Test benches are crucial tools in product development and quality control and are used in various industries.
A distinction is made between general test benches and specialized test benches. Regardless of the type, pressure sensors and flow meters always play a key role. They provide essential, precise measurement data that is needed to evaluate system performance and ensure the correct functioning of the system under test.
The following section describes specific applications and the performance of specific sensors for measuring pressure and flow in both general test benches and specialized applications.
Applications of pressure sensors and flow meters in general test benches
Checking the system integrity
In many industrial applications, especially in the development of machines and systems, general test benches are used to check the mechanical and thermal performance of systems. Pressure sensors and flow meters are crucial here to ensure the integrity of the system.
Pressure monitoring
Pressure sensors record the system pressure in real time and ensure that it remains within safe limits. Deviating pressure can indicate problems such as leaks, blockages or malfunctions of pumps and valves.
Flow control
Flow meters measure the amount of medium (e.g. liquids or gases) flowing through the system. This data is important to ensure that all components are adequately supplied and perform as required.
Optimization of systems
Pressure sensors and flow meters support the continuous optimization of machines and systems by providing precise data that can be used to fine-tune operating parameters. For example, in hydraulic test benches, both pressure and flow can be adjusted to achieve maximum efficiency without compromising safety.
Error analysis and diagnostics
Another advantage of sensor integration in general test benches is the ability to analyze faults. Sensors detect faults in real time, which enables immediate fault diagnosis. In this way, the use of sensors can minimize failures and increase the reliability of the tested systems.
Specific product information on pressure sensors and flow meters in general test benches
DDM Product Recommendation – Pressure sensors in general test benches:
The pressure sensors PV25 and PX25 are classic test bench sensors. They are available with voltage output signal (PV25) and current output signal (PX25). Thanks to the completely analog measuring chain, the sensors have a very high resolution without complex ADA conversion in the sensor.
DDM Product Recommendation – Ultrasonic flow meters in general test benches:
The ultrasonic flow meters in the Atrato series are particularly suitable for very low flow rates from 2 ml/min. The Atrato is available with a display and various interfaces. In the test bench and laboratory environment, the ASCII interface is of interest as it can be easily integrated into programs such as LabVIEW. The Process Atrato is suitable for more demanding environments thanks to its IP65 protection class and its more robust design.
DDM Product Recommendation – Impeller meters in general test benches:
Series 800, 900, 1000 and FT2 impeller meters are cost-optimized flow meters that nevertheless have a robust and durable sapphire bearing installed. This makes them interesting flow meters for products similar to water.
DDM product recommendation – Oval gear meters in general test benches:
Oval gear meters are particularly suitable for test benches with viscous or highly viscous media. These flow meters are independent of viscosity and are available in different pressure ratings of 10, 50, 400 and 700 bar. By using a reed contact (hazardous area) as a signal tap, the oval gear meters can also be used in ATEX zones.
Applications of pressure sensors and flow meters in specialized test benches
The use of pressure sensors and flow meters is particularly important in specialized test benches that are tailored to specific applications and requirements. These test benches are often tailored to specific industries or test methods, for example in the automotive, aviation or medical technology sectors.
Pressure sensors and flow meters in automotive test benches
In the automotive industry, specialized test benches are used to develop and optimize components such as engines, brake systems, fuel lines and cooling systems. Pressure sensors and flow meters perform important functions here.
- Engine test benches:
Engine test benches require accurate pressure and flow measurements in order to optimize combustion efficiency and the engine’s cooling circuit. Pressure sensors measure cylinder pressure, while flow meters monitor fuel and coolant flow. This is essential for increasing performance and fuel efficiency. - Brake test benches:
During the development of brake systems, the brake fluid pressure is monitored by pressure sensors in order to measure the braking force precisely. Flow meters can monitor the flow of brake fluid in order to detect leaks or faults in the system at an early stage.
DDM Product Recommendation – Pressure sensors in automotive test benches:
The PV22 and PV15 pressure sensors have been tried and tested in automotive testing and test bench construction for many years. The wide temperature range of -40 to 150°C makes them ideal for use close to the test specimen in the climate chamber. Due to the total error of <= 0.25% v.MB and the excellent long-term stability, these sensors are ideally suited for test bench applications. The PV15B brake pressure sensor has been specially developed for applications close to the brake.
DDM Product Recommendation – Flow meters in automotive test benches:
Turbine flow meters and oval gear meters are also suitable for use in test benches in the automotive sector. They can be used in extreme ambient conditions from -40 to 150°C.
Pressure sensors and flow meters in aviation test benches
In the aviation industry, test benches are used to test engines, hydraulic systems and fuel supply systems. The requirements for accuracy and reliability are particularly high here, as even the smallest errors can have serious consequences.
- Engine test benches:
Pressure sensors measure the pressure in the combustion chambers and in the aircraft’s hydraulic systems. Flow meters monitor the fuel flow to ensure even combustion and the correct functioning of the engine. Pressure sensors and flow meters are also used to monitor the hydraulic fluid to ensure optimum control of the aircraft. - Cabin air systems:
Specific test benches are also used to test the air pressure systems in the aircraft cabin. Pressure sensors ensure that the cabin is correctly pressurized, while flow meters regulate the flow of oxygen and air.
DDM Product Recommendation – Turbine measurement systems in aviation test benches:
Turbine flow meters are characterized by high dynamics, small installation space or low space requirements and high accuracy. The VCT measuring turbines paired with the VCA flow computer output a linearized and viscosity-corrected measuring signal. In addition to the flow measurement signal, the VCA-T can output the temperature signal of the wetted thermocouple as an analog voltage value. The VCA-CAN has a CAN-BUS 2.0B high speed interface in accordance with ISO 11989-2:2016. In addition to the flow rate and media temperature, the calculated viscosity, the K-factor, the real turbine wheel frequency and the serial numbers of the turbine and flow computer can be transmitted via the CAN bus.
Pressure sensors and flow meters in medical technology test benches
Specialized test benches also play an important role in medical technology in the development and validation of medical devices, especially those that transport liquids or gases.
- Blood pump test rigs:
In the development of blood pumps, pressure sensors and flow meters monitor pump performance and fluid flow to ensure that the pump simulates the natural blood flow in the body. - Ventilators:
In ventilators, flow meters accurately monitor the flow of air into the lungs, while pressure sensors measure the ventilation pressure. These measurements are crucial to ensure safe and effective ventilation.
DDM conclusion – Indispensable: pressure sensors and flow meters in test benches:
Pressure sensors and flow meters are indispensable components in both general and specialized test benches.
- In general test benches, they support the monitoring of system performance, fault diagnosis and optimization of systems.
- In specific test benches, such as in the automotive, aviation and medical technology industries, they make a decisive contribution to the precise control and monitoring of complex systems.
By using these sensors, test benches can provide highly accurate data that contributes to the development of safe, efficient and high-performance products. The continuous development of sensor technology will lead to test benches becoming ever more powerful and precise, which will ultimately increase the quality and reliability of the tested systems.
Focus on customer specificity
We develop pressure sensors for your customized application. With measuring range, output signal and gemoetry incl. flush diaphragm according to your specification. We will be happy to work with you to develop a solution that is tailored to your application – because your Mission Impossible is our passion!