Pressure detection plays a crucial role in automation systems, serving as a key technology for monitoring, controlling, and optimizing system operations. Its functions are reflected in multiple aspects of automation systems, ensuring the stability, efficiency, and safety of system operations. The following is a detailed explanation of its role:

1. Real-time Monitoring of System Operating Status

• Core Function: Pressure detection devices (such as pressure sensors) continuously collect pressure data in real time, converting physical pressure signals into electrical signals that can be recognized by automation systems.
• Application Scenarios:
  • In industrial production lines, it monitors the pressure of pipelines, reactors, and hydraulic systems. For example, in chemical plants, real-time monitoring of pressure in reaction vessels prevents overpressure caused by excessive reactions.
  • In HVAC systems, it detects air pressure in ducts to ensure stable air supply and adjust fan speeds.
• Example: In a water supply automation system, pressure sensors monitor water pipe pressure. When water consumption increases and pressure drops, the system automatically starts a booster pump to maintain stable water pressure.

2. Providing Key Feedback for Control Systems

• Control Loop Core: In closed-loop control systems, pressure detection serves as a feedback link to form a “detection-control-execution” cycle.
• Working Principle:
  • The system compares the detected pressure value with the set target value and adjusts control parameters (e.g., valve openings, pump speeds) through a controller.
• 典型案例 (Typical Cases):
  • In hydraulic press systems, pressure sensors detect the pressure applied to workpieces and adjust oil pump output in real time to ensure precise forming of the workpiece.
  • In pneumatic control systems, pressure feedback controls the movement speed and force of pneumatic actuators (e.g., cylinders).

3. Ensuring System Safety and Preventing Accidents

• Safety Protection Mechanism: Pressure detection acts as a critical safety barrier to prevent overpressure, underpressure, or pressure fluctuations that could lead to equipment damage or safety incidents.
• Specific Applications:
  • Overpressure Protection: In boilers or gas pipelines, when pressure exceeds the safety threshold, pressure sensors trigger alarms and automatically activate pressure relief valves to prevent explosions.
  • Leakage Detection: In oil and gas pipelines, pressure drops can indicate leaks, allowing the system to promptly shut off valves and locate faults.
• Data Support: For example, in natural gas transmission networks, pressure sensors distributed along the pipeline continuously monitor pressure changes. A sudden pressure drop can quickly alert the system to potential pipeline ruptures or leaks.

4. Optimizing System Efficiency and Energy Consumption

• Energy-Saving and Efficiency-Enhancing: By accurately detecting pressure, the system can adjust operating parameters to achieve optimal energy utilization.
• Application Examples:
  • In variable-frequency water supply systems, pressure sensors adjust the motor speed of water pumps based on actual water demand, reducing energy waste compared to constant-speed operation.
  • In air compressor systems, pressure detection controls the start/stop of compressors to maintain stable air pressure while minimizing idle running.
• Data Reference: Studies show that pressure-based variable-frequency control in water supply systems can reduce energy consumption by 30%-50%.

5. Guaranteeing Product Quality and Process Consistency

• Quality Control Link: In manufacturing, precise pressure control ensures uniform product quality.
• Industrial Applications:
  • In the pharmaceutical industry, pressure detection during tablet pressing ensures consistent tablet hardness and weight.
  • In the food packaging industry, pressure control during vacuum packaging ensures the vacuum degree, extending product shelf life.
• Example: In the production of semiconductor chips, precise control of gas pressure in deposition chambers (e.g., chemical vapor deposition, CVD) is critical for the uniformity and thickness of thin films, directly affecting chip performance.

6. Enabling System Integration and Intelligent Management

• Foundation for Industrial Internet of Things (IIoT): Pressure detection data is integrated into the overall automation system, supporting big data analysis and intelligent decision-making.
• Functions:
  • Remote monitoring: Pressure data is transmitted to the cloud platform for real-time tracking of equipment status across multiple sites.
  • Predictive maintenance: Analyzing pressure trend data predicts component failures (e.g., wear in pumps or valves) before they occur, reducing downtime.
• Application Scenario: In smart factories, pressure sensors on production equipment are connected to the management system, which uses pressure fluctuations to predict potential pipeline blockages or valve failures and schedules maintenance in advance.

7. Diverse Applications in Specific Industries

Summary: The Core Value of Pressure Detection in Automation Systems

• Sensory Nerve of the System: Analogous to the human body’s sensory system, it enables the automation system to “perceive” pressure changes.
• Foundation of Intelligent Control: Provides data support for realizing precise control, safety protection, and energy efficiency optimization.
• Key to Digital Transformation: Integrates with IoT and big data technologies, promoting the development of smart factories and intelligent systems.

As sensor technology advances (e.g., miniaturized MEMS sensors, wireless pressure sensors), pressure detection will play an even more pivotal role in future automation systems, driving higher levels of intelligence and reliability in industrial processes.