High Temperature Melt Pressure Sensor/Transmitter PT123

High-Temperature Melt Pressure Sensors/Transmitters

High-temperature melt pressure sensors/transmitters are industrial measurement devices designed for high-temperature, high-pressure, high-viscosity, and corrosive medium working conditions. They core function is to continuously monitor pressure parameters of melts (e.g., plastics, rubber, molten metals, chemical fiber raw materials), providing critical data support for process control, quality stability, and equipment safety. Widely used in rubber/plastic, metallurgical, and chemical fiber industries, they play a key role in production.

1. Core Features And Functions

1) Adaptability to Extreme Working Conditions (Core Feature)

• High-Temperature Resistance: With a wide operating temperature range and high-temperature-resistant materials, they directly contact high-temperature melts without damage.
• High-Pressure Resistance and Viscosity Resistance: Covering a broad measurement range, they withstand impact pressure from melt flow. Optimized probe structures (e.g., flush diaphragm, wedge-shaped diaphragm designs) prevent adhesion/clogging by high-viscosity melts, reducing measurement errors.
• Corrosion and Interference Resistance: Medium-contacting parts use corrosion-resistant alloys or ceramic coatings to resist erosion by acidic/alkaline or organic solvent-based melts. Built-in electromagnetic shielding modules counter grid interference and vibration interference (suitable for high-frequency vibrations in extruders, injection molding machines).

2) Precise Measurement And Stable Output

• High Precision and Repeatability: Measurement accuracy reaches ±0.1%FS–±0.25%FS, linearity ≤±0.2%FS, and repeatability ≤±0.1%FS, ensuring data consistency to meet precision production needs.
• Temperature Compensation Function: Built-in multi-point temperature compensation algorithms offset temperature drift under high-temperature environments, maintaining stable data across wide temperature ranges.
• Flexible Output Signals: Supports industrial standard signals, including analog signals (4-20mA, 0-10V, 0-5V) and digital signals (HART, RS485-Modbus, Profibus). Directly connectable to PLCs, DCS systems, and industrial computers for easy automation integration.

3) Structural And Installation Advantages

• Integrated/Modular Design: Compact size with customizable probe lengths (adapting to different equipment barrel/die depths). Flexible installation methods (threaded installation: M14/M18/M22; flange installation; clamp installation) require no complex equipment modifications.
• Overload and Explosion Protection: Equipped with 150%–200%FS overload protection to prevent damage from sudden pressure changes. Some models comply with Ex d II CT4 explosion-proof standards, suitable for flammable/explosive melt processing scenarios (e.g., solvent-based rubber production).

4) Additional Functions (Some High-End Models)

• Real-Time Display: Built-in LCD/LED display head for direct pressure reading without relying on control systems.
• Alarm Output: Set pressure threshold limits; triggers switch alarms (e.g., relay output) when exceeded, linking to equipment shutdown or adjustment.
• Remote Calibration: Supports HART protocol remote calibration, eliminating the need for sensor disassembly and reducing maintenance difficulty.

2. Core Industry Pain Points Addressed

In high-temperature melt working conditions, traditional pressure sensors (e.g., common strain-gauge sensors, ceramic sensors) suffer from "inability to withstand high temperatures, easy clogging, precision drift, and short service life." This product specifically resolves the following issues:

• Operational Condition Adaptation: Solves burnout and aging of traditional sensors due to insufficient high-temperature resistance, adapting to high-temperature environments like extruder dies, injection molding machine barrels, and molten steel pipelines.
• Measurement Precision: Addresses "data drift and large errors" caused by high-viscosity melt adhesion and pressure fluctuations, ensuring uniform product thickness (e.g., plastic films, pipes) and consistent density (e.g., rubber products).
• Equipment Safety: Monitors melt pressure in real time to prevent equipment overflow, die explosion, or pipeline leakage from excessive pressure, and material transport blockages or product shortages from low pressure.
• Maintenance Costs: Corrosion and clogging resistance reduce frequent disassembly, cleaning, and replacement of sensors, lowering downtime and maintenance costs (traditional sensors may require 1–2 monthly maintenance sessions; this product extends intervals to 3–12 months).
• Automation Integration: Standardized signal output is compatible with existing industrial control systems, resolving incompatibility issues of traditional sensors and supporting automated production upgrades.

3. User Experience Highlights

• Convenient Installation: Multiple installation methods fit different equipment interfaces. Installed and debugged in 10–30 minutes with no complex tools. Flush probe design prevents melt residue for easy subsequent cleaning.
• Stable and Reliable: Mean Time Between Failures (MTBF) ≥20,000 hours. Minimal data fluctuation (≤±0.1%FS/year) reduces frequent calibration and adjustment.
• User-Friendly Operation: Analog signals are plug-and-play; digital signals support remote parameter configuration. Models with display heads allow on-site reading without connecting to computers or control cabinets, facilitating inspections.
• Strong Compatibility: Compatible with mainstream PLCs (Siemens, Mitsubishi, Rockwell) and DCS systems, eliminating the need for additional signal converters and reducing integration costs.
• Outstanding Durability: Overload protection, vibration resistance, and corrosion resistance extend service life, maintaining stable performance under harsh conditions and reducing replacement costs.

4. Typical Application Scenarios

1) Rubber And Plastic Industry (Core Application)

• Extruders: Monitor melt pressure in dies or barrels during PE/PVC/PP pipe extrusion, plastic film blowing, and rubber seal extrusion to control extrusion speed and product thickness.
• Injection Molding Machines: Monitor barrel/nozzle pressure during injection molding to prevent product defects (e.g., shortages, burrs, sink marks) and ensure precision of injection-molded parts.
• Vulcanizers: Control pressure during rubber product vulcanization to ensure uniform vulcanization and enhance product strength/elasticity.

2) Chemical Fiber Industry

• Spinning Machines: Monitor melt pressure at spinnerets during polyester, nylon, and spandex spinning to control filament diameter uniformity and avoid breakage or fuzz.
• PET Melt Transportation: Monitor pressure in PET melt pipelines to ensure stable delivery to spinning components.

3) Metallurgical Industry

• High-Temperature Molten Metals: Monitor pressure in molten steel/aluminum/copper transport pipelines and casting molds to prevent melt overflow or insufficient casting.
• Refractory Material Molding: Control pressure in ceramic slurry and glass melt molding equipment to ensure uniform product density.

4) Food And Pharmaceutical Industries

• High-Temperature Food Processing: Monitor pressure during boiling and transportation of high-temperature melts (e.g., chocolate, syrup, jam) to ensure production safety and product texture.
• Pharmaceutical Excipient Processing: Control pressure of molten pharmaceutical resins and suppository bases, complying with GMP standards.

5) Other Special Scenarios

• Reactors: Monitor medium pressure in high-temperature, high-pressure reactors (e.g., chemical synthesis, polymer material polymerization).
• High-Temperature Coatings/Adhesives: Control transportation pressure of molten coatings and adhesives to ensure uniform application.

Summary

The core value of high-temperature melt pressure sensors/transmitters lies in "precise and stable measurement under extreme working conditions." By addressing pressure monitoring challenges in high-temperature, high-pressure, and high-viscosity media, they not only ensure production safety but also enhance product consistency. As key equipment for automated and intelligent production in rubber/plastic, chemical fiber, and metallurgical industries, their flexible installation, strong compatibility, and long service life reduce comprehensive usage costs and boost production efficiency.（来自飞书知识问答｜https://ask.feishu.cn）