Is Your Current System Costing You $40,000?

Title: Is Your Current System Costing You $40,000?

$40,000 in Scrap: How a Faulty Sensor Hid the Real Problem

Our 2000-ton hydraulic press was cycling slower than expected. The analog gauge showed a steady 1800 bar, but every batch of stamped parts was out of spec. Initially, we suspected mechanical wear or hydraulic fluid issues. However, after weeks of troubleshooting, we traced the problem to a faulty pressure sensor that couldn’t handle the extreme pressures and temperatures involved. Consequently, scrap rates climbed to 5%, costing us $40,000 annually in lost production.

What SCADA Didn’t Tell Us About Pressure Spikes

Analog Bourdon tubes physically twist at their elastic limit near 2500 bar, causing permanent deformation and calibration drift. In fact, this mechanical fatigue leads to false readings that hide transient pressure spikes. Thin-film strain gauge technology measures pressure electronically with no moving parts, providing unparalleled accuracy and durability. Nevertheless, in our application, we needed a sensor that could withstand the full range of pressures without mechanical fatigue. The DR3710A’s sputtered thin-film sensor with molecular bond captures ultra-high pressure spikes accurately at 2500 bar. With its solid-state design, no moving parts, and 1000Hz sampling rate, it ensures precise readings even during transient events.

How DR3710A Solved Our Hydraulic Pressure Measurement Challenge

We installed the DR3710A ultra-high pressure digital pressure gauge. This device features a solid-state thin-film pressure sensor with a 17-4PH stainless steel diaphragm for direct media contact. Its laser-welded construction ensures no moving parts, eliminating mechanical wear. The gauge offers multiple pressure ranges up to 2500 bar and accuracy options of ±0.2% FS, ±0.5% FS, and ±1.0% FS. Additionally, the digital sampling at 1000Hz captures rapid pressure changes, while the peak-hold function records maximum and minimum values for spike analysis. The large high-definition LCD with backlight provides clear readings even in low-light conditions. Moreover, the gauge includes a pressure progress bar for visual indication and an ambient temperature display. It also undergoes rigorous testing, including high/low temperature cycling and 2,000 fatigue cycles per sensor, ensuring reliability.

Can Your Process Afford to Miss Pressure Spikes?

The results were immediate: scrap rates dropped from 5% to 1%, saving us $40,000 annually. The DR3710A eliminated false negatives by providing real-time spike detection and peak-hold functions for pressure analysis. As a result, our production efficiency improved significantly. For more on pressure measurement best practices, see [Control Engineering’s guide](https://www.controleng.com).

Key Specifications

• Ultra-high pressure measurement: 1600bar, 2000bar, 2500bar options
• Accuracy: ±0.2% FS, ±0.5% FS, ±1.0% FS
• Digital sampling at 1000Hz
• Solid-state thin-film pressure sensor (sputtered alloy strain gauge, molecular bond)
• 17-4PH stainless steel diaphragm for direct media contact
• Laser-welded construction, no moving parts
• 304 stainless steel housing, IP65 protection
• Operating temperature: -40°C to +150°C with minimal drift
• Large high-definition LCD with backlight
• Peak-hold function (Max/Min capture for pressure spike analysis)
• Pressure progress bar for visual indication
• Multiple pressure connections: HP UNF 9/16, G1/2″, 1/2″ NPT, M20×1.5
• Pressure units: bar, MPa, kg/cm²
• Zero clearing function for easy field calibration
• Battery indicator with low battery warning
• Ambient temperature display (3-digit)
• Rigorous testing: high/low temperature cycling + 2,000 fatigue cycles per sensor

Closing Question

Is your current pressure measurement system hiding costly inefficiencies? Consider upgrading to the DR3710A for reliable, accurate readings that protect your bottom line.

Tags: #ultrahighpressuregauge #2500bardigitalpressuregauge #hydraulicpressuremeasurement #DR3710A