Practical application of ultrasonic level meter in industrial automation

Reading: 18 release time: 2018/5/18

Anhui Tiankang ultrasonic level meter does not have the durable precision sensing capability. Today, advances in technology have made some of the functions of ultrasonic level meters increasingly powerful. Driven by new technologies, the ultrasonic level gauge is easier to use, more flexible and less expensive. These new features greatly extend the range of applications compared to traditional ultrasonic sensor designs. Ultrasonic level meters help machine designers find innovative solutions that reduce costs, improve quality control efficiency, and enhance inspection capabilities in a wide range of industries. And its application in the field of packaging is getting deeper and deeper. With advances in technology, ultrasonic level meters have been able to be used in areas where traditional equipment cannot work:

1. Nowadays, ultrasonic level meters mostly use IP67 and IP69K protection covers, which can be detected in humid environment (such as bottle washer).
2, built-in temperature compensation circuit can compensate for the intense temperature changes that may occur during normal day and night operation.
3. The special coating on the sensor surface prevents the erosion of harmful chemicals.
4. The advanced filter circuit makes the ultrasonic level meter unaffected by the noise of the factory environment.
5, the new converter design makes its damage prevention performance greatly enhanced, and can be used more easily in an unclean environment.
6, the new generation of ultrasonic level meter is more convenient to use, the sensor can automatically resolve the window size and target distance; the setting is simple, the same ultrasonic level meter can be applied to different environments.
7, DIP switch programming, a sensor can be customized for special purposes. Other programmable features include: response time, output type, analog or discrete, and other special settings for detecting liquid levels.
8. Ultrasonic level gauges often have multiple outputs included in a single sensor.
A sensor can have two separate discrete outputs, so one sensor can detect two different distances. For other sensors, the same sensor has both discrete and analog outputs for both measurement and alarm output. These features make the ultrasonic level meter flexible and can replace other sensing technologies. Because the ultrasonic level meter is easy to use and flexible, it can make a significant contribution to significantly improve productivity and quality in industrial automation. Principle of use of the ultrasonic level meter The ultrasonic sensor has a frequency converter. When the converter element vibrates, the frequency converter emits inaudible high-frequency sound waves in one direction. If the sound wave hits the object and reflects back, the converter can receive an echo signal. The sensor determines the distance to the object based on the time between the issuance of the ultrasonic pulse and the return of the echo signal. Usually, the sensor can set the distance range of the distance by means of a button. The sensor determines if there are objects within the range of these settings. For example, when an ultrasonic level meter mounted on the top of a liquid tank or pallet emits sound waves into the interior of the container, the length of time that the echo returns can indicate whether the container is full, empty or half full. Some ultrasonic level meters use a transmitter and a receiver converter, respectively. This two-way mode ultrasonic sensor is suitable for situations where edge detection or faster response times are required, or when used in wet conditions. Ultrasonic sensors should be the first choice when detecting transparent objects, liquids, dense materials and irregular surfaces of any surface (rough, smooth, shiny). However, ultrasonic level meters are not suitable for use in high temperature environments or pressure tanks, nor can they be used to detect large foam objects. The following are important things to consider when applying an ultrasonic level meter:
1, the scope and size, the size of the object to be detected directly affects the large range of the ultrasonic sensor. The sensor must detect a certain level of sound before it can be output. Large parts reflect most of the sound to the ultrasonic sensor so that the sensor can detect the part at its far sensing distance. The widget can only reflect a small portion of the sound, resulting in a much smaller sensing range.
2, the object to be detected, the ideal object using ultrasonic detection should be bulky, flat and high density, and perpendicular to the front of the converter. An object that is difficult to detect by zui is an object that is small in size and made of a sound absorbing material (such as foam rubber), or an object that is at an angle to the transducer. Some difficult-to-detect objects can be detected by having the sensor detect the background surface and then reacting to the target object between the sensor and the background. If the liquid level is stationary and perpendicular to the sensor surface, it is easy to detect the liquid. If the liquid level fluctuates greatly, the response time of the sensor can be extended to take the average of the fluctuations to obtain a more consistent reading. However, the ultrasonic level meter is not able to accurately detect a liquid that is foamy on the surface because the foam deflects the direction of sound propagation. An inverse ultrasonic mode of the ultrasonic level meter can be used to detect irregularly shaped objects. In reverse ultrasound mode, the ultrasonic sensor detects a flat background, such as a wall. Any object that passes between the sensor and the wall blocks the sound waves. The sensor can detect the presence of an object by detecting the interference.
3. Vibration, whether it is the vibration of the sensor itself or the vibration of nearby machines, may affect the accuracy of measuring distance. Rubber anti-vibration devices can be used to reduce such problems when installing ultrasonic level meters. Rails can sometimes be used to eliminate or greatly reduce component vibration.
4. Attenuation, the sensor is also designed with a temperature compensation function to adjust the slow change of the ambient temperature. However, it does not adjust for rapid changes in temperature gradients or ambient temperatures.
5. Mistaken results, nearby objects (such as rails or poles) may reflect sound waves. To accurately detect a target object, the effect of the nearby sound reflecting surface must be reduced or eliminated. To avoid accidental detection of nearby objects, the ultrasonic level meter is equipped with an LED indicator to indicate the operator during installation to ensure proper sensor installation and reduce the risk of misdetection. New uses In the past, the use of ultrasonic level meters in some areas was difficult and costly. Now, due to cost reduction and ease of use, mechanical designers have gradually begun to use ultrasonic sensors in these areas. In industrial applications, ultrasonic level meters can be used to detect liquid levels, detect transparent objects and materials, control tension and measure distance. Industries that use ultrasonic level gauges include packaging, bottling, material handling, and the automotive industry. Here are some examples of uses:
(1) Used in the bottling plant to test bottles.
(2) Used in food processing plants to detect and control the liquid level in the liquid tank.
(3) Control the material transfer speed by monitoring the tension between the two rollers on the packaging line.
(4) Detecting the pins on the engine block of the car. Today, the industrial use of ultrasonic level meters is rapidly expanding.
This once costly but not reliable technology is now easy to use and inexpensive. Ultrasonic level meters are now routinely used for process monitoring to improve product quality, detect defects, determine presence and other aspects. These sensors also reduce waste generated by damaged parts and the resulting downtime, which increases productivity. The technology continues to develop new products in this direction. At present, how to make all walks of life realize that the application potential of ultrasonic level meter in manufacturing industry is a major challenge, including in quality control, process control and inspection.

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