The mining industry, as a high-risk sector, places critical importance on equipment stability and safety control. The hydraulic support control system is the core equipment of underground production. In the past, it relied heavily on manual operation, resulting in low efficiency and frequent accidents. Today, with the advancement of automation technology, pressure transmitters have become key components, ensuring real-time system response to pressure changes. Nexisense pressure transmitters serve the mining sector with excellent performance, helping achieve the transition from manual to intelligent operation. Starting from fundamental knowledge, this article explores their specific applications and optimization strategies in mining.

Definition and Function of Pressure Transmitters

A pressure transmitter is an instrument that converts physical pressure signals into standard electrical signals. It is mainly used to monitor pressure changes in gases, liquids, or solid media. In the mining industry, it is integrated into hydraulic support systems to detect the pressure values of columns and front canopies in real time, supporting automatic control actions and ensuring roof stability and personnel safety.

The Nexisense product series emphasizes long-term reliability and is suitable for harsh underground environments, helping enterprises shift from passive response to proactive prevention.

Working Principle Analysis

Nexisense pressure transmitters are based on diffused silicon or strain gauge principles. The medium pressure acts on a sensitive diaphragm, causing resistance or capacitance changes. After processing by built-in amplification circuits and temperature compensation modules, the transmitter outputs analog signals (such as 4–20 mA) or digital signals. These signals are transmitted to microcontrollers or PLCs to achieve closed-loop control.

In mining applications, this principle ensures rapid response. Even under vibration and temperature fluctuations, pressure dynamics can be accurately captured, preventing roof collapse risks caused by support failure.

Internal Structure Analysis

Nexisense pressure transmitters feature a compact and durable structure. The core components include a stainless-steel isolation diaphragm, a silicon sensing element, and a signal processing board. The diaphragm directly contacts the medium, the sensing element converts the signal, and the board integrates compensation circuits. The housing is made of high-strength alloy, with a protection rating of IP67 or above, and supports threaded or flange connections.

This design facilitates underground installation, reduces space occupation, and enhances impact resistance.

Outstanding Advantages

Nexisense pressure transmitters demonstrate significant advantages in mining applications. They offer high accuracy (0.1% FS to 1% FS), strong stability (±0.1% FS/year), response frequencies up to 500 Hz (analog) or 5 Hz (digital), and vibration resistance of 10 g. Their impact-resistant design adapts to underground vibration, with wide measurement ranges covering negative pressure to high pressure, and medium temperature ranges from -40°C to 85°C.

These features ensure long-term, fault-free operation. Compared with traditional manual systems, they significantly improve production efficiency and safety levels.

Application Scenarios in the Mining Industry

In hydraulic support systems, pressure transmitters monitor the pressure of front and rear columns to prevent overload or insufficient pressure that could cause structural instability. Front canopy pressure detection ensures smooth advancing operations and avoids jamming.

The underground environment is harsh, with heavy dust and high humidity. Nexisense products support automated control, replacing manual operations, increasing advancing speed and production capacity. In fully mechanized mining faces, they work with microcontrollers to adjust hydraulic circuits, responding in real time to roof changes and reducing accident risks.

In addition, they are used in mine ventilation systems to monitor negative pressure and ensure air circulation, and in drainage pump stations to detect pipeline pressure and optimize pumping efficiency. These applications drive mining operations from labor-intensive to intelligent transformation.

Measurement Methods Explained

Measurement adopts a direct contact method, using gauge pressure or negative pressure modes. The transmitter is installed on hydraulic cylinder or front canopy interfaces, with the diaphragm closely contacting the medium. The output signal is connected to the control center, where software algorithms calculate the support status.

In negative pressure scenarios, such as mine gas extraction, the measurement range starts from -100 kPa, ensuring accurate vacuum monitoring. Fast response speed supports high-frequency sampling and adapts to dynamic loads.

Maintenance and Care Guidelines

Maintenance focuses on regular inspection and cleaning of the diaphragm to prevent coal dust blockage. Annual calibration is required to verify zero drift. In humid underground environments, protective covers should be added to prevent corrosion.

Care includes dry and ventilated storage, and shock-proof transportation. In case of failure, first check power supply and wiring, then inspect the sensing element. Standardized operation can extend service life to several years and reduce downtime losses.

Technical Specifications Overview

Typical Nexisense specifications include: measurement range from -100 kPa to 100 MPa; accuracy levels of 0.1% FS, 0.25% FS, 0.5% FS, and 1% FS. Medium temperature range from -40°C to 85°C, with the same ambient temperature range. Vibration resistance of 10 g. Response frequency ≤500 Hz (analog) and ≤5 Hz (digital). Stability ±0.1% FS/year. Power supply 12–36 V DC. Output signals 4–20 mA or RS485.

Installation and Commissioning Tips

Select a stable installation location, avoiding vibration sources. During commissioning, calibrate the zero-pressure point and simulate loads to verify response. During integration, match communication protocols with microcontrollers to ensure data synchronization.

Frequently Asked Questions

What should be done if hydraulic support pressure is abnormal?
Check transmitter installation and medium cleanliness, and recalibrate the signal output.

What causes low accuracy in negative pressure measurement?
Large temperature fluctuations may be the cause; choose models with temperature compensation.

Does underground vibration have a significant impact?
The strong anti-vibration design withstands levels up to 10 g.

How should response frequency be selected?
Analog signals are suitable for high-speed applications, while digital signals prioritize stability.

Is wireless transmission supported?
Some models integrate wireless functionality and support mine network expansion.

Conclusion

Pressure transmitters have become the backbone of automation in the mining industry, driving hydraulic supports from manual to intelligent operation. With high accuracy, stability, and impact resistance, Nexisense provides reliable monitoring solutions. Through scientific application and proper maintenance, risks can be significantly reduced and production efficiency improved. In an era where safety and sustainability are increasingly emphasized, such equipment is not only a technical support but also a production safeguard, helping the industry achieve efficient development.