Sensata Solutions for Diversified Industrial Applications
Across its product brands, Sensata delivers an extensive range of solutions to manage a wide variety of diversified industrial applications – industrial automation and motion control, heating control, medical switching, and more.
Sensata Technologies provides a wide range of products that are integral to various industrial automation applications. These applications span across several industries, enhancing efficiency, safety, and reliability.
Industrial Applications:
- Manufacturing & Assembly Lines
- Robotics
- Material Handling & Conveyance
- HVAC/ Energy Management/ Power Distribution/ Renewable Energy
- Agricultural Automation
- Food & Beverage Processing
- Transportation & Logistics
- Industrial Safety Systems
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sensata's solutions
POSITION SENSING & ENCODERS
Sensata’s range of position sensors – including linear and rotary encoders, potentiometers, draw wires and inclinometers – are designed to deliver accurate and reliable performance in challenging environments. Our high quality components deliver precise motion control across a wide variety of applications – including those requiring functional safety designs or which require hazardous location certifications.
Challenges:
Application-specific requirements: Industrial applications vary widely, and each may have specific requirements for accuracy, resolution, speed, environmental conditions (such as temperature, humidity, and presence of contaminants), size, and mounting options. Identifying sensors that meet all these requirements can be challenging.
Compatibility with existing systems: Many industrial systems rely on legacy equipment or specific communication protocols. Ensuring that the chosen position sensors are compatible with existing systems and can seamlessly integrate into the overall setup is crucial.
Reliability and durability: Industrial environments can be harsh, with exposure to vibration, shock, dust, moisture, and other contaminants. Position sensors need to be robust enough to withstand these conditions without compromising accuracy or reliability over time.
Cost-effectiveness: While high-performance sensors may offer the best accuracy and reliability, they can also be expensive. Balancing the need for performance with budgetary constraints is a common challenge in selecting position sensors.
Maintenance requirements: Some sensors require regular calibration or maintenance to ensure accurate operation over time. Assessing the long-term maintenance requirements and associated costs is important when selecting position sensors for industrial applications.
Safety considerations: In certain industrial settings, safety is paramount. Ensuring that position sensors comply with safety standards and regulations is essential to prevent accidents or injuries.
Availability and lead times: In some cases, specific sensors may have limited availability or long lead times, which can impact project timelines and deadlines. It’s important to consider the availability of sensors and plan accordingly.
Technical support and expertise: Integrating complex sensors into industrial systems may require technical expertise. Ensuring access to adequate technical support and resources from the sensor manufacturer or supplier can help address any challenges or issues that arise during installation or operation.
The Sensata 2-part Hall effect sensor assemblies are designed to provide position sensing in industrial applications that are very compact or are sensitive to wear and tear. The ACW provides a single turn absolute output while the TCW can provide a multi-turn absolute signal. The two-part construction keeps the profile low, delivering a high degree of flexibility for tight installations. By using the IO-Link protocol, integration and set-up of sensors is greatly simplified, supporting the move to factory 4.0 and IIOT initiatives. The ACW4 and TCW4 IO-Link is sealed to IP65 making it suitable for even the harshest industrial environments.
Features & Benefits:
- IO-Link with COM3 transmission rate
- Easy commissioning and configuration with IO-Link
- Simple device replacement with Data Storage capability
- Universal power supply by IO-Link Master
- Robust and excellent resistance to shock and vibration
- Robust magnetic technology
- Standard IP65 protection (IP69K option)
- Standard M12 connector
- TCW4 IO-Link operating temp. range: -20 to 85 degrees C
- ACW4 IO-Link operating temp. range: -40 to 85 degrees C
Interbus Absolute Multi-Turn Encoder
The MHM Encoder is a miniature position sensor designed for applications where space is limited but high precision in position feedback is required.
Features:
- MHM506-INTB, standard encoder Ø58mm with Interbus interface
- Robust and compact conception
- Solid shaft version Ø 06 mm, servo flange
- Precision ball bearings with sealing flange
- High temperatures performances –40°C … +85°C
- Code disc made of unbreakable and durable plastic
- Mechanical memorisation of the number of turns by gears
- Resolution : 13 bits = 8192 steps/turn
- Number of turns : 12 bits = 4096 turns
- Polarity inversion and short circuit protection
- Highly integrated circuit in SMD-technology
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Pressure & Temperature Sensing
Managing temperature and hydraulic fluids are two of the core principles of industrial automation, providing reliable control over process and packaging equipment. With a variety of ceramic, MEMS, and other pressure sensing options, and a full range temperature and thermostat options allow for the fulfillment of all possibilities.
Challenges:
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Harsh Environments: Industrial environments often involve exposure to extreme temperatures, moisture, vibration, and other harsh conditions. The hermetic sealing of the PTE7300 sensors provides robust protection against these environmental factors, ensuring reliable performance over extended periods.
