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Cavity pressure sensors: single wire vs. coaxial

15.05.2020, Mould making

The cavity pressure is an important parameter in process monitoring during plastic injection moulding. Pressure sensors are therefore indispensable for comprehensive mould monitoring. The use of high-quality piezoelectric sensors leads to optimal process quality and increases part quality sustainably. Two different technologies are available on the market for charge transfer: single wire and coaxial cables. We will show you the essential differences and characteristics of these two variants.

Single wire

The single wire cable has a very small diameter. This means it can be routed flexibly with minimal bending radii in cable slots and holes and shortened as required. These cables are therefore ideally suited for moulds with limited space. In single wire technology, the mould provides shielding from the surrounding environment such as other voltage sources.

Coaxial

The coaxial cable is characterised by optimal shielding against external signals thanks to its steel sheath. The use of cavity pressure sensors with a coaxial cable is therefore ideally suited for moulds with a high number of electrical components, such as hot runner components or monitoring equipment. This variant is also used if the cable is routed outside of the mould. With the mini coaxial version, several sensor signals can be combined on one multi-channel connector.

Comparison of the two versions available at Meusburger for multi-channel connectors

	Single wire E 6760	Mini coaxial E 6757
Signal	Can be disturbed by signals from the environment (noise) if the shielding is insufficient	No signal interference thanks to shielding against environmental influences through steel sheath
Cable length	Available in lengths 2,000 and 5,000 mm; cables can easily cut to length as required	Available in consecutive lengths from 200 to 1,000 mm; can only be cut to length with a special tool
Cable diameter	1.2 mm	1.9 mm
Flexibility	Very flexible due to minimal bending radii but risk of kinking	Less flexible than single wire cable, but resistant to kinking
Installation	Easy to install thanks to the insulation displacement connector on the multi-channel connector	Easy to install thanks to mini coax female connector on the multi-channel connector
Price	Lower than for mini coaxial	Higher than for single wire

Multi-channel connector

With the E 6763 multi-channel connector, the signals from 4 to 8 cavity pressure sensors can be combined with minimum cabling effort. Depending on the version, the multi-channel connectors have insulation displacement contacts for the single wire cable (version S) and mini coax female connectors for the mini coaxial cable (version C). The mould recognition is done by a chip integrated on the circuit board and enables high process reliability during mould changes. In addition, the sensor data can be easily identified with the supplied labelling plate.

Connection options

The different connection options for direct and indirect cavity pressure sensors are shown in the following figures.

Cavity pressure sensor connection options – direct

Cavity pressure sensor connection options – indirect

Available from stock at Meusburger

In addition to the existing range of cavity pressure sensors, Meusburger now offers the single wire and mini coaxial cables as well as the matching multi-channel connectors from stock. For efficient mould design, the CAD data for the multi-channel connectors and installation spaces is immediately available.