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Acal BFi feature a wide range of high-quality specialist sensors from leading suppliers as well as having our own field engineers with great experience of working with applications across a number of harsh environments able to advise on the best sensors or combinations from this portfolio to achieve the best performance for each environment or application.
We also understand that for such demanding applications these specialist sensors may require further customisation in order to operate under these conditions, which we can also assist with.
Engineers must consider an application for a harsh environment prior to its design as the environment will affect the specifications of the product and its performance.
A top consideration is the protection and maintenance of the sensor. To maintain operation in a hostile environment, it would need to operate without failure or the difficulty (and expense) of maintenance or swapping it out. Therefore, choosing the right sensor, protection with the correct coatings, housings and materials is paramount for success.
If you are unsure which one is right for your design given all the choices available – we can help with an extensive specialist portfolio and in-house expertise.
Outdoor and environmental hostile environments
Sensors in these environments need to be able to tolerate high vibration and shock in applications such as; monitoring deterioration of bridges, dams and buildings in structural health monitoring, construction, agriculture or seismology equipment as well as changes in pressure, temperature and exposure to acids or alkalis such as salt water in a marine environment. These conditions would compromise a standard sensor, which may not be able to withstand the stresses or corrosive substances.
We recommend the following sensors that are specially designed for vibration applications that require low noise, low power, resistance to repetitive high shocks and insensitivity to temperature environments that will guarantee confidence of measurements in harsh environments with high accuracy.
Seismic
sensor
Safran Colibrys SI1000 series
Designed specifically for strong motion class B seismic measurements, this small hermetically sealed sensor guarantees accurate and stable seismic measurements and requires no re-calibration or maintenance during its lifetime.
Key features
- Ranges: +/-3, 5 g
- Low Noise: 0.7 µg/vHz (+/-3g)
- Bandwidth: 0-550Hz (+/-3g)
- Non linearity : ±0.3% FS
- Size : <1cm²
- Embedded logic functions: Self-test, reset
Humidity and temperature
sensor
Amphenol T9602
IP67 Harsh environment combined humidity and temperature sensor
Key features:
- Ready to use - Fully-calibrated and temperature-compensated
- Water resistant - IP67 Certified
- Digital Output or Pulse Density Modulated (PDM) Output converted to Analog
- Available in multiple flexible cable lengths
- Precise and accurate (±2% RH, ±0.5°C, 14 bit resolution)
- Low current consumption
- Reliable in harsh environments
- Flexible mounting options
Temperature
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TTO series are IP68 waterproof temperature probes encapsulated with thermoplastic elastomer materials in over moulding technology, specifically designed for harsh environment conditions.
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Industrial applications
Industrial applications are a challenge for thermistor sensors, needing to cope with heat, cold, humidity and repeated or rapid changes in pressure and temperature. These sensors need to be hardy and able to withstand constant changes in pressure, extreme temperatures from freezing cold to boiling hot and in exposure to corrosive substances.
These applications can vary across Oil & Gas exploration, Heating, Ventilation and Air-conditioning (HVAC), Refrigeration, industrial hydraulics that need monitoring for safety and control purposes.
Sensors recommended for these types of applications need superior mechanical strength and Robust casing protection, High heat resistance, fast response and excellent heat, oil and solvent proof with strong sealing.
Recommended specialist sensors:
Shibaura advanced sensors
These world leading sensors provide best-in-class quality, precision, and extreme reliability. Their range of sensors are unmatched in performance, featuring a unique design and a fully automated, zero defect manufacturing process which means Shibaura thermistors work consistently - without failure or deterioration in harsh conditions and extreme temperatures.
In addition, their sensors are highly customisable, offering a flexible choice of mouldings, assemblies, cable lengths and colours plus a variety of housings. Custom sensing assemblies are particularly useful for harsh and high-end applications, and our team of engineers, with more than 25 years' experience designing custom sensor probes and assemblies for a range of applications, will help ensure you choose the right sensor element, design a suitable housing, and add the appropriate cable and connectors.
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Colibrys TS1000High temperature inclinometer
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Variohm Eurosensor EPT3100Pressure transducer
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Automotive environments
Applications for automotive range from engine motors and converters, radiators, heaters, lithium batteries to EV charging, motor coils and air-con. The sensors in most of these applications are likely to be exposed to a range of substances, corrosive chemicals and high temperatures.
High temperatures can cause some of the components such as the O-rings used in a standard sensor to deteriorate leading to performance failure.
Acal BFi have extensive experience in working with applications for automotive and recommend sensors from our partner Shibaura, who are a world leader in the field of advanced temperature sensor technology for harsh environment applications.
Suitable for applications that are prone to frequent thermal cycles and high levels of humidity, their sensors give the extreme reliability, resistance and precision needed with a unique zero defect design - featuring gold contacts in addition to waterproof glass coatings, resulting in almost no drift in the resistance over time and allowing the sensors to be used in permanent operating temperatures ranging from -60°C to +1000°C without failure.
Recommended Temperature Sensors for Automotive:
Shibaura advanced sensors
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There are also customisable options available for more challenging environments - with sensors that offer a flexible choice of mouldings, assemblies, cable lengths and colours plus a variety of housings.
Bespoke sensing and connectivity solutions
Our range covers all key parameters across any environment, but to help solve more complex challenges for your application, we can design and build a complete solution to your needs with customer-specific combinations and custom designed solutions along with wireless connectivity.
So, if you’re not sure where to start, contact our sensor experts who can help guide you through all of the options and find the best choice for performance and protection for your application in a harsh environment.
Sensor guides
Please find below a set of guides designed to help you choose the best temperature, pressure, humidity, and airflow sensors for your application. The guides cover the basics of each type of sensor, factors to consider during your design process, as well as highlighting specific models and ranges from our world-leading partners such as Honeywell, Amphenol, Shibaura and Cubic.
Airflow
Humidity
Pressure
Temperature