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Accuracy and Precision: In industrial processes, accurate pressure measurement is essential for maintaining quality, safety, and efficiency. The PTE7300 sensors offer high accuracy and precision, enabling precise monitoring and control of pressure levels within industrial systems.
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Long-Term Stability: Industrial operations often require continuous and long-term pressure monitoring. These sensors are designed to maintain stability over time, reducing the need for frequent recalibration and ensuring consistent performance throughout their operational lifespan.
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Compatibility with Various Media: Industrial processes may involve a wide range of fluids and gases. The PTE7300 sensors are compatible with different media types, allowing for versatile use across various industrial applications without compromising performance or reliability.
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Remote Monitoring and Control: With the digital output interfaces (such as I2C or SPI), these sensors facilitate seamless integration into industrial control systems, enabling remote monitoring and control of pressure levels. This capability is particularly valuable for industrial automation and process optimization.
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Cost-Effectiveness: Industrial operations often face pressure to optimize costs without compromising on quality or performance. The reliability, longevity, and low maintenance requirements of the PTE7300 sensors contribute to cost-effectiveness by minimizing downtime and reducing overall operational expenses.
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Compliance and Safety: Industrial processes are subject to regulatory requirements and safety standards. The accurate and reliable pressure measurement provided by these sensors helps ensure compliance with industry regulations and enhances overall safety within industrial facilities.
The PTE7300 pressure sensor is the sensing platform from Sensata Technologies, offering best-in-class accuracy with excellent mechanical shock resistance and EMC protection to meet the most demanding applications in mid to high-pressure ranges. Available with a wide range of ports, low power consumption, fast response time, and increased sensor diagnostics capabilities, it enables customers to standardize and simplify designs.
Features
- Rugged Design – Built to meet demanding applications with high vibration and requirements
- Configurable Port Design – Allows for many different port configurations
- Enhanced Data Integrity – Cyclic Redundancy Check (CRC) assures you that communications and data are reliable
- Mid to High Pressure Range – Pressure ranges from 16-600 bar (230-8700 psi) with high proof and burst pressures
- IP69K Design – Hermetic M12 Connector option
- Easy Integration – Small form factor option for easy integration
Utilizing Sensata’s industry leading ceramic capacitive technology, the 116CP is housed in a small and innovative plastic package ideal for boilers, pumps, and other light industrial applications. The 116CP is offered in a wide range of configurations including various pressure ports, electrical outs and pressure ranges from 0-4 to 0-16 bar.
Features & Benefits:
- Multiple port & Connector options
- High accuracy: +/-1.5%Vs
- Small & compact size
- 100% automated calibration
- REACH/RoHS/CE compliant
- Drinking water safe options available (126CP and 127CP only)
Solid State Relay Solutions
Sensata | Crydom continues to be the global leader in Solid State Switching technology for over 45 years, by offering the most extensive range of standard and custom solid state relays and contactors suitable for any load control application. Our SSRs can control almost any type of load in applications that can benefit from the many advantages that SSRs have over traditional electromechanical relays, such as extended life expectancy, faster switching speed, lack of acoustical noise, higher resistance to shock and vibration, among others.
Challenges:
- Reliability and Longevity
- High-Speed Switching
- Noise and Interference
- Heat Dissipation
- Control and Precision
- Vibration and Shock Resistance
- Size and Weight
- Energy Efficiency
- Maintenance and Downtime
WHITEPAPER: Three Phase Solid State Relays and Their Application in Three Phase Motor Circuits Whitepaper
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Learn More & Shop Sensata’s SSRs
Crydom’s signature family of solid state relays. Ratings from 10 A to 40 A @24-140 VAC, 12 A to 90 A @ 80-530 VAC and 10 A to 125 A @ 24-280 VAC – SCR output for heavy industrial loads – AC or DC control – zero voltage (resistive loads) or instantaneous turn-on (inductive loads) output.
- SCR output for heavy industrial loads
- UL/CSA/VDE Approved, CE Compliant to EN60950-1
With MOSFET output, this 1-DC Series Panel Mount DC output Solid State Relay offers reliable fast switching of DC loads through low On-State resistance. Power ratings for this DC output SSR range up to100 Amps at 100 VDC and 10 Amps at 500 VDC.
- High PWM switching capability (up to 5 kHz on selected models)
- UL approved, CE compliant to EN60950-1
- Epoxy-free design
CX & CMX PCB Mount Solid State Relays provide engineers smaller and more power-dense solutions for discrete or traditional panel-mount applications. This makes them prime targets for engineers who are trying to reduce the size of their overall system. Crydom PCB mount single-in-line packaged (SIP) solid state relays are an ideal alternative to discrete or traditional panel mount solutions. These highly functional SSRs provide quick, precise, and reliable switching – the perfect alternative for discrete or traditional panel mount solutions.
