In modern manufacturing, precision and efficiency are critical. One component that plays a key role in achieving both is the pressure sensor. These devices monitor and control pressure levels in fluids and gases, helping engineers maintain safe, consistent, and energy-efficient operations. From hydraulic systems to pneumatic controls, pressure sensors are essential for process optimisation and automation.
What is a pressure sensor?
A pressure sensor is a device that converts pressure into an electrical signal. This signal can be used for monitoring, control, or data logging. Pressure sensors come in various types, including:
- Absolute pressure sensors – measure pressure relative to a vacuum
- Gauge pressure sensors – measure pressure relative to atmospheric pressure
- Differential pressure sensors – measure the difference between two pressure points
These sensors are commonly used in applications such as pump control, leak detection, HVAC systems, and industrial automation. They help ensure that systems operate within safe and efficient pressure ranges, reducing wear and preventing failures.
Benefits of pressure sensors in manufacturing
For design engineers, integrating pressure sensors into manufacturing systems offers several key advantages:
Improved process control
Real-time pressure monitoring enables precise adjustments to maintain consistent process parameters, reducing variability and improving overall product quality.
Energy efficiency
Monitoring and maintaining optimal pressure levels reduces waste in compressed air and fluid systems, cutting energy consumption and operating cost.
Predictive maintenance
Pressure anomalies often signal wear, blockages, or leaks. Early detection allows intervention before failures escalate into costly downtime.
Safety & compliance
Pressure sensors help ensure systems operate within safe limits and provide monitoring data useful for regulatory compliance and safety reporting.
In automated environments, pressure sensors are typically linked to PLCs or SCADA systems for continuous monitoring and control - enabling smarter, faster responses and centralised data logging.
Selecting the right pressure sensor
When specifying a pressure sensor, engineers should consider:
- Pressure range and type – Match the sensor to the system’s operating conditions
- Output signal – Choose between analog (e.g., 4–20 mA) or digital (e.g., I²C, SPI) depending on the control system
- Environmental factors – Consider exposure to temperature, vibration, moisture, or corrosive substances
- Mounting and connection – Ensure compatibility with existing equipment and ease of installation
It’s also important to evaluate long-term reliability, calibration requirements, and whether the sensor supports diagnostics or fault detection.
Optimise your performance
Pressure sensors are vital tools for optimising manufacturing performance, offering real-time insights that improve control, efficiency, and safety. For design engineers, selecting the right sensor ensures systems run smoothly and reliably, supporting both productivity and compliance.
View full range
{{SessionBasket.ItemCount }}
