I. Core Functions and Working Principle
Pressure Monitoring
Pressure sensors are installed at key parts of the air compressor (such as the outlet of the compression chamber, the storage tank, the oil-gas separator, etc.), using built-in sensitive elements (such as strain gauges, capacitive elements) to sense pressure changes and convert physical pressure signals into electrical signals (typically 4-20mA current signals or 0-10V voltage signals).
System Regulation
The control system automatically adjusts the loading/unloading status and intake volume of the air compressor based on the pressure signals received from the sensors:
When the pressure reaches the upper limit set value, the unload mechanism is triggered, stopping the intake or reducing the output;
When the pressure drops to the lower limit set value, the loading is initiated, restoring normal gas supply.
Safety Protection
Some pressure sensors (such as overpressure protection sensors) can trigger shutdown protection when the system pressure is abnormally high, preventing equipment damage due to overpressure.
II. Common Types and Installation Locations
Exhaust Pressure Sensor: Installed at the exhaust port of the compressor, monitoring the output pressure of compressed air, it is one of the core pressure sensors.
Oil-Gas Separator Pressure Sensor: Monitoring the pressure difference before and after the oil-gas separator to determine if the oil filter element is clogged (a large pressure difference requires replacement).
Intake Pressure Sensor: In some models, it is used to monitor the pressure at the intake port, assisting in adjusting the opening degree of the intake valve.
The sensor models and installation locations of different series of air compressors (such as GA, ZR, G series, etc.) vary slightly, and they need to be matched with specific models.
III. Fault Manifestations and Impacts
Sensor Failure
Abnormal pressure signals: If the displayed value does not match the actual pressure (too high, too low, or fluctuating), it causes the control system to misjudge, resulting in frequent loading/unloading of the air compressor, inability to start, or abnormal shutdown.
Signal Interruption: No pressure signal output at all, which may cause the equipment to lose control (such as continuous loading to overpressure).
Accuracy Drift
After long-term use, accuracy may decrease, resulting in deviation in the pressure control range, affecting the stability of gas supply or increasing energy consumption.
Physical Damage
Affected by vibration, high temperature, or medium corrosion, the sensor housing or connection terminals may be damaged, causing abnormal signals.
IV. Maintenance and Replacement Key Points Regular calibration
Based on the equipment maintenance cycle (such as once a year), calibrate the pressure sensor to ensure measurement accuracy (use professional calibration equipment).
Inspection and cleaning
Regularly check if the sensor wiring is loose or aged, and if the interface is leaking;
Clean the oil stains and dust on the sensor surface to prevent corrosion or poor heat dissipation.
Replacement precautions
It is necessary to select a sensor that matches the original factory specifications. Providing the specific model of the air compressor (such as GA75, G11, etc.) can ensure compatibility;
Before replacement, cut off the power supply and release the system pressure to avoid dangerous operations under pressure;
After installation, conduct a pressure test to confirm normal signal transmission.
