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Transducers are technical devices that record a physical, chemical or electrical quantity and convert it into a usable electrical signal.

This signal can then be processed by a control system, display unit or data acquisition system. Sensors are therefore at the heart of modern measurement and automation technology, as they create the link between the real and digital worlds.

Below is an overview of the basic principle and mode of operation, different types and their measured variables, signal types and interfaces of transducers, as well as an overview of their use and the requirements for modern designs:

Basic principle and mode of operation of transducers:

The functionality of transducers consists of three basic steps:

1. Detection of the measured variable: this is done by a sensor element that physically interacts with the measured variable - e.g. through deformation, temperature change, magnetic fields or light absorption.
2. Conversion into an electrical signal: The measured variable is converted into an electrical variable, e.g. voltage, current, frequency.
3. Signal processing: The raw signal is amplified, filtered, linearized or digitized in order to make it usable for downstream systems.

The type of conversion principle, whether mechanical, optical, piezoelectric, magnetic, chemical, etc., depends on the measured variable in question.

Types of transducers and their measurands:

Transducers are highly specialized and can be subdivided according to the respective measurand:

1. Mechanical variables:
   Pressure sensors: measure the static or dynamic pressure of liquids and gases, often using piezoresistive or capacitive elements.
   Force sensors: Convert mechanical force into an electrical signal, often using strain gages.
   Displacement and distance sensors: Use optical, inductive, capacitive or ultrasonic methods to determine position.
   Torque sensors: Measure the torsion of a shaft, often using strain gauges or magnetic methods.
2. Thermal variables:
   Temperature sensors: these include thermocouples, resistance thermometers, semiconductor temperature sensors or infrared sensors.
   Heat flow sensors: Determine the flow of heat through a layer of material, often using thermoelectric principles.
3. Electrical and magnetic quantities:
   Current and voltage transducers: Detect electrical quantities in power supplies, circuits or systems.
   Magnetic field sensors: Utilize the Hall effect or magnetoresistive principles to measure field strengths.
4. Chemical and physico-chemical variables:
   Gas sensors: detect concentrations of certain gases (e.g. oxygen, CO₂, ammonia) using electrochemical, optical or semiconductor methods.
   pH sensors and conductivity sensors: Are used in process and environmental measurement technology to determine the chemical properties of liquids.
   Humidity sensors: Measure the relative or absolute humidity in air or materials.

Signal types and interfaces of transducers:

Most modern transducers provide standardized output signals:

1. Analog signals: often 4-20 mA or 0-10 V, suitable for simple transmission paths.
2. Digital interfaces: Such as I²C, SPI, CAN, Modbus or IO-Link for intelligent sensors with additional functions.
3. Fieldbus systems: Such as Profibus, EtherCAT or Profinet in industrial automation.

Depending on the application, the sensor may already be internally calibrated, temperature-compensated and self-diagnostic.

Use of transducers:

Transducers are used in almost all technical areas. The most important fields of application include:

1. Automation technology:
In industrial production plants, sensors continuously monitor pressure, temperature, position, speed, flow and other process variables.
The signals are used for regulation, control and safety.

2. Energy technology:
Transducers record parameters such as current, voltage, frequency, power or insulation values in energy distribution systems, substations and transformers.

3. Automotive engineering:
Transducers are elementary for vehicle dynamics control, airbags, engine control, exhaust gas measurement or battery management systems.

4. Medical technology:
Biocompatible sensors are used here to measure vital parameters such as blood pressure, body temperature, glucose levels or respiratory gases.

5. Building technology:
In heating, air conditioning and ventilation systems, sensors measure temperature, humidity, CO₂ content and light intensity to control comfort and energy efficiency.

6. Environmental measurement technology:
Specialized transducers are used to record weather data, air quality, water analyses or emissions.

Requirements for modern transducers:

• Accuracy and repeatability: Particularly crucial in quality assurance or control technology.
• Long-term stability: Important for continuous measurements over many years, for example in energy systems or environmental stations.
• Fast response time: Especially for dynamic processes (e.g. explosion detection or shock measurements).
• Robustness: Protection against dust, water, vibrations, chemical influences and temperature.
• Calibratability: For traceability of measured values to national standards.

