Pressure sensors for process monitoring must measure accurately and provide stable signals under fluctuating pressure and temperature conditions. DDM Sensors develops miniaturized pressure sensors and differential pressure sensors tailored for compact installation spaces, dynamic processes, and industrial series applications. Key focus areas include temperature-compensated measurement and analog output signals for seamless integration into control and evaluation systems.
Your Partner for Highly Integrated Pressure Measurement Technology
DDM Sensors supports technical decision-makers in selecting pressure sensors for process monitoring when installation space, signal stability, and interface requirements must align perfectly. For demanding applications, series such as the PV-10, PV-15, PV-22, PV-25, PX-22, and PX-25 are utilized engineered for restricted spatial layouts and robust signal transmission.
Depending on the series, voltage or current output options are available, including 0.5 to 4.5 VDC, 1 to 6 VDC, 0 to 10 VDC, or 4 to 20 mA. This enables smooth integration into existing automation environments for use as control, monitoring, or condition variables.
How Pressure Sensors for Process Monitoring Work
Pressure sensors in process monitoring capture applied pressure as an electrical signal for control, regulation, or condition monitoring. Critical parameters include not only the measuring range but also sensor behavior across temperature variations, load cycles, and long-term operation.
For demanding process environments, the Total Error Band (TEB) across the operating temperature range serves as a key performance metric. It accounts for non-linearity, hysteresis, zero and full-scale offset tolerances, and thermal effects. In dynamic systems, TEB offers a far more realistic performance assessment than room temperature specifications alone.
With differential pressure sensors, the system measures the pressure difference between two points rather than absolute pressure. This approach is ideal for filter monitoring, flow measurement, and condition diagnostics.
Custom Pressure Sensors for Process Monitoring
In addition to standard sensor lines, DDM Sensors develops customized pressure solutions for process monitoring. Modifications cover mechanical housing adjustments and custom fittings, as well as electrical adaptations including custom connectors, output signals, or specific signal characteristics.
Key customization areas for system integration include:
- Adapted pressure ranges for specific operating conditions
- Compact designs for tight installation envelopes
- Custom process connections matching existing thread specifications
- Analog output signals for direct PLC or control unit connection
- Temperature-compensated variants for changing ambient environments
These choices ensure sensors deliver precise pressure readings while fitting perfectly into both the mechanical and electrical architectures of your system.
Relevant Measuring Methods and Technologies
For process monitoring, DDM Sensors primarily deploys miniaturized pressure sensors and differential pressure sensors. Miniaturized sensors are ideal when mounting space is limited or when measurement points must be embedded directly into compact subassemblies. Differential pressure sensors are well-suited for applications where pressure drop across two points provides the essential diagnostic data.
Key technical characteristics include:
- Operating temperature range up to −40 °C to +150 °C on selected series
- Analog output signals such as 0.5–4.5 V, 1–6 V, 0–10 V, or 4–20 mA
- Bidirectional pressure ranges on select models
- Configurations for gauge, absolute, and differential pressure
For differential pressure monitoring, the PV2722 and PX2722 series offer tailored solutions. For compact installation environments, options like the PV22 and PX22 are ideal. When space is extremely constrained, ultra-compact series such as the PV10 and PV15 can be specified. The PV25 and PX25 series are designed for applications with stringent signal quality demands.
Application Areas
Hydraulic and Pneumatic Systems
In hydraulic and pneumatic architectures, process monitoring pressure sensors regulate, monitor, and safeguard operating pressures. Typical measurement points include suction pressure, discharge pressure, and interstage pressure ratios.
For stationary hydraulic systems, the PV25 and PX25 provide stable signals for closed-loop control. In compact or mobile machinery, the PV22 or PX22 are widely used where compact dimensions and wide temperature tolerances are required.
Filter Monitoring
Filter monitoring relies on measuring pressure drop across filter elements to assess contamination levels or cartridge loading. Differential pressure sensors are ideal for this task, as they capture the relevant differential pressure directly.
The PV2722 and PX2722 series provide a space-optimized solution with high measurement stability. Voltage and current outputs are available depending on system requirements.
Pump and Compressor Control
In pump and compressor installations, process monitoring pressure sensors play a core role in closed-loop control and system safety. They detect pressure shifts to identify overpressure, underpressure, and operational anomalies.
Robust, fully welded stainless steel constructions featuring temperature compensation are essential here. Depending on mounting space, the PV22 or PX22 can be deployed; for tighter envelopes, the PV15 or PX25 are ideal options, with 4–20 mA current loops available for enhanced signal immunity.
Plant Engineering and Machinery Construction
In plant engineering and machinery manufacturing, process monitoring pressure sensors are utilized in hydraulic axes, clamping systems, cooling and lubrication loops, as well as dosing and filling stations. Reproducible measurement results, compact footprints, and clean electrical integration are essential.
DDM Sensors assists in sizing the ideal measuring range to capture operating pressures with high resolution. The PV22 and PX22 serve standard industrial requirements, while the PV15 offers distinct advantages in extremely tight mounting spaces.
Test Bench Technology
Test bench applications demand rapid response to dynamic pressure changes, thermal stability, and reproducible measurement results. Sensors used in test environments must deliver stable performance across the full temperature envelope rather than relying solely on room-temperature ratings.
Depending on media and thermal profiles, the PV15H or PV25H series are frequently selected for test rigs. Essential attributes include a compact form factor, temperature compensation, and stable output signals for seamless data acquisition.
Process Engineering in Food and Pharmaceuticals
In the food and pharmaceutical industries, process monitoring pressure sensors monitor filtration, dosing, filling, and cleaning processes. Key requirements include corrosion-resistant materials, seal-free constructions, and reliable signal transmission.
Depending on whether fluid or gaseous media are monitored, the PV22 or PX25 offer suited options. These sensors integrate cleanly into existing control networks to support continuous pressure monitoring in sensitive production environments.
DDM Sensors as Your Partner
DDM Sensors acts as a development partner for process monitoring pressure sensors when standard products require mechanical or electrical adaptation. Beyond our standard catalog, custom configurations are available to meet specific spatial, connection, and signal requirements.
Engineering teams can collaborate closely with DDM Sensors during the design phase to select measuring ranges, optimize temperature parameters, and define output signals and process connections.
Request Technical Consultation
If you are looking for process monitoring pressure sensors for a specific machine, plant system, or test bench setup, DDM Sensors is here to support your engineering selection. Contact our technical team to discuss pressure ranges, electrical interfaces, and mounting requirements for your application.
FAQ – Pressure Sensors for Process Monitoring
Which pressure sensors are best suited for compact installation spaces in process monitoring?
For compact installation spaces, miniaturized product lines such as the PV15, PV22, or PX22 are ideal. They combine small physical dimensions with industrial-grade pressure ranges and analog output signals.
When is a differential pressure sensor recommended?
A differential pressure sensor is recommended when measuring the pressure difference between two points rather than absolute pressure. This is particularly relevant for filter monitoring, flow measurement, and system diagnostics.
Which output signals are available for process monitoring pressure sensors?
Depending on the product series, voltage and current outputs are available, including 0–5 V, 1–6 V, 0–10 V, 0.5–4.5 V, or 4–20 mA. For noisy industrial environments, 4–20 mA current loops provide optimal noise immunity.