Soft Clipping: An Often-Overlooked Non-Linear Amplitude Response of IEPE/ICP Piezoelectric Sensors

This article reviews soft clipping, a non-linear amplitude response of IEPE/ICP sensors, which occurs when the internal electronics of an IEPE/ICP sensor exceed their specified linear operating range, typically corresponding to an output of ±5 V. Because most measurement systems allow a wider voltage range of ±10 V, this non-linear behavior can occur without triggering system-level warnings. Shaker tests indicate that prolonged operation beyond the rated measurement range results in significant signal distortion, particularly attenuating negative acceleration values and producing asymmetric signals. Even after returning to nominal operating conditions, a recovery time of several seconds is required. While the soft clipping effect appears largely frequency independent up to 5 kHz, it may be difficult to detect in real-world vibration tests with complex, broadband signals. Impact tests further reveal that soft clipping subtly affects shock responses, primarily altering initial peaks and potentially obscuring high-frequency modes that decay rapidly. In contrast, frequency-domain analyses are less affected. Overall, the findings emphasize that avoiding operation outside the rated measurement range and implementing appropriate monitoring or warning strategies are essential for reliable IEPE/ICP measurements, especially for time-domain analysis methods.