A pressure transducer is a type of sensor used to measure pressure and then convert that pressure reading into a continuous voltage output. Depending on where you put it and how you connect it, a pressure transducer can tell you the pressure in a pipe or tank, the weight of an object, or even the depth of fluid above it. Most industrial pressure transducers are made of two technical parts, a transducer and a transmitter, inside a third, equally important part, the housing.
A transducer converts a physical action--often a vibration--into an electrical signal. Microphones and the pickups on an electric guitar, which both convert sound waves into electrical signals, are transducers. Pressure transducers, then, convert pressure--air pressure, fluid pressure, oil pressure, etc.--into electrical signals.
Piezoelectric pressure transducers or piezoelectric sensors are devices that use the piezoelectric effect to measure any changes in acceleration, pressure, strain, temperature or force. This type of pressure transducer sensor works by converting the energy they are measuring into an electric charge.
A notable characteristic of a piezoelectric pressure transducer sensor is when they flex. When this type of pressure transducer flexes, it produces a voltage. The voltage generated by a piezoelectric pressure transducer can even be used to power the “deflection detection” circuit (the circuit the transducer is a part of).
Piezoresistive pressure transducer sensors are one of the most common types of pressure transducer sensors. This kind of pressure transducer uses the change in electrical resistance of a material when that particular material is being stretched.
The main difference between piezoresistive and piezoelectric is that piezoresistive pressure transducers change the resistance of a circuit as they are flexed, whereas piezoelectric pressure transducers produce a voltage. Another big difference between piezoelectric and piezoresistive pressure transducers is that piezoresistive transducers need power supplied to them.
It's easy to mix the two up. A quick internet search will turn up plenty of conflicting uses and descriptions, sometimes even within a single site. Throw in more general terms, like "strain gauge," or specific configurations, such as "Wheatstone bridge," and it looks like chaos reigns. But remember, that's the internet. (Also, "Hello," from the internet!) Some careful consideration helps solve most confusion. (I did say _most_.) Strain gauge really is a more general term than either piezoelectric or piezoresistive, but is usually used as shorthand only for piezoresistive transducers. For example, some people use piezoelectric for piezoelectric transducers, and strain gauge for all others, including piezoresistive ones. A Wheatstone bridge is a specific configuration of the bridge electric circuit that is usually used on pressure transducers.
We touched on part of how a pressure transducer works above: an electrical circuit (usually a bridge) is attached to the backside of a diaphragm, a small piece of flexible material. As the pressure that the diaphragm is exposed to changes, the diaphragm flexes, changing the characteristics of the circuit. That's the transducing part of a pressure transducer. However, in order for the measurement to be of much use, it has to be transmitted somewhere: to a display, or a control system, etc. So a transmitter converts the measurement into a standardized signal--4-20 mA, Modbus, mV/V, etc.--and communicates it to whatever control or display system it is connected to.
There are some instances when it is advantageous to denote a pressure transducer as separate from a pressure transmitter, i.e., differentiating between the physical measurement and the electronic signal. In reality, neither can be used without the other. A pressure transducer sensor without a pressure transmitter generates a signal far too weak to be communicated to a controller, and a transmitter without a transducer has no message to communicate.
An integral part of how a pressure transducer works is how it is built to measure pressure. There are five main types of pressure measurement:
Some pressure transducers are used for single-point-pressure detection, i.e. as pressure switches. But most are used for continuous pressure readings, with the analog or digital output signal always indicating the current pressure reading. In fact, it's often easy to configure a control system for individual, pressure-based outputs, thus allowing a continuous output pressure transducer to generate single-point actions.
What a pressure transducer is needed to measure, and where, and the required output will do most of the determining when choosing between pressure transducers. Is a local readout for the pressure reading all that's necessary? Then a pressure gauge--a transducer and display combined into a single unit--will do the job nicely. On the other hand, line pressure on fracking rigs can only be measured safely by pressure transducers with hammer union process connections. So, as we say quite frequently around here, the application will largely determine what kind of pressure transducer one chooses. Some of the questions that need to be answered to ensure a good technology fit are:
There are so many ways and places a pressure transducer can be used. Any kind of commercial or industrial system that uses pumps needs to be able to monitor line pressure before and after those pumps; pressure transducers can do that. Pressure transducer sensors can be used to monitor the weight applied by a hydraulic ram, or even a fighter jet! The output of a pressure transducer at the bottom of a liquid-containing-vessel can be used to calculate the level of the liquid above it. Thus, submersible pressure transducers can measure the level of water in a deep well, sewage at a lift station, or even refined diesel fuel in a storage tank. Need to make sure that a pressurized system has the appropriate pressure in multiple places? Pressure transducers are the way to go. From fracking rigs to industrial process systems to water system pressure relief valves, pressure transducers provide important pressure readings to keep people and equipment safe.
Best practices for pressure transducers are going to vary a bit, depending on what kind of pressure transducer is being used in what sort of environment. Pressure transducers built for light-duty applications (i.e., indoors, low vibration, low moisture and dust) are going to need different care than hammer union transducers in an oil field. That said, installing any threaded pressure transducer is fairly easy if you follow the right procedure. And while this video is specifically for cleaning submersible pressure transducers, we hope it's obvious that touching the diaphragm on any pressure transducer is just asking for trouble. In general, the Measurement Experts here at APG suggest the following:
If you have further questions about pressure transducers, including how a pressure transducer can help your system operate more safely, let us know. Our Measurement Experts can help you find the right technology to fit your application like a glove. Give them a call or drop them an email today.
