Many industrial applications rely on pressure sensors to efficiently and safely operate and maintain equipment. If the pressure sensor malfunctions, it may cause the entire control system to malfunction, leading to equipment failure or system shutdown; Depending on the type of system, it may cause significant damage to the equipment and surrounding environment. For systems experiencing periodic pressure peaks, if the sensor selection process considers overpressure elasticity, it is usually possible to prevent damage caused by pressure sensor failures.

Why does the sensor fail?

Pressure sensors may fail for various reasons. One of the most common causes of malfunctions is overpressure. Most standard industrial sensors are based on strain gauges or piezoresistive sensing and cannot withstand overvoltage, especially in the low voltage operating range. Strain gauge based sensors typically have limited 3X FS overpressure ratings. Piezoresistive MEMS sensors are usually even lower, with only a 2X FS withstand voltage level.

使用标准压力传感器避免过压损坏往往意味着选择比预期更高的压力范围。这会严重影响准确性和可用的模拟输出。这方面的一个例子是选择 5,000 PSIG 范围来抵抗超压损坏，而不是需要 100 PSIG 来监测水压。

What is overpressure?

Overpressure is the maximum pressure that a sensor can withstand without affecting its performance. When the pressure value exceeds this limit, the sensor will experience overpressure. The pressure sensor can withstand occasional pressure peaks, up to its overpressure level; Although this is not ideal, the transducer will eventually return to its normal state. The causes of overpressure include hydraulic hammer, unexpected heating of the system, water freezing, and pressure regulator failure.

Burst pressure can permanently damage the sensor. Burst pressure is the maximum pressure that can be applied to the positive pressure port without physically damaging the internal sensing components. Experiencing burst pressure can cause the diaphragm of the sensor to rupture and cause leakage. When the sensor is subjected to pressure higher than the overpressure rating but lower than the burst pressure, its diaphragm will permanently deform, causing output offset, thereby affecting operational performance and reading accuracy.

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