Pressure Sensors

Pressure sensors are available in multiple technologies designed for different operating conditions, media types and performance requirements. The correct sensor is usually determined by application-specific engineering factors rather than pressure range alone.

Common industrial pressure sensor technologies include:

• Piezoresistive pressure sensors
• Thin film pressure sensors
• Silicon-on-Sapphire pressure sensors
• Bonded foil strain gauge pressure sensors
• Piezoelectric pressure sensors
• Capacitive pressure sensors

Engineering considerations when selecting a pressure sensor include:

• Operating temperature
• Pressure cycling frequency
• Corrosive media exposure
• Ingress protection requirements
• Signal output compatibility
• Response time requirements
• Long-term calibration stability

For example, piezoelectric pressure sensors are ideal for dynamic pressure measurements and vibration monitoring, while Silicon-on-Sapphire sensors provide excellent thermal stability for aerospace and high-temperature applications.

Pressure sensors start with the sensitive element that will convert the pressure of a gas or liquid into an electrical signal. The easiest way to understand this principle is to consider them as strain gauges. There are many technologies of pressure sensing elements, each has a unique feature which offers a better solution for the application. Piezo resistive technology example is great for volume applications, gas measurement, barometrics or flow measurements; however for liquids there are some compromises to be made. For liquids, it is very common to have a diaphragm to isolate the pressure sensing element which in itself presents challenges with diaphragm materials, sensing technology, calibration, size, accuracy etc.

There are several outputs available for Pressure Sensors. The most common by far is an amplified output (referred to as analogue output) such as 4-20mA, 0-5 V, 0-10 VDC for example. Digital outputs such as SDI, I2C, RS-485 or RS-232 are available as an option on most Pressure sensor families however reduce the frequency response, but would increase the user flexibility and accuracy of the sensor. On some Pressure sensors, mV output is available which delivers an excellent frequency response but may need some signal conditioning.

Pressure Sensor:

A pressure sensor is a device that measures the pressure of a fluid or gas and converts it into an electrical signal. It is designed to detect changes in pressure and provide an output that corresponds to the measured pressure. Pressure sensors can be based on various principles, such as piezoresistive, capacitive, or piezoelectric, and they are often used in a wide range of applications, including industrial processes, automotive systems, medical devices, and consumer electronics.

Pressure Transmitter:

A pressure transmitter is a type of pressure sensor that is specifically designed to provide a continuous and proportional output signal, typically in the form of a 4-20 mA current loop or a digital signal. It measures the pressure and converts it into an electrical signal that can be transmitted over long distances without significant loss or interference. Pressure transmitters are commonly used in industrial applications where precise pressure measurement and transmission are required, such as in process control systems and automation.

Pressure Transducer:

The term "pressure transducer" is commonly used interchangeably with "pressure sensor" or "pressure transmitter." In general, a pressure transducer refers to a device that senses pressure and converts it into an electrical signal however is not amplified, such as a mV output. So, both pressure sensors and pressure transmitters can be considered as types of pressure transducers.

Engineers typically evaluate pressure sensors based on:

• Pressure range
• Operating temperature
• Media compatibility
• Required output signal
• Accuracy and stability
• Environmental protection
• Response time
• Installation constraints

Selecting the correct sensing technology is essential for ensuring measurement stability, operational safety and long-term reliability.

The best position sensor depends on your application's measurement range, required accuracy, operating environment, and output signal. For example:

• Linear Potentiometers provide accurate linear displacement measurement for machinery and test systems.
• Rotary Potentiometers measure angular movement and shaft position.
• String Potentiometers (Draw Wire Sensors) are ideal for long-stroke displacement measurements where installation space is limited.
• LVDTs offer highly accurate, frictionless linear measurement with excellent repeatability and long service life.
• Inclinometers measure tilt, slope, or angular orientation using gravity as a reference.

If you're unsure which technology is best for your application, our technical team can help you select the most suitable sensor based on your measurement requirements and operating conditions.

Selecting the right position sensor depends on several factors, including the required measurement range, accuracy, operating environment, mounting arrangement, and electrical output. Consider whether you need to measure linear or rotary movement, whether contact or non-contact sensing is preferred, and whether the application requires analogue or digital output signals. Environmental factors such as vibration, moisture, temperature, and dust should also be considered to ensure reliable long-term performance. If you are unsure which sensor is best suited to your application, the StrainSense technical team can provide guidance.

Position sensors are used wherever accurate movement or displacement measurement is required. Common applications include industrial automation, hydraulic cylinders, factory machinery, robotics, automotive testing, aerospace systems, construction equipment, medical devices, material handling equipment, and research and development. They are commonly used for position feedback, motion control, machine safety, quality inspection, and process monitoring where precision and reliability are essential.

Yes. Many position sensors are designed specifically for demanding industrial environments. Depending on the model, they may feature sealed housings, anti-vibration mounting, corrosion-resistant materials, high-temperature components, and high ingress protection (IP) ratings to protect against dust and moisture. Selecting a sensor with the appropriate environmental protection helps ensure accurate measurements, reliable operation, and a long service life, even in challenging operating conditions.

There are several types of position sensors, each designed for different measurement requirements. The most common types include:

• Linear Potentiometers – Used to measure linear displacement with reliable, cost-effective performance in industrial and automation applications.
• Rotary Potentiometers – Measure angular position or shaft rotation, making them suitable for rotary motion and control systems.
• String Potentiometers (Draw Wire Sensors or String Pots) – Ideal for long-range linear displacement measurement where installation space is limited.
• LVDTs (Linear Variable Differential Transformers) – Provide highly accurate, frictionless, non-contact linear position measurement with excellent repeatability and long service life.
• Inclinometers – Measure tilt, slope, or angular orientation using gravity as a reference, making them ideal for monitoring equipment positioning and stability.

The most suitable position sensor depends on factors such as the required measurement range, accuracy, operating environment, installation constraints, and the type of output needed for your application.