When heavy equipment operates under extreme pressure; like a 400-ton excavator in a mine or a demolition hammer running at 1,500 bar — failure is not an option. That’s why piston pressure switches are trusted in mining and construction equipment around the world. They are strong, simple, and built to survive where electronic sensors often fail.
What Is a Piston Pressure Switch?
A piston pressure switch is a mechanical device that monitors hydraulic or pneumatic pressure.
Inside the switch:
- A solid metal piston moves when pressure increases.
- When the set pressure is reached, it activates a snap-action electrical switch.
- When pressure drops, it resets.
No delicate electronics.
No circuit boards.
Just solid mechanical movement.
Why Are Piston Pressure Switches Better for Mining and Construction?
1. They Handle Extreme Pressure Spikes
Hydraulic systems in excavators and crushers may run at 300–350 bar but pressure spikes can hit 600 bar in milliseconds.
Electronic sensors can fail under shock loads.
Piston switches absorb impact through solid metal components.
2. They Survive Vibration and Shock
Mining and construction equipment constantly vibrates. Drilling, crushing, hauling; these machines never operate gently.
Mechanical piston switches:
- Resist vibration
- Tolerate shock loads
- Last for millions of cycles
3. They Operate in Extreme Temperatures
Heavy equipment may operate in:
- -40°C cold climates
- +50°C desert heat
- Underground high-heat mining environments
Quality piston switches operate reliably from -40°C to +125°C without electronic drift.
Where Are Piston Pressure Switches Used?
Mining Equipment
- Longwall roof supports
- Continuous mining machines
- Hydraulic drill systems
- Haul truck lift systems
Construction Equipment
- Excavators
- Bulldozers
- Cranes
- Concrete pumps
- Hydraulic demolition hammers
They are used for:
- Overpressure protection
- Low pressure alerts
- Pump failure detection
- Safety shutdown systems
- Hydraulic circuit monitoring
What Makes a Pressure Switch “Heavy Duty”?
Not all piston switches are equal.
For mining and construction, look for:
Stainless Steel Housing (316L)
Resists corrosion from:
- Moisture
- Contaminated hydraulic oil
- Salt exposure
- Outdoor weather
Proper Pressure Rating
Best practice:
Switch rating should be at least 1.5× system pressure
If your system runs at 300 bar → choose minimum 450 bar rated switch.
Proper Hysteresis
Prevents rapid ON/OFF cycling.
Example:
If switch activates at 220 bar with 10% hysteresis, it resets at about 198 bar. This prevents switch chatter and extends life.
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Fixed vs Adjustable Pressure Switches
Fixed Setpoint
- Highest reliability
- No tampering
- Best for safety systems
Adjustable Setpoint
- Flexible during commissioning
- Good for variable equipment
- Can be locked after calibration
Electrical Configuration Matters
Choose the right contact type:
- SPST (Simple ON/OFF)
- SPDT (Dual function – warning + shutdown)
Make sure electrical rating matches your load.
Inductive loads (solenoids, relays) require higher rated contacts.
Certifications for Mining Applications
For underground or hazardous environments, switches may require:
- ATEX certification
- IECEx certification
- CE marking
- SIL safety compliance (for safety-critical systems)
Always verify certification requirements based on your application.
Installation Best Practices
Even the best pressure switch can fail if installed incorrectly.
Best practices:
- Mount near main pressure source
- Avoid dead-end lines
- Protect from physical impact
- Use proper sealing
- Minimize vibration stress
Routine annual testing ensures long-term reliability.
Why Choose SUCO Piston Pressure Switches?
SUCO manufactures high-quality, reliable piston pressure switches designed specifically for:
- Mining equipment
- Heavy construction machinery
- Mobile hydraulic systems
- Harsh industrial environments
With over 80 years of engineering experience, SUCO switches are built for:
- High pressure durability
- Long service life
- Vibration resistance
- Corrosion protection
- Safety compliance
Need help selecting the right piston pressure switch?
Contact our technical team serving USA, Canada, and Latin America.
Email: sales@sucoesi.com
Phone: 1-561-989-8499
Visit SUCO at CON EXPO 2026 in Las Vegas and don’t miss the opportunity to connect with industry leaders and explore solutions that keep your equipment running smoothly!
When Should You Use a Piston Pressure Switch?
Choose a piston pressure switch if:
✔ Your equipment operates above 150 bar
✔ Your system experiences pressure spikes
✔ Your machine vibrates heavily
✔ You need simple, reliable ON/OFF monitoring
✔ Downtime is expensive
✔ Safety is critical