Six Key Factors to Watch to Prevent Pressure Sensor Issues

As core sensing elements in industrial systems, pressure sensors accurately convert mechanical pressure into electrical signals, widely used in hydraulics, automotive, medical, and manufacturing fields. However, even high-quality sensors can drift, fail, or suffer permanent damage if exposed to adverse conditions during storage, assembly, or operation. Industry data shows that extreme temperature, overpressure, and EMI/RFI account for more than 60% of sensor failures. Timely identification and mitigation of these risks not only extends sensor life but also significantly reduces system downtime and maintenance costs. Nexisense's product lines offer built-in protection for these factors through optimized designs such as high overpressure protection and integrated filtering. This article analyzes each of the six key factors and shares practical prevention measures.

Temperature: The Hidden Threat and How to Address It

Excessive or rapid temperature changes are the most common causes of pressure sensor failure. Internal components like diaphragms, strain gauges, and circuits function properly only within specified temperature ranges (e.g., -40°C to 125°C). Exceeding these limits can cause uneven thermal expansion, material fatigue, or zero-point drift.

For example, mounting a sensor near a steam pipe can quickly degrade dynamic performance and distort output signals. Simple solutions include relocating the sensor away from heat sources or adding buffer pipes/coolers. For steam measurements, pre-cooling the buffer pipe with water prevents direct impact from high-temperature media.

Nexisense's diffused silicon and ceramic sensors feature built-in temperature compensation circuits, maintaining 0.1%FS accuracy across wide temperature ranges. In industrial applications, this design has helped reduce temperature-related failures by over 30%.

Voltage Spikes: The Hidden Threat of Transient High Voltage

Voltage spikes are brief, high-energy surges, often lasting only milliseconds, but enough to damage internal sensor circuits. Sources include lightning, motor startups, or power fluctuations. They are hard to detect but destructive.

OEM engineers should evaluate potential risks in the manufacturing environment and communicate with suppliers to identify sources early. Nexisense sensors use transient suppression diodes and filter networks to provide built-in protection. Selecting surge-protected products during design effectively mitigates these issues.

Fluorescent Lighting: Unexpected Interference from High Voltage Starts

Fluorescent lamps require high-voltage arcs to ignite, generating transient voltage spikes and magnetic fields that may couple to sensor wiring, causing the control system to misinterpret noise as valid signals.

Prevention is simple: avoid placing sensors directly under or near fluorescent lamps. Switching to LED lighting or maintaining sufficient distance eliminates the risk. Though seemingly minor, this factor is common in older factories.

EMI/RFI: The Ongoing Challenge of Electromagnetic Interference

Pressure sensors convert pressure into electrical signals and are inherently susceptible to electromagnetic radiation. Common sources include contactors, power lines, computers, radios, phones, and high-power machinery producing fluctuating magnetic fields.

Manufacturers implement internal protection, but best practices require external measures: shielded cables, filters, suppressors; avoid parallel runs with power lines; single-point grounding of shields to prevent ground loops. Shielding reflects and absorbs electromagnetic waves for effective attenuation.

Nexisense industrial sensors support shielded enclosures and twisted-pair wiring, maintaining signal integrity in high-EMI environments. Testing shows these measures reduce noise by over 20 dB.

Shock and Vibration: Accumulated Mechanical Stress

Shock and vibration can cause housing dents, broken wires, PCB cracks, signal errors, or reduced lifespan. Mounting near vibration sources accelerates these issues.

Prevention includes positioning sensors away from vibration sources and using isolation mounts or shock absorbers. Nexisense sensors feature robust enclosures and vibration-damping structures, supporting high-g shocks. In heavy machinery, this significantly enhances reliability.

Overpressure: The Fatal Test of System Limits

Overpressure is the most direct destructive factor for sensors, including water hammer, accidental heating, or regulator failure. Occasional pressure up to the proof pressure may be recoverable, but exceeding burst pressure can permanently deform or rupture diaphragms.

Design requires full understanding of system dynamics: interactions between pumps, valves, and tanks. Use high overpressure sensors (e.g., 10x FS), or add snubbers, relief valves, and buffers. Nexisense patented overpressure stop technology ensures diaphragm integrity under extreme conditions.

FAQ

What are the most common causes of pressure sensor failure?
Extreme temperature, overpressure, and EMI/RFI interference dominate. Prevention focuses on environmental assessment and proper installation.

How to protect against EMI/RFI?
Use shielded cables, filters, single-point grounding, and maintain distance from interference sources.

Practical overpressure protection methods?
Select high proof-pressure sensors, add snubbers or relief valves, consider system dynamics in design.

How do Nexisense sensors perform against these factors?
They include temperature compensation, surge protection, and overpressure stops, providing comprehensive reliability.

What installation factors are often overlooked?
Distance from vibration sources and fluorescent lighting placement—simple adjustments can prevent issues.

Conclusion

The six key factors to prevent pressure sensor issues—temperature, voltage spikes, fluorescent lighting, EMI/RFI, shock and vibration, and overpressure—may seem separate, but collectively determine sensor reliability and system stability. Through upfront design assessment, correct installation, and high-quality product selection, these risks can be greatly mitigated. Nexisense is committed to providing high-performance, interference-resistant, overpressure-safe sensors to help industrial customers achieve longer life and lower maintenance operation. In the fast-evolving smart manufacturing era, attention to these details is the key to efficient and sustainable development.