How to Improve the Pressure Resistance of Vibration Sensors

Optimization in three areas-design and selection, installation procedure, and use and upkeep-can increase the pressure resistance of vibration sensors. The following are specific techniques:

1. Selection and Design Stage Optimization (Improving from the Source)

Diaphragm Selection: Prioritize 17-4PH stainless steel or Hastelloy materials when selecting thicker, high-strength alloy diaphragms. Increasing the diaphragm thickness by 0.2–0.5 mm over standard specifications can greatly increase the pressure resistance limit while maintaining sensitivity.

Encapsulation Optimization: To remove pressure-resistant weak points at splicing seams, select sensors with integrated, all-stainless steel welded encapsulation. Steer clear of splicing and fastened connections. To increase the pressure resistance at the connection point, use a double-seal structure consisting of a metal seal and PTFE filler at the wiring outlet.

Allow for Sufficient Pressure Margin: To prevent rapid aging from prolonged full-pressure operation, choose a sensor whose rated pressure resistance is 1.5–2 times higher than the actual maximum working pressure.

2. Optimization of the Installation Process (Preventing Installation Errors that Lower Pressure Resistance)

Sealing Matching: To ensure long-term sealing at the installation site, use PTFE or high-pressure, high-temperature resistant metal gaskets instead of regular rubber ones.

Compliant Installation Torque: Adhere to the torque specified by the manufacturer when tightening the sensor. Steer clear of excessive torque that could harm the diaphragm or housing and insufficient torque that could cause leakage at the sealing surface.

Vibration-Averse Installation Site: Prevent the molten material from striking the flow channel directly. To lessen direct effect from the high-pressure molten material and delay the aging of pressure resistance, place the sensor on the side of the flow channel.

3. Optimal Utilization and Upkeep (Postponing Decline in Pressure Resistance Performance)

Prevent Frequent Overpressure Operation: To lessen fatigue damage to the diaphragm brought on by alternating high pressure, avoid exceeding the rated operating pressure for prolonged periods of time during production.

Frequent Disassembly and Inspection: Every three to six months during production, disassemble and examine the diaphragm and seals. To stop minor flaws from leading to pressure resistance failure, replace any deformed seals or diaphragm pitting corrosion as soon as possible.

Clean Molten Material Crystals: To avoid agglomeration that raises local pressure load and decreases pressure resistance margin, clean any remaining molten material crystals from the sensor diaphragm surface on a regular basis.

Note: After leaving the manufacturer, the withstand voltage performance of sensors that are already completed products is essentially fixed. Optimizing installation and maintenance is the only way to slow down the decrease; it cannot be greatly reversed. The optimization of the design during the selection phase still determines the improvement in core withstand voltage.