This article was published on July 23, 2023, and updated on April 21, 2025.
Pressure transducers, such as those used in tire manufacturing and other hydraulic applications, must be designed to withstand the rigorous demands of their environments. These sensors play an important role in measuring and monitoring process pressure to ensure your systems operate safely and efficiently.
In tire manufacturing, for instance, transducers must endure high temperatures and pressures during the vulcanizing process, where the rubber is molded and hardened. Similarly, in other hydraulic applications, they must be resilient against factors like hydraulic shock, vibration, and pressure spikes, which can significantly impact their performance and longevity. Therefore, selecting the right transducer involves considering its ability to handle these challenging conditions while maintaining precision and reliability.
In my 30+ years of experience working with pressure sensors, I’ve been able to help thousands of customers ensure that they have the right transducer for the job. This article will help you understand the critical factors you should consider when selecting pressure transducers for challenging environments such as vulcanizing and other hydraulic applications that experience tough conditions.
When you are done reading, you will also see additional resources to help deepen your knowledge about pressure transducers and mistakes to avoid when selecting the right instrument for your needs.
What is vulcanizing in tire manufacturing?
Vulcanizing is the process of molding and hardening rubber with chemical treatments at a high temperature. This critical step in the tire manufacturing process ensures that you can deliver quality, reliable tires for everyday use.
A typical vulcanizer uses several hydraulic pressure systems to cure tires. These systems help power multiple parts of the machine, from molding the tire to transferring it to the next step in the manufacturing process. As raw tire rubber is molded into a shape that closely resembles its final state, a tire curing press uses the heat generated by steam along with pressure to mold the tire into its final form. For the safety of the operators, it is essential to release the steam and pressure from the vulcanizer's curing press before opening it.
Vulcanizing is a great example of a challenging hydraulic application that experiences vibration, shock and high temperatures, one where hazardous approvals may be required. There are other examples of similar hydraulic applications in industries like construction, energy and chemical manufacturing. In situations like these, it’s vital to select a transducer that meets all necessary performance standards.
Critical factors for pressure transducers used in vulcanizing and other hydraulic applications
Many factors can impact the performance of a pressure transducer in demanding applications. However, three of the most challenging are hydraulic shock, vibration, and pressure spikes or pulsations. Here's a quick look at each one.
1. Hydraulic shock
Hydraulic shock is a pressure surge caused when a fluid or gas in motion is forced to stop or change direction suddenly. These pressure surges are usually caused by external impacts on the system. This produces a very fast and large amplitude spike in pressure, sometimes four to five times the normal maximum operating pressure of the system. Due to the fast response time of most transducers (< 5 msec), these spikes can affect the performance and cycle life of the transducer.
2. Vibration
Vibration is a mechanical oscillation or noise that occurs in a system from motors, pumps, actuators, valves, hydraulic lines and other components. Hydraulic vibration is mostly a fast and low amplitude pulse that also affects the performance and cycle life of a pressure transducer. Vibration can cause wear in the mechanical components of a transducer leading to drift in the output signal of the sensor.
3. Pressure spikes
A pressure spike or pulsation, which is often referred to as water hammer, is a pressure surge caused when a fluid or gas in motion is forced to stop or change direction suddenly. Pressure spikes are usually caused by a closed valve near the transducer. This produces a very fast and large amplitude spike in pressure, usually many times the normal maximum operating pressure of the system. Since a transducer is a dead-ended device, coupled with the fast response time of most transducers (< 5 msec), these spikes can affect the performance and cycle life of the transducer.
In each of these cases, it's critical to make sure that the transducer is properly designed and located in the system to protect the sensors from these hazards.
Choosing a pressure transducer for vulcanizing and other hydraulic applications
Demanding applications like these require rugged pressure instruments built to withstand extreme and unpredictable conditions. One example is the Ashcroft® E2 Pressure Transducer, engineered with Ashcroft’s proven sensor technology to provide accurate, repeatable output with long-lasting durability. This dependable instrument ensures your hydraulic systems operate safely and perform consistently, regardless of the stress they encounter.
How the Ashcroft® E2 Pressure Transducer works
The stability and durability of the E2 can be attributed to its integrated sensing element, which uses a proprietary chemical vapor deposition (CVD) sensing technology. The result is an accurate and repeatable measurement with high reliability and performance across all mid to high-pressure applications.
Additional benefits of the E2 Pressure Transducer
- Wide temperature ranges. The CVD sensing technology means that the E2 can offer repeatability, durability and stability over a wide range of temperatures, with operating limits between -40 °F and 257 °F.
- Compatible materials. Since the sensing element is made from stainless steel it can be safely welded to an array of different pressure fittings to maintain a secure seal in your process.
- Unique external calibration process. If the offset and span of the E2 need to be adjusted, an external magnetic adjustment feature makes it easy to do. This feature is also available in the E2F Explosion-proof (flameproof) and E2S Intrinsically Safe (non-incendive) models of the E2 transducer product line.
Other hydraulic applications for Ashcroft® E2 Pressure Transducers
For vulcanizing, it's essential to choose a sensor that fulfills all the hydraulic application requirements. Other processes with stringent demands include:
- Operating heavy-duty hydraulic power equipment in extreme weather conditions
- Using load moment indicators (LMIs) and similar real-time load weighing systems for safety in major hauling applications
- Monitoring tank levels in hydraulic systems with ranges as low as 0 to 1.5 psi
The features of Ashcroft® E2 Pressure Transducers are designed to meet even the most extreme requirements of the hydraulic systems. If the appropriate pressure sensors are not used, your systems may experience errors that adversely affect the transducer's pressure readings, resulting in inaccurate measurements.
Ready to learn more about pressure transducers for hydraulics and other challenging applications?
Vulcanizing during the tire curing process is just one of several applications that can benefit from reliable, high-performance pressure sensors. Now that you have a better understanding of the factors that go into selecting the right pressure transducer, you can research to find an option that fulfills your performance needs as well as your company’s budget. Stay mindful of these factors and you’ll be able to avoid errors and keep your hydraulic systems running smoothly and accurately.
For your reference, here are a few other relevant articles for you to review:
- How Does Media Temperature Affect Pressure Transducer Performance
- How Are Pressure Transducers Affected by Hydrogen Permeation?
- How to Protect and Optimize Pressure Transducers on Mobile Hydraulics
- How Much Do Pressure Transducers Cost? (6 Factors Impacting Price)
You can also contact us to talk with one of our industry experts and get your questions answered.
In the meantime, download our guide to learn about mistakes you can avoid when selecting pressure transducers. 