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Detailed Comparison Between Nexisense Pressure Sensors and Pressure Gauges: Selection Guide and Application Analysis
In industrial process control and equipment monitoring, pressure measurement instruments are critical. Pressure sensors and pressure gauges, as two common tools, are often confused, yet they exhibit significant differences in functionality, application, and performance. The Nexisense pressure sensor series focuses on digitalization and remote transmission, making it suitable for modern automation systems. This article compares the two from multiple dimensions to help you understand their differences and make informed choices.
Definition and Role of Pressure Sensors
A pressure sensor is a device that converts pressure signals into standard electrical signals. It is primarily used to transmit physical pressure to electronic devices for display and processing within computers or control systems. It supports remote monitoring, data logging, and automatic regulation, making it a key component of industrial automation.
Nexisense pressure sensors adopt advanced pressure-sensitive technologies to provide highly stable output, suitable for continuous monitoring in complex environments.
Definition and Role of Pressure Gauges
A pressure gauge is a mechanical instrument that uses elastic elements (such as Bourdon tubes) as sensitive components to directly measure and locally indicate pressure values above ambient pressure. It requires no external power supply, features a simple structure, and is suitable for quick on-site readings.
Traditional pressure gauges are mostly pointer-type or digital display types, emphasizing intuitiveness and independence.
Comparison of Working Principles
Pressure sensors are based on piezoresistive, capacitive, or strain effects. When pressure acts on the diaphragm, it generates changes in electrical signals, which are amplified and converted into standard outputs such as 4–20 mA, supporting remote transmission and system integration.
Pressure gauges rely on mechanical deformation. Pressure causes elastic elements to bend, driving a pointer or digital display to directly reflect the value. This purely mechanical principle requires no power but is more susceptible to vibration and temperature influences.
Internal Structure Analysis
The structure of Nexisense pressure sensors includes a sensitive diaphragm, signal processing circuitry, and a stainless-steel housing. The diaphragm isolates the medium, while the circuitry provides temperature compensation and linearization. The terminal box supports cable connections.
The core of a pressure gauge is a Bourdon tube or diaphragm capsule, with a linkage mechanism driving the pointer. The overall structure is integrated, with no electronic components, offering simplicity and durability.
Key Differences Analysis
Power Supply and Display Methods
Pressure sensors require external power supply (typically 12–36 V DC) and output current or voltage signals. They can be displayed locally or remotely and are compatible with data acquisition systems.
Pressure gauges require no power supply and provide only local display. Readings are intuitive but cannot be transmitted remotely.
Accuracy and Stability
Pressure sensors offer high accuracy (±0.1%–0.5% FS), strong resistance to interference, overload, and shock, with minimal temperature drift and excellent long-term stability.
Pressure gauges have lower accuracy (typically ±1%–2.5%) and are more affected by environmental factors, with potential drift during long-term use.
Connection and Installation
Pressure sensors require wiring to backend equipment and support various interfaces such as threaded and flanged connections, facilitating integration into automation systems.
Pressure gauges are installed directly via threaded connections, offering simple installation without wiring.
Distinct Advantages
The main advantages of pressure sensors lie in remote monitoring, signal output, and system integration, making them suitable for digital transformation. Nexisense products further enhance corrosion resistance and response speed, ideal for precision control.
The advantages of pressure gauges include strong independence, low cost, and minimal maintenance, making them suitable for simple on-site observation.
Diverse Application Scenarios
Pressure sensors are widely used in chemical pipelines, hydraulic systems, compressors, HVAC refrigeration, and automated production lines, supporting real-time data analysis and alarm functions.
Pressure gauges are commonly found in boilers, pump stations, and mechanical equipment for local monitoring, suitable for traditional scenarios without remote requirements.
Measurement Methods and Selection Recommendations
Pressure sensors output standard signals (such as 4–20 mA) and connect to display instruments or PLCs to calculate pressure values, supporting gauge pressure, absolute pressure, and differential pressure measurements.
Pressure gauges provide direct readings without conversion. During selection, choose pressure sensors for automation needs, and pressure gauges for simple on-site viewing.
Maintenance and Care Guidelines
Pressure sensor maintenance includes regular calibration, inspection of wiring, and cleaning of diaphragms, while avoiding overpressure. Nexisense products integrate protective features to extend service life.
Pressure gauge maintenance focuses on vibration resistance and corrosion protection, with regular verification of pointer zero position. Annual inspection is recommended for both.
Technical Parameters Overview
| Instrument Type | Technical Parameters |
|---|---|
| Nexisense Pressure Sensor | Range -0.1 MPa to 100 MPa, Accuracy ±0.25% FS, Output 4–20 mA / RS485, Protection IP65–IP68 |
| Pressure Gauge | Range 0–60 MPa, Accuracy ±1.6%, Mechanical display, No output signal |
Frequently Asked Questions
Can pressure sensors replace pressure gauges?
They can with an added display module, but at a higher cost.
Why do pressure sensors have higher accuracy?
Electronic compensation and advanced materials significantly reduce errors.
Are pressure gauges suitable for remote monitoring?
No, they do not provide signal output.
Which is more durable under overload conditions?
Pressure sensors generally offer stronger overload capability, typically 150%–200%.
What should be noted when installing pressure sensors?
Ensure proper grounding and keep away from interference sources.
Conclusion
Although pressure sensors and pressure gauges are both pressure measurement tools, the former focuses on digital transmission and system integration, while the latter emphasizes independent local display. Nexisense pressure sensors represent the modern trend in measurement technology, offering higher accuracy and flexibility. By understanding these differences, you can select the appropriate instrument based on actual needs and drive equipment monitoring toward intelligent development. In today’s industrial environment, where efficiency and safety are increasingly important, making the right choice brings significant operational optimization and cost control benefits.
