The core of this method is "step-by-step troubleshooting using controlled variables," which can quickly differentiate between the two in three steps with an accuracy rate exceeding 95%:
1. Step One: Perform a swap test (fastest way to differentiate)
Swap the installation positions of the two sensors, reheat and stabilize them, then test the deviation:
If, after swapping, the direction/magnitude of the deviation is basically the same as before → it indicates a problem with the sensor itself (a single sensor's accuracy/characteristics are substandard);
If, after swapping, the deviation significantly decreases, or the direction of the deviation changes with the sensor's position → it indicates an installation problem (caused by incorrect installation accuracy/position).
2. Second Step: Precise Troubleshooting for Installation Issues
If the issue is installation-related, perform two additional tests:
Coaxiality/Mounting Plane Check: Use a dial indicator to measure the height difference between the sensing surfaces of the two sensors, and the coaxiality of the mounting holes. If the height difference exceeds 0.05mm and the coaxiality deviation exceeds 0.1mm, it indicates an installation accuracy problem.
Torque Consistency Check: Use a torque wrench to disassemble and re-tighten to the same torque. If the deviation significantly decreases after tightening, it indicates that the installation stress deviation is caused by inconsistent torque.
3. Third Step: Confirming Issues with the Sensors Themselves
If the deviation remains unchanged after swapping, test each sensor individually:
Connect both sensors to the same acquisition channel and test their outputs under zero pressure and rated pressure respectively:
If the output deviation of one sensor exceeds the nominal accuracy, it indicates that the sensor itself is not accurate enough.
If both sensors pass the individual test, but the deviation exceeds the standard when assembled together, it indicates that the characteristics of the two sensors are incompatible (large batch/accuracy differences), which is a sensor pairing issue.
In short: If the deviation follows the sensor after swapping, it's a sensor problem; if it follows the installation location, it's an installation problem. This method can be done on-site without additional equipment.
