Mechanical vs. electronic pressure switches: Functionality

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 also its limitations. The main differences in functionality between mechanical and electronic pressure switches will be the way the applied pressure can be used to operate the switch, the kind of switch technology, and the way the switch point could 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. Miracle has either a preset or an individually, mechanically adjustable switch point. Each time the switch is actuated, a mechanical pressure switch sends a power switching signal, but will not need a voltage supply.
Ordinarily, mechanical pressure switches are simple devices which are either created for cost-effective applications or optimised for long-term use, based on how usually the switching signal should be transmitted. The switches are thus designed either for a low application rate (hardly any 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 are often used to switch high currents, such as for example pumps and drives. However, mechanical contacts often have problems switching the very low voltages in PLCs and modern electronics, unless expensive, gold-plated switch contacts are used.
Functionality of electronic pressure switches
An electronic pressure switch generates electronic switching signals and, frequently, also yet another, 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. Delay time, switch point, reset switch point, hysteresis or window function, normally closed or normally open, and more functions can be programmed in modern electronic pressure switches.
The local display of an electric pressure switch also offers a continuous pressure indication and shows if the switch outputs are active or not. Last but not least, modern technologies, such as the use 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.
Also read our articles
Mechanical vs electronic pressure switches: Application areas
Mechanical pressure switches: How does one set the switch point?
Pressure switches in booster pumps

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