Improving Safety in Fluid Power Systems

As fluid power systems become more automated, pressure instrumentation must do more than provide accurate measurements. Many safety-critical applications now require redundant pressure signals that enable continuous system monitoring, fault detection, and compliance with evolving functional safety standards.

This Use Case demonstrates how a customized pressure transducer helped a customer meet new safety requirements while maintaining reliable performance in demanding operating environments.

Customer/application

An original equipment manufacturer (OEM) was developing industrial equipment systems that required continuous pressure monitoring to safely control machine movement, maintain load stability, and protect both equipment and personnel.

The application required reliable performance under conditions such as:

• High-pressure fluid power systems operating under demanding conditions
• Constant vibration and mechanical shock
• Wide ambient temperature variations and outdoor exposure
• Electrically noisy environments requiring strong electromagnetic compatibility (EMC) protection

Challenge

While the existing pressure transducer provided accurate measurements, evolving safety requirements introduced design challenges that conventional instrumentation could not address.

To support the next generation of control systems, the solution needed to:

• Generate independent pressure output signals for both continuous validation and fault detection
• Meet industry-applicable functional safety requirements
• Maintain reliable operation despite the vibration, shock, temperature extremes, and EMC exposure common in mobile equipment
• Integrate into the existing system without compromising measurement accuracy or durability

Addressing these requirements demanded more than a standard pressure transducer. The application called for a sensing solution designed specifically for redundant safety monitoring.

Engineering assessment

Evaluation of the system and control architecture confirmed that the application needed a redundant measurement strategy rather than a conventional single-output sensor. Simply duplicating the pressure signal would not deliver the diagnostic depth needed to meet the application's safety objectives.

The assessment found that:

• Additional diagnostic capability and a more robust measurement strategy was necessary.
• Standard pressure transducers could not provide the inverse signal outputs required for this level of diagnostic validation.
• Meeting the standards requires changes to both the sensor electronics and the broader system architecture.

These findings pointed to the need for a customized transducer that combined multiple outputs, robust electronics, and durable mechanical construction in a single sensor.

Solution

Based on the assessment, an Ashcroft® S1 OEM Pressure Transducer customized with dual output was developed to address the application's safety, diagnostic, and environmental requirements. Rather than modify an existing design, the team combined new electronics with a rugged mechanical platform built specifically for demanding applications.

The customized transducer addressed these requirements through several key design features:

• Signal architecture. The transducer generates multiple output signals that support enhanced system diagnostics
• Enhanced electronics. A redesigned electronics platform supports two independent outputs while preserving measurement accuracy, signal stability, and long-term reliability.
• Functional safety support. The design supports the functional safety objectives and standards required by the application.
• Rugged environmental performance. The instrument withstands vibration, mechanical shock, wide temperature swings, and demanding EMC conditions typical of fluid power systems.
• Efficient production and implementation. Localized manufacturing supported rapid development, testing, and production, and helped the customer move quickly from design validation to deployment.

Result

The customized solution helped the OEM meet its safety compliance goals while improving system performance, reliability, and diagnostic capability. Integrating multiple pressure outputs into the control system strengthened fault detection without sacrificing performance in the field.

• Stronger fault detection. Independent signals let the control system continuously verify sensor performance and catch potential issues before they affect machine operation.
• Compliance achieved. The solution delivers the level of safety compliance the application required.
• Consistent performance in the field. The robust mechanical and electronic design holds up under vibration, shock, temperature swings, and electrical interference.
• Faster time to production. Streamlined engineering, testing, and localized manufacturing helped the customer move from concept to production on schedule.

Key takeaways

Redundant pressure measurement improves system safety. Providing independent pressure outputs allows the control system to continuously validate sensor performance and catch faults before they become operational issues.

Safety requires more than accurate measurement. Meeting today's functional safety standards calls for instrumentation designed to support redundancy, diagnostics, and reliable long-term performance.

Customized electronics can solve application-specific challenges. An electronics platform enabled dual-output functionality while maintaining measurement accuracy and signal stability.

Harsh operating environments require robust sensor design. Sensors used in fluid power systems must hold up under vibration, shock, temperature extremes, and electrical interference without compromising performance.

Application-specific solutions create long-term value. Designing instrumentation around an application's safety and environmental requirements improves reliability, simplifies system integration, and prepares equipment for evolving standards.

Learn more

Developing fluid power systems for safety-critical applications requires instrumentation that delivers accurate measurement, reliable diagnostics, and dependable performance under demanding conditions.

If you're evaluating pressure transducers for mobile equipment or other functional safety applications, contact us and a product expert can help you identify the right solution for your requirements. In the meantime, download our guide to learn more about the S1 OEM Pressure Transducer and why it may be right for your application.