- May 6, 2025
How Differential Pressure Sensors Work: Types, Applications and Benefits
A differential pressure sensor is a device that measures the difference in pressure between two input ports. Unlike absolute or gauge pressure sensors that measure pressure relative to a fixed reference, differential sensors measure the relative pressure between two environments or systems. Differential pressure sensors play a crucial role in monitoring fluid systems across various industries.
These sensors work by allowing pressure from two sources to act on opposite sides of a sensing diaphragm. The resulting deflection is converted into an electrical signal, which corresponds to the pressure difference. This pressure difference serves as an indicator of factors such as flow rate, pressure drop and filter condition, allowing effective system monitoring and streamlined maintenance.
How Differential Pressure Sensor Works?
- Two ports are connected to opposite sides of a system.
- The sensor detects the force exerted by each pressure source on a diaphragm.
- The deflection of the diaphragm is translated into an electrical output.
- The output indicates the pressure difference between the two sides.
Sensor Types: Transmitter vs. Transducer
Differential pressure sensors come in two common forms: differential pressure transducers and differential pressure transmitters. While the terms are sometimes used interchangeably, they have key differences in how they process and output data.
| Pressure Transducer | Pressure Transmitter | |
| Output Type | Voltage output (mV or V) | Current or digital output |
| Signal Conditioning | May require external signal amplification | Built-in amplification and filtering |
| Distance / Cable Length | Suitable for short-distance signal transmission | Ideal for long-distance signal transmission without signal degradation |
| Application Focus | Compact design for high-volume manufacturing and high-resolution measurements in localised systems | Designed for robust, reliable data transmission in industrial environments |
| Typical Applications |
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Transducers are ideal for short-range, high-resolution measurements, while transmitters are better suited for industrial applications where signals must travel over long distances.
Applications of Differential Pressure Sensors
Differential pressure sensors are used in a wide range of industries due to their accuracy, reliability, and adaptability.
Key Industries
- HVAC Systems – Monitoring air filters and airflow in ventilation ducts.
- Oil & Gas – Monitoring pressure drops across filters and pumps.
- Pharmaceutical – Ensuring cleanroom integrity and pressure control.
- Automotive – Measuring EGR valve operation and fuel system performance.
- Water Treatment – Monitoring membrane pressure in filtration systems.
Real-World Examples
- Maintaining pressure differentials in isolation rooms and cleanrooms to prevent contamination.
- Measuring airflow across ducts to balance air distribution in smart buildings.
- Measuring pressure loss across pipelines to detect leaks or blockages.
- Tracking pressure differences in brake assist systems for safety checks.
- Measuring cabin pressure differentials to ensure passenger safety.
Key Benefits of Differential Pressure Sensors
- Improved Efficiency: Ensures optimal system performance and early fault detection.
- Cost Savings: Reduces downtime and unnecessary maintenance.
- High Accuracy: Provides precise measurements critical for safety and compliance.
Choosing the Right Differential Pressure Sensor
Selecting the right differential pressure sensor depends on your specific application needs. Key factors include:
- Pressure Range: Ensure the sensor can measure within your system’s pressure range.
- Media Compatibility: Choose materials compatible with the gas or liquid being measured.
- Accuracy Requirements: Higher accuracy is essential in regulated or sensitive environments.
- Output Type: Decide between voltage, current, or digital signal based on your system.
- Environmental Conditions: Consider temperature range, humidity, and vibration resistance.
Not sure which product is right for you?
Contact MeasureX to speak with our experts about your requirements and we will help to find the best solution or get flexible and customised solutions for your applications.
