How Precision Pressure Transmitter Eliminated $20K Scrap
Our extrusion line was producing inconsistent sheet thickness. The melt pressure reading seemed normal, but the product quality remained subpar. We traced the issue to a faulty melt pressure sensor that couldn’t handle the 400°C+ environment. However, the root cause was deeper than a simple sensor failure.
What Our SCADA System Didn’t Tell Us About Melt Pressure Drift
The SCADA system showed steady pressure, yet our extruded sheets varied in thickness by up to 5%. This discrepancy cost us $20,000 annually in scrap and rework. We initially suspected process issues, but further investigation revealed a hidden problem: the pressure sensor’s accuracy was degrading over time due to thermal effects.
Traditional Pressure Sensors vs. Temperature Compensated Design: The 0.2% Per Hour Drift
Pressure sensors are temperature sensors first. Without proper compensation, accuracy claims are meaningless. In our R&D lab, ambient temperatures fluctuate by 20°C during production runs. The previous transmitter lacked the necessary stability and compensation features required for such harsh conditions. As a result, we observed a drift of up to 0.2% per hour. This small but persistent error accumulated over time, leading to the noticeable inconsistencies in our extruded sheets. Moreover, the rapid thermal changes from 25°C to 400°C+ caused the sensor’s diaphragm to expand unevenly, introducing further errors.
How DR3419 Precision Pressure Transmitter Solved Our Thermal Drift Problem
We installed the DR3419 Precision Pressure Transmitter. With its 0.05% FS accuracy and excellent long-term stability, it provided the precise measurements needed for our demanding applications. The temperature compensation ensured that readings remained accurate even under extreme conditions. Additionally, the low total error band minimized the impact of thermal transients. The variety of electrical and pressure connections allowed easy integration into our existing system.
$20,000 Annual Savings: How Precision Pressure Measurement Eliminated Scrap
The installation resulted in a marked improvement. Quality checks showed a consistent thickness across all sheets produced by the extrusion line. We saved $20,000 annually on scrap material and rework costs. The DR3419 provided reliable data, allowing us to optimize our process control systems and reduce downtime. Consequently, our production efficiency increased by 8%.
Key Specifications
– High accuracy 0.05% FS
– Excellent long-term stability
– Temperature compensated
– Low total error band
– Variety of electrical and pressure connections
How would you ensure your critical processes are free from such hidden errors? Consider evaluating your current pressure sensors for temperature compensation and long-term stability to avoid costly quality issues.
🔧 Need a Reliable Pressure Transmitter FOR Precision Pressure Measurement?
Contact our engineering team for a free consultation on DR3419 solutions tailored to your application.
Tags: #precisionpressuretransmitter #0.05%accuracy #temperaturecompensatedpressuresensor #DR3419 #PrecisionPressureMeasurement
