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Hvorfor vælge tilpassede sensorer over standard er det foretrukne valg

Brugerdefinerede standard sensorer

Sam Drury, salgs- og marketingdirektør på Impress Sensors & Systems Ltd, forklarer, hvorfor nogle ingeniører foretrækker brugerdefinerede trykfølere over standard-off-the-shelf versioner.

A standard, off-the-shelf pressure sensor refers to one whose specification or build standard remains unchanged. The term ‘custom’ or ‘customised’ refers to a pressure sensor that is based on a standard product but whose software or hardware has been modified so that it meets a specific customer’s requirements. For example, a customised pressure sensor might be a standard unit but fitted with a special subsea connector, high temperature electronics, a modified housing, or a specific communications interface.

But with such a huge selection available, no shortage of sensor suppliers and Internet search engines that provide a fast, easy method of comparing performance, price and availability, why would an engineer choose anything other than a standard ‘off-the shelf’ pressure sensor?

The most obvious reason to choose a custom pressure sensor is that there is not a standard ‘off-the-shelf’ sensor that meets all of the customer’s requirements. In addition, contrary to popular belief, custom sensors are not necessarily just for unusual one-offs or small batches. They are often the most appropriate choice for higher volume, mainstream applications up to 10,000 pieces.

Quite simply, not every pressure sensing challenge can be solved with a standard sensor solution. If a customer’s pressure sensing application requires some kind of modification, it can often be more cost effective to outsource this to a third-party pressure sensor supplier with the necessary skills, experience and in-house engineering design services. Working from original or customer-supplied drawings, a reputable supplier can often incorporate advanced engineering techniques and field-proven mechanical design best practices to create a robust, cost-optimised solution that is fully in-house tested.

Andre grunde til at vælge en brugerdefineret sensor er slutbrugsmiljøet, som ofte kan medføre store risici for forurening, korrosion, høje temperaturer, høj vibrationer, overtryk eller forbrænding. I mere ekstreme tilfælde kan de også involvere meget brandfarlige væsker eller gasser.

In these cases, a carefully designed custom (or fully bespoke) engineered pressure sensor may be the most suitable option. Even if you think you or your end user customer’s application is unique, if you contact a reputable sensor supplier, there’s every chance their engineers have seen a similar application before.

Even if you’re lucky enough to find a standard sensor that fits a demanding specification, it is likely that such a sensor will have a mechanical form, electrical interface and functionality that has been designed for a group of applications rather than your specific one. This means you’ll be paying for hardware and functionality that you may not require. You may also need to modify the design of your host equipment to accommodate a standard unit. This means your overall unit costs may actually increase by purchasing standard off-the-shelf sensors rather than custom versions.

Nedenfor er nogle nyere eksempler på specialdesignede trykfølere fra Impress Sensors & Systems til specifikke kundeapplikationer:

Transmitter med subsea serie elektrisk forbindelse
Dette produkt var designet til at fungere i applikationer, hvor det udvendige tryk på huset og den elektriske forbindelse kunne nå så højt som 400 bar. Ved at anvende en subsea serie elektrisk forbindelse og ved hydrostatisk afprøvning af produktet for at sikre, at det opfyldte disse krav, blev der udviklet en egnet brugerdefineret trykføler.

Betonopslæmningspumpe
Denne trykføler i rustfrit stål blev designet til at måle 12-bar af betonopslæmning, der pumpes langs en udleveringslinie. I denne applikation er der mulighed for blokeringer, og tryk kan nå så højt som 200 bar. Derfor var tryksensoren specialdesignet til at modstå dette niveau af tryk uden brud. Designet med en ANSI 1500 flange og sekundær indeslutning sikrer sensortypen en robust fejlfinding. De er klassificeret til IP67 for at modstå de konkrete hældningsforhold på stedet. Sensoren er et unikt indbygget design med et specielt polyurethan beskyttelsesdæksel på membranen, som fungerer som et effektivt mekanisk filter for at sikre, at aggregaterne i betonen ikke ødelægger sensorelementet.

Remotely Operated Vehicle (ROV) – offshore
Til denne applikation blev en meget præcis trykføler specialdesignet til en OEM-producent af ROV-udstyr til geologiske undersøgelser. Størrelsesbegrænsningerne, nøjagtigheden og omkostningerne blev alle løst med et innovativt design, samtidig med at man opretholdt en meget konkurrencedygtig pris på et stadig mere konkurrencedygtigt marked.

Pumpekontrol i bygningsstyring
Der blev udviklet en tryktransducer, der behandlede vanskelighederne ved trykmåling til opretholdelse af vandtrykket i store kommercielle bygninger fra et pumpestyringssystem. Et meget bredt driftsspændingsområde, en lille nulforskydningsspecifikation og et behov for, at alle befugtede dele er WRAS-godkendte og kompatible med klor, blev opfyldt af den tilpassede tryktransducer.

Lækstyring / datalogging i brugsindustrien
The water industry is under constant pressure to reduce leaks in the water distribution system. A common method is to control the mains pressure by utilising data from portable battery-operated pressure loggers. Impress was tasked with designing a low power pressure transducer with an integral ‘quick-release’ fitting and static errors of better than 0.1%.

Lavpris PCB-monterbar tryksensor
Elektroniske dækpumpestyremaskiner i benzinstationer er et voksende marked. Impress Sensorer designet en PCB-monterbar enhed, der præcist styrer trykket indstillet af brugeren for at stoppe luftstrømmen, når det ønskede dæktryk er blevet opfyldt. Denne enhed opfylder de strengeste krav med hensyn til at være meget lave omkostninger, men nøjagtige.

Impress is an ISO 9001 accredited company, with more than 25 years’ experience in instrumentation design and manufacturing for a diverse range of applications. In addition to its standard range of pressure, level, distance and temperature instrumentation products, Impress offers a customised design service for customers that require non-standard instruments. These services are provided by a dedicated team of highly qualified professional engineers with experience of electronics, software, mechanical engineering and instrument design. 65% of all instrumentation products sold by Impress Sensors are custom designed.

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