A few years ago, ultrasonic level meters did not have the durability and precision sensing capabilities. Nowadays, scientific and technological progress has made some functions of ultrasonic level meters increasingly powerful. Driven by new technologies, ultrasonic level meters are easier to use, more flexible, and less expensive. Compared with the traditional ultrasonic sensor design, these new features greatly expand its application range. Ultrasonic level meters can help mechanical designers find innovative solutions that reduce costs, improve quality control efficiency, and enhance inspection capabilities in many industrial areas. And its application in the packaging field 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 instruments mostly use protective covers of IP67 and IP69K, which can be probed in wet environments (such as bottle washers).
2. The built-in temperature compensation circuit can compensate for the severe temperature changes that may occur during normal day and night shift operation. 3. The special coating on the sensor surface can prevent the erosion of harmful chemical substances.
4. The advanced filter circuit enables the ultrasonic level meter to be free from factory noise.
5, the new inverter design greatly enhances its loss prevention performance, and can be used in dirty environments more convenient.
6, the use of a new generation of ultrasonic level instrument is more convenient, the sensor can automatically distinguish between the window size and the target distance; set simple, the same ultrasonic level instrument can be used in different environments.
7, DIP switch programming, can be customized for a special purpose sensor. Other programmable features include: response time, output type, analog or discrete, and other special settings for detecting the liquid level.
8, ultrasonic level instrument usually has a single sensor contains multiple outputs. A sensor can have two separate discrete outputs so that one sensor can detect two different distances. For other sensors, there are both discrete and analog outputs in the same sensor to achieve both the measurement and the alarm output.
These functions make the ultrasonic level meter flexible and can replace other sensor technologies. Because the ultrasonic level meter is easy to use and flexible in application, it can make a significant contribution to significantly improve productivity and improve quality in the field of industrial automation. The principle of use of ultrasonic level instrument There is a frequency converter in the ultrasonic sensor. When the transducer element vibrates, this frequency converter will send inaudible high-frequency sound waves in one direction. If the sound wave hits an object and is reflected back, the transducer can receive the echo signal. The sensor determines the distance to the object based on the time from sending the ultrasonic pulse to returning the echo signal. In general, sensors can set the range of distance by the button. The sensor determines whether there are objects within the range of these settings. For example, when an ultrasonic level meter mounted on the top of a tank or pallet emits sound waves inside the container, the length of return of the echo can indicate whether the container is full, empty or half full.
Some ultrasonic level meters use one transmitter and one receiver converter, respectively. This bi-directional mode ultrasonic sensor is suitable for situations that require edge detection or faster response times, or when used in wet environments. Ultrasonic sensors should be preferred when detecting transparent objects, liquids, dense materials that are rough (smooth, smooth, and bright), and irregularities. 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 the important things to consider when using ultrasonic level meters:
1, the scope and size, the size of the object to be detected directly affects the maximum range of the ultrasonic sensor. Sensors must detect certain sound levels before they can output. The large part can reflect most of the sound to the ultrasonic sensor so that the sensor can detect this part at its furthest sensing distance. The widget can only reflect a small part of the sound, which results in a greatly reduced sensing range.
2. The object to be detected, using ultrasonic detection of the ideal object should be bulky, flat and high density, and perpendicular to the front of the converter. The most difficult objects to detect are objects that are small and made of sound-absorbing material such as foam rubber, or objects that are angled from the transducer. Some difficult-to-detect objects can be detected by having the sensor detect the background surface and then react to the detection target object between the sensor and the background. If the liquid level is stationary and perpendicular to the sensor surface, detecting the liquid is easy. If the fluid level fluctuates, the response time of the sensor can be extended to take the average of the fluctuations to obtain a more consistent reading. However, ultrasonic levelers cannot accurately detect liquids that are foamy on the surface because foam can deviate the direction of sound propagation. You can use the Ultrasonic Positioner's inverse ultrasonic mode to detect irregularly shaped objects. In reverse ultrasound mode, the ultrasonic sensor detects a flat background, such as a wall. Any object passing between the sensor and the wall blocks the sound waves. The sensor can detect the presence of an object by detecting this interference.
3. Vibration, whether it is the vibration of the sensor itself or the vibration of a nearby machine, may affect the accuracy when measuring the distance. A rubber antivibration device can be used to reduce this problem when installing ultrasonic level meters. Rails can also be used to eliminate or greatly reduce component vibrations.
4, attenuation, the sensor also designed a temperature compensation function to adjust the slow changes in the ambient temperature. However, it cannot adjust for rapid changes in temperature gradient or ambient temperature.
5. Mismeasurement results. Nearby objects (such as guide rails or fixed bars) may reflect sound waves. To accurately detect the target object, the influence of the nearby sound reflection surface must be reduced or eliminated. In order to avoid mismeasurement of nearby objects, the ultrasonic level meter is equipped with LED indicators for indicating the operator during installation to ensure that the sensor is correctly installed and reduces the risk of false detection. New uses In the past, the use of ultrasonic level meters in some areas was difficult and costly. Now, due to the reduced cost and ease of use, mechanical designers have begun to use ultrasonic sensors in these fields. In industrial applications, ultrasonic level meters can be used to detect liquid levels, detect transparent objects and materials, control tension, and measure distances. The industries that use ultrasonic level instruments include packaging, bottling, material handling and the automotive industry. Here are some examples of uses:
(1) In the bottling plant for testing bottles.
(2) It is used in food processing plants to detect and control the liquid level in liquid tanks.
(3) Control the material's transmission speed by monitoring the tension between two rollers on the packaging line.
(4) Inspect the pins on the car engine block. 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 absence, and other aspects. These sensors also reduce the amount of waste generated by damaged components and the resulting downtime, which increases productivity. The technology continues to develop new products in this direction. At present, how to enable all walks of life to realize the potential application of ultrasonic level instruments in the manufacturing industry is a major challenge for us, including quality control, process control and inspection.
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