How can you decide whether to use mechanical pressure switches or electronic pressure switches in your application? Each kind of pressure switch has individual advantages, but additionally its limitations. The main differences in functionality between mechanical and electronic pressure switches are the way the applied pressure is used to use the switch, the type of switch technology, and the way the switch point can be adjusted.
Functionality of mechanical pressure switches
A mechanical pressure switch converts the pressure of a fluid right into a mechanical movement that actuates the mechanical switch contact in the pressure switch. The switch has the preset or an individually, mechanically adjustable switch point. Each time the switch is actuated, a mechanical pressure switch sends a power switching signal, but does not need a voltage supply.
Ordinarily, mechanical pressure switches are simple devices that are either created for cost-effective applications or optimised for long-term use, based on how often the switching signal should be transmitted. The switches are thus designed either for a minimal application rate (very few switching cycles e.g. in safety applications) or for a high application rate (frequent switching changes e.g. in process control). The hysteresis is normally not adjustable, thus the reset point for switching can’t be configured and is preset by factory setup.
Mechanical pressure switches can be used to switch high currents, such as for example pumps and drives. However, mechanical contacts frequently have problems switching the very low voltages in PLCs and modern electronics, unless expensive, gold-plated switch contacts are employed.
Functionality of electronic pressure switches
An electronic pressure switch generates electronic switching signals and, very often, also an additional, analogue output signal proportional to the pressure. They’re either programmed at the factory to the desired switch points or they feature a programming interface with integrated display and buttons.
Electronic pressure switches have integrated, programmable logic. This enables the switch points and the output signal to be adapted to the application-specific needs. Secrets , switch point, reset switch point, hysteresis or window function, normally closed or normally open, and many more functions can be programmed in modern electronic pressure switches.
The neighborhood display of an electronic pressure switch also provides a continuous pressure indication and shows whether the switch outputs are active or not. Last but not least, modern technologies, including the usage of IO-Link, enable programming remotely via signal cables.
Note
Further information on mechanical pressure switches and electronic pressure switches are available on the WIKA website.
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