High pressures, extreme temperatures, tight tolerances: Before pressure sensors are deployed under real conditions, STS simulates their durability using the finite element method – for maximum safety even in the deep sea.
Simulation as Safety: Why FEM Is Essential
Offshore oil fields present conditions that pose real challenges for measurement technology. Sensors mounted at depths of over 2,000 meters must withstand continuous pressure of over 200 bar – reliably, because failures would be extremely costly. That's why STS relies on mechanical simulations before manufacturing or installing a sensor.
The Finite Element Method in Practice
Using the finite element method (FEM), the housing of a pressure sensor is divided into many small parts to calculate forces, stresses, and deformations. The goal is to simulate the component's behavior under real loads – such as pressure peaks, which can occur in deep-sea or production processes.
For offshore applications, this means accounting for pressures of 250 bar and more, plus additional process pressures. FEM helps secure the design in advance to ensure mechanical stability at all times.
Hyperbaric Tests for Validation
Following digital simulations, tests are conducted in pressure chambers: hyperbaric tests that expose the housing to, for example, 1,500 bar – equivalent to a depth of 15 km in water. This checks whether the optimized design withstands the stresses.
The image shows no difference between the housing before and after the test – an indicator of mechanical excellence.
Other Application Examples: Temperature & Low Pressure
FEM is also helpful in other critical applications:
- Exhaust gas sensors: FEM can be used to investigate how a sensor must be constructed to ensure that no more than 150°C affects the measuring cell.
- Low-pressure measurement: In the mbar range, even small deformations or stresses can lead to measurement errors. Even adhesive bonds between chip and housing are modeled here to avoid errors caused by incorrect torque during assembly.
Conclusion: Simulation Saves Costs – and Enhances Safety
FEM enables targeted optimization of sensors for extreme conditions. It saves costs on testing, reduces failures, and increases safety in critical applications. STS combines simulation with practical validation – for pressure sensors that deliver what they promise.
