Solution to the vibration influence of vacuum pressure switches

When vacuum pressure switches operate in a vibrating environment, problems such as increased measurement errors, false actions, and loose components may occur, affecting their normal functions. The following are effective methods to solve the influence of vibration on vacuum pressure switches:

Mechanical structure optimization

Enhance the rigidity of the switch housing: The housing is the first line of defense for protecting the internal components of the vacuum pressure switch. The rigidity of the shell can be effectively enhanced by increasing the thickness of the shell material, using high-strength metal materials (such as stainless steel), or setting reinforcing ribs inside the shell. For instance, increase the thickness of the casing from the original 2 millimeters to 3 millimeters, or weld several crisscrossing reinforcing ribs inside the casing, so that it is less likely to deform when subjected to vibration, thereby reducing the impact on the internal components.

Optimize the fixation method of internal components: For key components such as pressure-sensing elements and circuit boards inside the switch, adopt a more reliable fixation method. Elastic rubber pads or shock-absorbing rubber can be used to isolate the components from the casing, which not only serves a fixing function but also absorbs part of the vibration energy. For instance, a rubber pad of moderate thickness can be placed between the pressure-sensing element and the housing. The elasticity of the rubber pad can buffer the impact of vibration on the sensing element, preventing it from shifting or being damaged due to vibration.

Improve the connection structure of components: For the connection between internal components, flexible connection methods should be adopted as much as possible to avoid the vibration transmission caused by rigid connections. For instance, by using a hose to connect the pressure-sensing element with the pressure interface, the hose can absorb vibration to a certain extent and reduce the impact of vibration on pressure measurement. Meanwhile, ensure that the connection parts have good sealing to prevent pressure leakage.

Improvement of installation location and method

Select an appropriate installation location: When installing a vacuum pressure switch, try to choose a location with less vibration. Avoid installing it near vibration sources (such as motors, pumps, etc.) or on the vibration nodes of the equipment. Vibration tests can be conducted on the equipment to identify areas with less vibration and install the switch at that position. For instance, on a large mechanical device, if vibration tests show that the top of the equipment or the side far from the power source vibrates less, vacuum pressure switches can be installed at these positions.

Use shock-absorbing mounting brackets: Use dedicated shock-absorbing mounting brackets to fix the vacuum pressure switch. Shock-absorbing installation brackets are usually made of shock-absorbing materials such as rubber and springs, which can effectively absorb and isolate vibrations. When installing, fix the switch on the shock-absorbing bracket and then install the bracket onto the equipment. In this way, the vibration generated by the equipment will be greatly weakened by the shock-absorbing bracket before being transmitted to the switch.

Increase installation tightness: Ensure that the switch is firmly installed to avoid the impact of intensified vibration due to looseness. During the installation process, the installation screws should be tightened to the specified torque, but they should not be over-tightened to avoid damaging the switch or the installation bracket. A torque wrench can be used to precisely control the tightening torque to ensure the reliability of the installation.

Electrical and signal processing optimization

Adopt anti-vibration circuit design: In the circuit design of the vacuum pressure switch, anti-vibration measures are added. For example, low-noise and highly stable electronic components are adopted to reduce the noise interference of the circuit itself. At the same time, the circuit should be reasonably laid out and wired to avoid mutual interference between signal lines and power lines. A filter circuit can be added to the circuit to filter out the interference signals caused by vibration and improve the stability of the signal.

Signal filtering and processing: At the signal output end of the switch, add a signal filtering link. Digital filtering algorithms or analog filters can be used to process the output signal to remove noise and burrs caused by vibration. For example, by using the sliding average filtering algorithm to average multiple continuously collected pressure signals, the influence of random vibration on the signals can be effectively reduced, and the accuracy of pressure measurement can be improved.

Redundant design enhances reliability: For application scenarios with high requirements for precision and reliability, redundant design can be adopted. That is, install two or more vacuum pressure switches to monitor the same pressure. When one of the switches malfunctions due to vibration or has a large measurement error, the other switches can still work normally to ensure the normal operation of the system. Meanwhile, by comparing the measurement results of multiple switches, the accuracy and reliability of the measurement can be further improved.

Regular maintenance and inspection

Establish a maintenance plan: Develop a detailed regular maintenance plan and conduct regular inspections and maintenance of vacuum pressure switches. The maintenance content includes checking whether the switch is firmly installed, whether the casing is damaged, and whether the internal components are loose, etc. Based on the usage frequency of the equipment and environmental conditions, determine a reasonable maintenance cycle, such as conducting a comprehensive inspection every three months or half a year.

Check the connection lines: Vibration may cause the connection lines of the switch to become loose or have poor contact. During the maintenance process, carefully inspect the power lines, signal lines and other connection lines of the switch to ensure a firm connection. If any damage or aging of the circuit is found, it should be replaced in time.

Calibration and debugging: Regularly calibrate and debug the vacuum pressure switch to ensure that its measurement accuracy meets the requirements. Since vibration may affect the zero point and range of the switch, it is necessary to simulate the vibration conditions in the actual working environment during calibration to make the calibration results more accurate and reliable. If the accuracy of the switch is found to have decreased significantly, it should be adjusted or replaced in a timely manner.