- SCR output for heavy industrial loads (CX)
- AC or DC control (CX)
- MOSFET output (CMX)
The DC60 Series are DC Solid State Relays with a cost effective bipolar transistor output in an industry standard panel mount package and ratings up to 7 Amps at 60 VDC.
- Ratings from 3A to 7A @ 60 VDC
- Bi-Polar Transistor Output
- UL Approved, CE Compliant to EN60950-1
- Improved SEMS Screw and Washer
- Redesigned Housing with Anti-Rotation Barriers
- AC and DC Control
- Epoxy Free Design
Sensata | Crydom SeriesOne DR family of DIN Rail mount Solid State Relays incorporate proprietary thermal management technology to achieve exceptional output ratings. These compact SSRs are ideal for use in demanding applications where space may be limited, providing greater power density than other DIN Rail Solid State Relays.
- Ratings of 3, 6 & 12 Amps
- Load voltage ratings of 24-280 VAC and 48-600 VAC
- Fits standard 35mm DIN Rail
- LED input status indicator
- AC or DC control
- Zero Voltage (resistive loads) or Instantaneous (inductive loads) turn-on output
- UL and cUL Listed, HP Rated, CE & RoHS Compliant
- UL 508 Endurance Rating for Enhanced Reliability
- UL Class I and II, Division 2, for Hazardous Locations
high voltage & reed relays
High Voltage and Reed Relays Deliver in Isolation-Intensive Applications
Sensata’s High Voltage and Reed Relays from its Cynergy3 and Gigavac brands deliver the switching solutions needed in the medical, semiconductor, and insulation testing industries – where the needs for higher voltages and better isolation create the need for solutions beyond standard EMRs or SSRs.
Benefits:
- Durability and Longevity: Both high voltage and reed relays are designed to be highly durable and offer a long operational life, reducing the need for frequent maintenance and replacements.
Enhanced Safety: These relays contribute to safer industrial operations by providing reliable performance in high voltage and sensitive applications, thereby reducing the risk of accidents and equipment failure.
Versatility: Sensata’s relays are versatile and can be used in a wide range of industrial applications, from automation and control systems to power management and telecommunications.
Sensata | Cynergy3 produces a wide range of reed relays in a variety of package sizes for high voltage or radio frequency applications. Sensata’s HV Relays are designed with low contact resistance delivering up to 15kV DC isolation, while the RF Relays have low stable contact resistance up to 20A, with up to 8kV DC isolation between contacts.
These products play an important role in the field of medicine being used in defibrillators that save lives every day, with other applications including semi-conductor and insulation testing, military in-the-field communications, electrosurgical equipment and charging of electric vehicles.
SIP (Single Inline Pckage) – These are designed for high-density applications and are available in various configurations to suit different needs.
DIP (Dual Inline Package) – These relays offer a robust design and are suitable for PCB mounting.
High Voltage Reed Relay – Designed to handle higher voltage loads
RF – these provide minimal signal loss and high isolation
Industrial Challenges:
- Precise and Fast Switching
- Low Power Consumption
- Small Size and Lightweight
- High Sensitivity and Low Actuation Force
- Hermetic Sealing
- High Isolation Between Control and Load Circuits
- Output Type: AC, DC
- Voltage Range: AC – Up to 15,000V, Current Up to 20Amps. DC – Up to 15,000V, Up to 20 Amps
- Miniature, Fully Screened
- Certifications: UL, REACH, RoHS
Sensata | GIGAVAC brings you decades of experience in DC and RF applications of high voltage relays. With a variety of voltages from 2- 100kV Gigavac has the largest selection of High Voltage Relays in the world. Sensata’s High Voltage Relays deliver the switching solutions needed in the medical, semiconductor, and insulation testing industries – among others. Their HV relays are sealed, providing rugged, small, and efficient high voltage designs for most demanding applications.
GH Series – Known for high isolation and robust design
HGV Series – Designed specifically for high voltage applications with enhanced thermal management and compact form factor
EP Series – Offers high reliability and excellent electrical performance
CX Series – Provides high voltage switching with a focus on compact design and efficient operation
Industrial Challenges:
- Handling High Voltage Loads
- Insulation and Isolation
- Compact Design for High Voltage Applications
- Reliability Under High Stress
Features:
- Output Type: AC, DC
- Voltage Range: AC – Up to 70,000V. Current Up to 150 Amps. DC – Up to 70,000V. Current Up to 150Amps
- Vacuum, Gas Filled
- Certifications: ISO, RoHS, REACH
circuit breaker & circuit protection
Hydraulic Magnetic Circuit Protectors: Series IAL/IUL/IEL/LEL
Hydraulic-Magnetic circuit breakers are used when precision is critical. Their overcurrent protection performance is largely independent of the ambient temperature within the specified operating range and can be fine-tuned to 1/10 of an ampere. These circuit breakers can also be made to compensate for transient conditions such as the motor inrush currents, to avoid nuisance tripping.
