Instrumentation & Controls

Every year, we design and deliver hundreds of thousands of instrumentation-specific sealed connectors and hermetic electrical feedthroughs for sensors, analyzers, and control systems. Feedthroughs are engineered to withstand pressures as high as 15,000 psi and voltages up to 35kV.  While this industry can serve a variety of markets, Douglas Electrical Components has experience designing and manufacturing to service across them, including: Automotive, MIL/Aero, Medical, Oil/Gas/Energy, Semiconductor, UHV, HVAC/R, and Industrial.

Seal the sensing element

The sensor industry can integrate hermetic seals at the sensing element through our CircuitSeal hermetic circuit assembly options transmitting both power and signal. This includes applications such as humidity and temperature sensors or mass flow controllers with the sensing element directly in contact with the liquid or gas it is measuring. Our hermetic technology offers a wide media compatibility range and sealing capability to prevent liquids and gases from reaching the housings protecting the electronics.

Hermetically sealing the electrical connection

Douglas Electrical Components also designs our sensor feedthroughs for the electrical connection between sensors and instrumentation and controls. Douglas offers standard wire bushings to save time on the installation of instrumentation in the field. Additionally, we customize designs for customers to hermetically seal the electronics for certification under the customer’s hazardous location file. For non-hazardous applications, electronics still require environmental protection, such as LiDAR sensors or level sensors. Douglas Electrical can design a moisture-tight electrical connection that is compatible with a variety of liquids and gases.

Customized mechanical interfaces

Customers can design a direct cast seal within their own housing or create a design that is suitable for manufacturing and the field. Sensor feedthrough housings can be constructed using a variety of materials including stainless steel, specialty alloys, and plastic materials. Our hermetic epoxy will seal to both the housing and the electrical connection to create a full hermetic assembly. Our design engineers have the experience and capability to aide your next design or upgrade to meet hazardous location approvals, with approvals for North America, Europe, and the international IECex standards. This saves you time and money when working with approval agencies to certify a sensor or transducer. Our team designs across a variety of industries and hermetically seals assemblies utilizing various housing, cable, and fiber materials.

Mechanical examples

• Radial O-rings: Our hermetic feedthroughs are integrated into housings, radial O-ring feedthroughs, and direct cast assemblies.  This allows for a low profile, lightweight assembly. Additionally, achieve high pressures in a compact package.
• NPT / Metric threads: For industries such as industrial, HVAC, and oil and gas, NPT threaded fittings are commonly used.  These assemblies can be machined from stainless steel, brass, aluminum or specialty alloys to meet customer cost and environmental requirements. Metric threads are also available.
• Welded options: While available, we recommend laser-beam or electron-beam welding in most applications.
• Custom flanges and fittings: from vacuum face seals to ASME/ANSI flanges are available with wire, connector, or power feedthrough integration.
• Back-potted connector assemblies and circuit board seals are popular when integrating directly into a sensor assembly to increase protection while minimizing installation time.

Hermetic seals for microelectronics

Douglas Electrical Components also offers microelectronic hermetic packages through our Electronic Products brand. This includes glass-to-metal seal (GTMS) technology and our multilayer HTCC ceramic sealing technology, designed for miniature and high-temperature sensor applications.