Which optimization scheme offers the greatest improvement in withstand voltage performance?

"Material and structural upgrades during the selection phase," which contributes more than 70% of the increase in withstand voltage, is the plan that gives the biggest gain in withstand voltage performance. It is significantly more effective than installation and maintenance optimizations.

Main reason: The manufacturing design of the sensor determines its withstand voltage. Its intrinsic withstand voltage capability cannot be altered by post-design modifications; they can only postpone attenuation.

The following is a ranking of the improvement effect, from highest to lowest:

Upgrades to the material and packaging structure (improvement rate 50%–100%): The sensor's ultimate withstand voltage is directly and significantly increased by substituting 17-4PH/Hastelloy alloy thick film sheets for regular carbon steel/thin film sheets and switching from spliced to integrated all-stainless steel welded packaging. For instance, the most important improvement plan is to directly raise the initial rated withstand voltage of 150 MPa to 200–250 MPa.

Optimized Installation Location and Buffer Structure (Improvement 15%–25%): By adding a buffer chamber and avoiding direct impact from the molten material, the immediate impact is reduced, hence reducing the real pressure load on the sensor and consequently raising the effective pressure margin. This prolongs the sensor's life and lessens fatigue damage without altering its intrinsic pressure resistance.

Upgraded Sealing Structure (10%–15% Improvement): Using high-pressure resistant sealing materials and replacing a single seal with a double seal mainly tackles seal failure, avoiding pressure failures brought on by seal failure and enhancing overall reliability.

Optimized Maintenance Process (Improvement 5%–10%): This is a maintenance-oriented optimization that only slows down the rate at which the sensor's intrinsic pressure resistance deteriorates.

Hastelloy diaphragm + integrated welded encapsulation + 1.5–2 times the pressure margin is the most economical and proven solution to the pressure resistance issue for high-pressure hot runners over 150 MPa.