Application Solutions of Ultrasonic Sensors in Real-time Tank Level Detection Devices
Solutions for Water Tank Level Detection
In the industrial sector, liquid level detection is a critical concern that affects virtually all industries. The dynamic nature of liquid levels often presents challenges, including delays, lag time, unstable parameters, and complex variability. Structural or positional constraints of many water tanks prevent direct observation of internal liquid levels, complicating timely replenishment when levels fall short. This can lead to unmet demands during critical usage periods. Additionally, the inner walls of tanks used for long-term liquid storage are susceptible to impurity accumulation and dirt formation, which not only makes cleaning difficult but may also compromise the quality of the stored liquid.
To address the need for real-time monitoring of liquid levels, especially in scenarios requiring non-contact measurement (e.g., corrosive liquids), ultrasonic sensors offer an ideal solution. These sensors use sound waves to detect objects, eliminating the need for direct contact with the measured material and being unaffected by the color, reflectivity, or transparency of the target. Balancing efficiency and cost, the CSC series ultrasonic sensors from DADISICK are a highly recommended choice.
Tank Level Monitoring
Traditional methods for verifying liquid levels, such as observation glasses and float-type level gauges, have a long history of use in industrial tanks. However, observation glasses require complex installation and costly sealing measures. Float-type level gauges, on the other hand, are prone to failures due to float corrosion, jamming, or puncturing, which affects their reliability and stability. In contrast, ultrasonic level sensors offer greater reliability by eliminating the need for complex sealing and the absence of moving parts.
Ultrasonic level sensors, as advanced threshold sensors, determine the liquid level by emitting ultrasonic pulses towards the bottom of the tank and accurately measuring the time it takes for these pulses to reflect back from the liquid surface. The accuracy of this method is based on the direct correlation between the liquid level height and the round-trip time of the ultrasonic pulses, allowing the sensor to calculate the liquid level with precision. Consequently, ultrasonic level sensors are ideally suited for applications requiring high-precision liquid level monitoring, such as pump protection, oil film detection, and shutdown systems.
Tank Level Monitoring
The CSC series ultrasonic sensors are installed on the lid of a standard 55-gallon drum. When activated, the device emits ultrasonic waves that reflect off the liquid surface below (as illustrated in the accompanying image). By measuring the time it takes for these reflected waves to return to the sensor, the distance between the sensor and the liquid surface can be calculated based on the speed of sound.
Enhancing Efficiency and Productivity through Real-time Alerts
Integrating ultrasonic sensors with networked devices allows staff to access precise real-time liquid level data from tanks, significantly improving operational efficiency and productivity. Remote monitoring enables managers to plan visits and dispatches based on actual liquid levels, rather than inaccurate predictions, saving time and costs while maintaining optimal tank capacity and smooth process flows.
Additionally, the system can automatically alert staff to potential issues, minimizing emergencies like tank dry-outs or overflows. If the liquid level exceeds predetermined thresholds, the real-time monitoring system promptly alerts relevant personnel via SMS, email, or other channels, enabling timely responses to prevent critical situations and ensure production safety and continuity.
Using Ultrasonic Sensors for Precise Measurement of Liquid Levels in Tanks Offers Advantages
Non-contact Measurement:
Avoids Contamination and Corrosion: Ultrasonic sensors measure liquid levels by emitting ultrasonic waves and receiving their reflected signals, ensuring that the sensor remains non-contact with the liquid. This eliminates the risk of contamination, corrosion, or clogging that could occur with direct contact. This is particularly crucial for measuring corrosive or viscous liquids.
High-Precision Measurement:
Provides Accurate Data: Ultrasonic sensors boast high measurement accuracy, often achieving millimeter-level precision. This precision is vital for industrial processes requiring stringent control over liquid levels, such as in the chemical, petroleum, and food processing industries.
Wide Measurement Range:
Accommodates Diverse Needs: Ultrasonic sensors offer a broad measurement range, typically spanning several meters to over ten meters (The maximum measurement distance of DADISICK ultrasonic sensors can reach up to 6000 mm). making them suitable for various liquid level measurement requirements. This versatility allows their application in tanks of all sizes, from small laboratory containers to large industrial storage tanks.
Strong Anti-interference Capability:
Stable and Reliable: Ultrasonic sensors operate effectively in complex environments, with robust resistance to interference factors such as temperature, gas, and humidity. This ensures the sensor's stability and reliability under diverse operating conditions, minimizing measurement errors caused by environmental factors.
Easy Installation and Maintenance:
Simplifies Operations: Ultrasonic sensors are straightforward to install, typically requiring only positioning, alignment, and fixation. They usually require minimal maintenance and have a long service life, reducing operational costs and maintenance challenges.
Real-time Monitoring and Remote Management:
Enhances Management Efficiency: Ultrasonic sensors can be connected to control systems or data acquisition devices, enabling real-time monitoring and remote data management. This allows personnel to monitor tank levels anytime, anywhere, facilitating prompt adjustments and optimizations, thereby improving management efficiency.
Multiple Output Signals and Functions:
Offers Flexibility: Ultrasonic sensors provide various output signal types, including analog signals (e.g., 4-20mA or 0-10V) and digital signals (e.g., RS485 or Modbus), facilitating seamless integration with other systems. Additionally, some advanced ultrasonic sensors offer extra features and information, such as temperature measurement, liquid level trend analysis, and alarm functions, catering to diverse application scenarios.
Recommended Ultrasonic Sensors
- Detection range models: 60 mm - 1000 mm or 150 mm - 2500 mm;
- Dimension: M18 thread, 55 mm length or M30 thread, 60 mm length;
- Protection rating: IP67;
- Connection type: 5-pin M12;
- Output types: Analog current output 4 - 20 mA, analog voltage output 0 - 10 V, supports RS485 Modbus-RTU;
- PVDF corrosion-resistant flange probe design, suitable for various corrosive environments;
- Built-in temperature compensation;
- Detection distance learning function via gray wire.
DADISICK Popular Ultrasonic Sensors
Small blind spot, small sound cone, suitable forclose range fine detection.
Non-contact detection independent of colour, transparency or surface characteristics of the object
Ultrasonic sensors are devices that use sound waves to measure distance.
Ultrasonic sensors are devices that use sound waves to measure distance.
