean media like hydraulic oil, lubricants, and gases; for highly corrosive media, a special isolation diaphragm version is available.

Special considerations in extreme cold?

Standard range covers -40℃, but adding antifreeze or heating protection for wiring is recommended to prevent condensation and freezing affecting electrical performance.

Supported communication protocols?

Standard outputs: 4–20mA, voltage; customizable: CAN, RS485-Modbus, suitable for smart automation upgrades.

Conclusion

Every efficient operation and safety measure in construction machinery and heavy industry relies on precise pressure monitoring. The Nexisense 800-4002, with its glass microfusion integrated structure, intelligent temperature compensation, exceptional anti-interference, and extreme environment adaptability, provides OEMs and projects a reliable, long-lasting pressure monitoring solution.

With ongoing infrastructure development, rapid iteration of mining equipment, and increasing industrial automation, choosing a sensor that truly understands field conditions is both a technical upgrade and a strategic guarantee for project reliability and overall benefit. 800-4002 proves that a quality sensor itself is productivity.