The anti-vibration working principle of vacuum pressure switches

The anti-vibration working principle of vacuum pressure switches mainly involves the optimization of multiple aspects such as mechanical structure design, signal processing mechanism and material selection to ensure stable and reliable operation in a vibrating environment. The following is a detailed analysis of its anti-vibration working principle:

Optimization of mechanical structure design

Shock absorption and buffering structure

Installing shock-absorbing devices, such as rubber shock-absorbing pads, spring shock absorbers or damping materials, inside or outside the switch can effectively absorb and disperse vibration energy. For instance, adding a rubber vibration isolation pad between the switch and the installation bracket can reduce the direct impact of high-frequency vibration on the internal sensitive components.

Compact layout

By optimizing the layout of internal components, the relative motion space between components is reduced, and the risk of component misalignment caused by vibration is lowered. For example, the pressure-sensing diaphragm is closely integrated with the microswitch to avoid poor contact caused by vibration.

Rigid connection design

Rigid fixation methods, such as thread locking or welding, are adopted at key connection points to prevent loosening or displacement caused by vibration. For example, the connection between the pressure interface and the pipeline adopts a double ferrule sealing structure to ensure that the sealing performance can still be maintained in a vibrating environment.

2. Improvement of signal processing mechanism

Digital filtering technology

Introducing the digital filtering algorithm into the signal processing circuit can effectively filter out the noise signals caused by vibration. For instance, high-frequency vibration noise is removed through a low-pass filter to ensure the accuracy of the pressure signal.

Threshold hysteresis design

Set reasonable action thresholds and hysteresis intervals to avoid misoperation of the switch caused by pressure fluctuations due to vibration. For example, set the starting pressure at -90 kpa and the stopping pressure at -80 kpa to form a hysteresis range of 10kPa, preventing frequent starts and stops when the pressure fluctuates.

Self-diagnosis and calibration function

The high-end vacuum pressure switch is equipped with a built-in self-diagnostic program, which can monitor the impact of vibration on the signal in real time and automatically calibrate when necessary. For example, when pressure offset caused by vibration is detected, the switch can automatically adjust the set value to ensure the accuracy of the action.

3. Material selection and process optimization

High-strength shell material

The shell is made of high-strength and impact-resistant engineering plastics or metal materials (such as aluminum alloy and stainless steel), which can effectively resist deformation or cracking caused by vibration. For instance, the aviation aluminum alloy shell undergoes anodic oxidation treatment, which not only enhances its strength but also improves its corrosion resistance.

Anti-fatigue element

Pressure sensing elements (such as diaphragms and bellows) and contact materials need to have excellent fatigue resistance. For instance, Hastelloy diaphragms are adopted, which have tensile strength and fatigue life much higher than those of ordinary stainless steel, and can maintain stable performance under long-term vibration environments.

Precision processing technology

Through precision processing technology, the fit accuracy between components is ensured, reducing wear or loosening caused by vibration. For instance, the contacts of the microswitch adopt a silver plating process, featuring low contact resistance and wear resistance, which enables it to maintain stable electrical performance in a vibrating environment.

4. Anti-vibration measures in practical applications

Installation direction optimization

Adjust the installation Angle of the switch according to the vibration direction to avoid the vibration direction coincident with the sensitive direction of the pressure sensing element. For instance, on equipment that vibrates horizontally, install the switch vertically to reduce the impact of vibration on the diaphragm.

Selection of fixed mode

Adopt multi-point fixation or elastic fixation methods to reduce the transmission of vibration. For example, fixing the switch to the equipment with rubber shock-absorbing bolts can not only absorb vibration but also prevent loosening.

Environmental adaptability test

During the product development stage, vibration tests (such as sinusoidal vibration and random vibration) are conducted on the switch to verify its performance under different vibration frequencies and amplitudes. For example, conduct vibration tests in accordance with the IEC 60068-2-6 standard to ensure that the switch can still operate normally within the frequency range of 5-200Hz.

5. Typical cases of anti-vibration performance

Vehicle-mounted vacuum pump system

In the automotive braking system, the vacuum pressure switch needs to withstand engine vibration and road bumps. By adopting rubber shock-absorbing pads and digital filtering technology, the switch can operate stably under a 5g vibration acceleration, with a false action rate of less than 0.1%.

Application of Industrial Robots

In the vacuum suction cup system of the robot arm, the switch needs to adapt to the vibration caused by high-speed movement. By optimizing the internal layout and setting the threshold hysteresis, the switch can accurately control the vacuum degree under a vibration displacement of ±2mm, ensuring the reliability of grasping.

Aerospace field

In the satellite vacuum thermal test chamber, the switch needs to withstand the intense vibration during the launch stage. By adopting a high-strength housing and self-diagnostic function, the switch can still maintain pressure monitoring accuracy under 10g vibration and shock, ensuring the reliability of the test data.

The anti-vibration working principle of the vacuum pressure switch ensures its stable and reliable operation in a vibrating environment through comprehensive measures such as mechanical structure design, signal processing mechanism, material selection and process optimization. These measures not only enhance the anti-interference ability of the switch but also extend its service life, providing a strong guarantee for the safe operation of the vacuum system.