Safeguarding Industrial Strength: Performance Tuning of Hydraulic and Pneumatic Systems with Ellenex Pressure Sensors
- Andrae Navaratne
- 3 days ago
- 3 min read
Background
Hydraulic and pneumatic systems are integral to industrial operations, providing the necessary force and control in sectors such as manufacturing, mining, and construction. These systems rely on precise pressure management to function efficiently. Variations in differential pressure can lead to energy inefficiencies, equipment wear, and system failures. Therefore, continuous and accurate monitoring of pressure differentials is essential for predictive maintenance and operational reliability.
Challenge
Implementing effective monitoring solutions in industrial environments presents several technical challenges:
Remote and Harsh Environments: Equipment is often deployed in locations with extreme temperatures, humidity, and exposure to dust or chemicals, necessitating robust and durable monitoring devices.
Power Supply Limitations: Remote sites may lack stable power sources, requiring monitoring equipment to operate on low power or battery systems.
Manual Data Collection Inefficiencies: Traditional manual monitoring methods are labor-intensive and prone to errors, making them unsuitable for near real-time system diagnostics.
System Reliability: Monitoring devices must maintain high accuracy and reliability over extended periods, even under challenging environmental conditions.
Solution
Ellenex introduced the PDS2-L: a LoRaWAN-operated low-power differential pressure transmitter, specifically designed for monitoring hydraulic and pneumatic systems in demanding environments.
Key Technical Features:
Pressure Range: Selectable between 0.1 to 25 bar, accommodating various application requirements.
Accuracy: Typical accuracy of ±0.25% of span, ensuring precise measurements.
Resolution: ±0.01% of span, allowing for detailed pressure monitoring.
Temperature Compensation: Compensated over a range of 0°C to +60°C, with temperature coefficients of zero and span at ≤±0.02% FS/°C for ranges >1 bar and ≤±0.04% FS/°C for ranges <1 bar.
Long-Term Stability: ≤0.3% of span over one year, reducing the need for frequent recalibration.
Overpressure Capability: Withstands up to 200% FS on the positive side and 100% FS on the negative side (maximum 10 bar), enhancing durability.
Pressure Cycles: Designed for over 10 million pressure cycles, ensuring longevity.
Power Supply: Operates on a built-in replaceable 3.6V lithium battery, supporting over 100,000 readings and 20,000 transmissions, equating to more than 10 years of operation for most applications.
Enclosure: Constructed with SS304 body and SS316 diaphragm, featuring an IP66-rated, UV-protected ASA/POM enclosure for durability in harsh conditions.
Process Connection: Standard G1/4 male, with other options available upon request.
Communication: Compatible with LoRaWAN® 1.0.2revB, Class A (Class C on request), supporting frequencies AS923, EU868, US902-928, and AU915-928.
Activation: Supports Over-The-Air Activation (OTAA) and Activation By Personalization (ABP).
Sampling and Transmission: Configurable sampling period via downlink (default 4 hours), with options for periodic, event-triggered, or conditional transmission.
Integration: Compatible with major LoRaWAN® networks and integratable with various IIoT platforms, including AWS, Azure, and The Things Network.
Implementation
An industrial manufacturing company integrated the Ellenex PDS2-L into its hydraulic and pneumatic systems to enhance performance monitoring and predictive maintenance capabilities.
Deployment Steps:
Sensor Installation: PDS2-L transmitters were installed at critical points within the systems, such as pump outputs and actuator inlets, to monitor pressure differentials accurately.
Network Integration: Utilizing the LoRaWAN® protocol, the transmitters connected seamlessly to the company's existing network infrastructure, enabling reliable long-distance data transmission without the need for extensive wiring.
Power Management: The ultra-low-power design of the PDS2-L ensured prolonged battery life, reducing maintenance requirements and operational downtime.
Data Integration: Transmitted data was integrated into the company's centralized monitoring system, providing near real-time access to performance metrics and facilitating timely decision-making. Results:
Enhanced Monitoring: The company achieved continuous, accurate monitoring of pressure differentials, enabling early detection of system anomalies such as filter blockages or pump inefficiencies.
Operational Efficiency: Automated data collection reduced the reliance on manual inspections, decreasing labor costs and minimizing the potential for human error.
System Reliability: Improved monitoring capabilities contributed to increased system uptime and extended equipment lifespan, even in harsh operating conditions.
Scalability: The successful integration of the PDS2-L demonstrated its scalability for broader deployment across the company's operations.
The Ellenex PDS2-L has transformed how they monitor their hydraulic and pneumatic systems. Its robust design and low power consumption have allowed them to maintain accurate, near-real-time monitoring in some of the most challenging environments. The integration with our existing LoRaWAN network was straightforward, and the data insights have been invaluable for maintaining system efficiency and reliability. This solution has been instrumental in enhancing their operational capabilities.
Conclusion
The Ellenex PDS2-L differential pressure transmitter has proven to be an essential tool for performance monitoring in hydraulic and pneumatic systems. Its deployment by the industrial manufacturing company underscores its effectiveness in overcoming key operational challenges, resulting in improved efficiency, cost savings, and enhanced system reliability. The PDS2-L ensures that industrial strength is safeguarded through precise performance tuning and reliable pressure monitoring.