Transducers are indispensable components in almost all technical, industrial and scientific applications. Their main task is the precise recording of real variables and their conversion into a usable signal. The variety of available technologies allows precise adaptation to a wide range of measurement tasks. With the advent of intelligent sensors (smart sensors) and integration into digital systems, the transducer is increasingly becoming a key component in the age of Industry 4.0 and the Internet of Things (IoT).

Here is an overview of the most important points to consider when purchasing transducers.

The purchase of transducers for recording mechanical, thermal, electrical or chemical-physical variables requires a holistic view of technical, application-specific and economic criteria. It is not just about the pure measuring function, but also about the interplay of precision, robustness, integration, calibration and system compatibility.

• The first step is to define exactly which physical quantity is to be measured and under what conditions:
• Mechanical variables: Force, pressure, torque, weight
• Thermal variables: Temperature, heat flow
• Electrical quantities: Voltage, current, resistance, capacity
• Chemical-physical variables: pH value, conductivity, concentration, humidity
• Each of these variables requires a different sensor technology - and therefore different requirements in terms of design, signal processing and material.
• The choice of the right measuring principle is crucial for recording the desired measured values:
• Strain gages (DMS): For mechanical variables such as force and pressure
• Thermocouples or RTDs (Pt100): For temperature measurements
• Hall effect or inductive methods: For electrical and magnetic variables
• Ion-selective electrodes or optochemical sensors: For chemical-physical measured variables
• The choice of measuring principle determines the sensitivity, robustness and signal processing.
• The choice of sensor must match the expected measuring range - neither too large (loss of resolution) nor too small (risk of overload).
• At the same time, the desired resolution and accuracy must be checked, depending on whether it is for rough process monitoring or high-precision laboratory applications.
• It is particularly important that the transducer fits the installation situation mechanically:
• Size and geometry: Must be able to be integrated into existing systems
• Installation position: Horizontal, vertical, rotationally symmetrical
• Mounting options: Flange, screw mounting, plug-in systems
• Cable routing and connector types: Must match the cabling on site
• Depending on the environment, the sensor must be particularly robust:
• Corrosion resistance: For chemical processes or outdoors, for example
• Temperature resistance: For high-temperature applications or cryogenics
• Tightness (IP protection class): E.g. IP67 or higher for moisture or dirt
• Mechanical load capacity: Vibration, shock, pressure pulses
• The transducer must be suitable for the existing evaluation technology and automation environment:
• Analog signals: e.g. mV/V, 0-10 V, 4-20 mA
• Digital interfaces: e.g. CANopen, Modbus, EtherCAT, IO-Link
• Compatibility with control systems and data loggers
• EMC protection and interference immunity: particularly important in electrical or industrial environments
• Only calibrated sensors provide reliable measured values, so a factory calibration with test report is a minimum requirement.
• DAkkS calibration or equivalent for the highest requirements, e.g. QS according to ISO 9001, automotive, pharmaceuticals.
• Traceability to national standards guarantees comparability. Recalibration cycles should be defined according to the intensity of use.
• A transducer must measure stably over many years:
• Therefore, the zero point and sensor drift should be evaluated as a function of temperature, ageing and mechanical stress.
• The creep behavior under constant load should be taken into account. Especially for mechanical variables.
• Conformities are crucial, especially in industrial or safety-relevant environments:
• CE marking and product-specific EU directives.
• ATEX approval for potentially explosive atmospheres.
• RoHS and REACH conformity.
• Specific industry requirements such as GMP (pharmaceuticals), HACCP (food), SIL (process industry).
• The quality of the transducer is closely linked to the manufacturer's experience and references, technical support and application advice.
• It is not just the unit price that is decisive, but the overall cost-effectiveness.

A clearly defined application, the choice of the right measuring principle, proper integration into the measuring chain and support from an experienced manufacturer are particularly important. This is the only way to build a measuring system that is permanently precise, stable and low-maintenance - regardless of whether it measures mechanical forces, temperatures, electrical variables or chemical-physical parameters.

Transducers can be obtained from various suppliers. Comprehensive information about manufacturers and suppliers of Transducers from all over the world can be found on exportpages.