A customer required a robust replacement pressure sensor for the high-pressure hydraulic suspension system on a fleet of heavy-duty mining haul trucks. The application presented significant challenges, including a non-standard process thread, extreme environmental contamination, and high levels of shock and vibration. A configurable autosport-grade pressure sensor was identified and customised to provide a durable, drop-in solution.
- Application: Hydraulic suspension pressure on heavy mining trucks.
- Challenges: Harsh environment (dust, oil, mud), high vibration, and a 10,000 psi range.
- Key Requirement: Custom ½ – 20TPI UNF thread process thread and a specific industrial connector.
- Solution: A modified Titan-Moto A-Series pressure sensor featuring a pressure port restrictor.
A product development specialist for a service provider in the Indonesian mining sector required a robust and reliable pressure sensor. The specific application was to monitor the hydraulic pressure within the suspension system of a heavy-duty haul truck used in coal mining operations. The environment presented extreme challenges, including constant exposure to high levels of dust, oil, and mud, coupled with the significant shock and vibration inherent in large-scale mining vehicle operations.
The customer’s requirements were highly specific. They needed a sensor capable of measuring a pressure range of 0 to 10,000 psig. A critical and unusual requirement was the need for a non-standard process connection, specified as an ½ – 20TPI UNF thread with a length of 15mm, incorporating a captive O-ring seal to ensure a perfect fit and prevent leaks in the existing suspension assembly. Furthermore, the sensor needed a 3-wire configuration terminated with a specific 3-pin Deutsch connector to integrate with the truck’s existing wiring harness. The required output was a 0.5 to 4.5V ratiometric signal, operating from the vehicle’s 5V DC power supply.
The proposed solution was the Titan-Moto A-Series pressure sensor. Although originally designed to meet the rigorous demands of on-vehicle measurement in the motorsport industry, its inherent robustness made it a perfect candidate for this heavy-duty industrial application. The sensor’s flexible design platform was a key advantage, allowing for significant customisation to meet the client’s unique needs.
The sensor’s IP67 environmental protection rating ensures it is fully sealed against the ingress of dust and fluids, making it ideal for the contaminated mining environment. Its construction, featuring a 303 stainless steel body, a ceramic (Al2O3) sensing element, and peroxide-cured FKM (Viton™) seals, provides excellent resistance to corrosion from hydraulic fluids and external contaminants. To address the high shock and vibration, the sensor’s design is rated to military standards (MIL-STD-810C) for vibration resistance, ensuring long-term stability and performance on the haul truck’s active suspension.
Most importantly, the sensor could be manufactured with the customer’s exact mechanical and electrical specifications. The non-standard ½ – 20TPI UNF process thread thread and the specified Deutsch connector were incorporated into the design for a seamless, drop-in replacement. A special option, a pressure port restrictor, was also included. This feature dampens the severe pressure spikes and hydraulic shocks common in heavy vehicle suspension systems, protecting the piezoresistive sensing element from damage and significantly enhancing the sensor’s operational lifespan and reliability. By providing a custom-engineered solution that met every specific requirement, from the high-pressure range to the unique thread, a reliable and durable monitoring solution was delivered for a critical vehicle system operating in one of the toughest environments.
Titan-Moto A-Series Pressure Sensor
- Part No: AS-AA-AX-AV-P10KS-0C
- Output / Supply Type: 0.5 to 4.5V (3-wire), 5V dc ratiometric
- Accuracy Class: 0.50%
- Electrical Connection: FEP Insulated Screened Cable, 26AWG terminated with Deutsch Connector (18-DT3G)
- Process Connection: ½ – 20TPI UNF thread, 15mm in length with captive O ring seal
- Housing Material: 303 Stainless Steel
- Seal Material: FKM (Viton™ Peroxide cured)
- Pressure Range: 0 – 10,000 Psi
- Pressure Datum: Sealed Gauge
- Special Options: Pressure port restrictor, thread type and connector fitted