Sensata |Airpax™ Hydraulic-Magnetic circuit breakers are recognized and listed by globally recognized agencies such as UL, TUV, CCC, CSA and Military Standards and designed to protect your valuable equipment and personnel. Our circuit protection products are available in many mechanical and electrical configurations to provide maximum versatility for the designer, along with a wide variety of packages, mounting types, terminations, handle types, and other features to construct the ideal solution for each application.
IAL/IUL/IEL/LEL magnetic circuit protectors provide low-cost power switching, reliable circuit protection and accurate circuit control for equipment in the international marketplace.
LEL magnetic circuit protectors provide low-cost power switching, reliable circuit protection and accurate circuit control for equipment in the international marketplace. IEL models are for those applications where the unit’s inherent attributes are desired, but compliance with the various standards is not required. Single or multi-pole versions are available with a variety of pole arrangements to meet your specifications. Please see the appropriate product specification table for ratings and limitations.
Features:
- LEL versions meet IEC spacing requirements for installation in equipment that must comply with IEC 601 and 950 and VDE 0730, 0804 and 0805
- Multi-pole options with multi or single handle
- Auxiliary switch options
- Snap-in mounting option
- Mid-trip handle option
- Various actuator options
- Dual frequency delay options
Benefits:
- Enhanced Safety: Overload and Short Circuit Protection & Reliable Tripping Mechanism
- High Performance and Reliability: Consistent Operation & Durability
- Compact and Lightweight Design: Space Efficiency & Ease of Integration
- Versatility and Flexibility: Wide Range of Current and Voltage Ratings & Multiple Mounting Options
- Cost Efficiency: Reduced Downtime & Longevity
- Compliance and Standards: Adherence to Industry Standards & Quality Assurance
- Operational Efficiency: Manual and Remote Operation & Quick Response
- Application Diversity: Industrial Machinery Protection & Power Distribution Management
IUL magnetic circuit protectors provide low-cost power switching, reliable circuit protection and accurate circuit control for equipment in the international marketplace, and single or multi-pole versions are available with a variety of pole arrangements to meet your specifications. Please see the appropriate product specification table for ratings and limitations.
Features:
- Poles – One through six poles available.
- Insulation Resistance – Not less than 100 megohms at 500 volts DC.
- Trip Free – Will trip open on overload even when forcibly held in the ON position. This prevents the operator from damaging the circuit by holding the breaker on.
- Trip Indication – The operating handle moves to the OFF or mid-trip position on electrical overload. Ambient Operation IUL/IEL protectors operate in temperatures between –40°C to +85°C.
- Dielectric Strength – IUL/IEL protectors withstand 3750Vac (1250Vac for LEL), 60Hz for 60 seconds between all electrically isolated terminals except auxiliary switch terminals shall withstand 600Vac, 60Hz for REG and REC types. Four terminal dual coil and relay construction (not offered in the LEL) will withstand 1500Vac.
- Endurance – Operating as a switch, the operating life exceeds 10,000 operations, 6000 at rated load, 4000 without load, at a rate of 6 per minute.
- Electrical Characteristics – .050-100 amperes 80Vdc, 240Vac Max., 240/415Vac at 50 amperes Max., 50/60Hz and 400Hz. Consult factory for specific product ratings. Units rated for 240/415Vac and above 50 amperes are not suitable for across-the-line motor starting.
- Construction – Series, shunt, relay dual coil and series with auxiliary switch available in various delays and combinations.
- Auxiliary Switch – When supplied shall be S.P.D.T. configuration. Non-TUV approved switches have a maximum UL rating of 10.0 amperes, 250 volts, 60Hz; 3.0 amperes, 50 volts DC (REC type) or 0.1 amperes, 125 volts, 60Hz (REG type). TUV approved switches have a maximum UL rating of 10.0 amperes, 250 volts, 60Hz (REC type); or 0.1 amperes, 125 volts, 60Hz (REG; type). The maximum TUV ratings are 1.0 amperes, 125 volts, 60Hz (REC type); 0.1 amperes, 125 volts, 60Hz (REG type).
- Salt Spray (Corrosion) – Meet the requirements of MIL-PRF-55629 when tested in accordance with Method 101 of MIL-STD-202.
- Moisture Resistance – Meet all the requirements of MIL-PRF-55629 when tested in accordance with Method 106 of MIL-STD-202.
- Shock – Circuit protectors shall not trip when tested per MIL-STD-202, Method 213, Test Condition I with 100% rated current applied to delayed units and 80% rated current to instantaneous units.
- Vibration – Shall not trip when vibrated per MILSTD- 202, Method 204, Test Condition A with 100% rated current applied to delayed units and 80% rated current to instantaneous units.