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Ultrasonic sensors measure the distance to an object by emitting a sound wave and analysing the time it takes for the echo to return. They are used in various applications, including industrial automation and robotics. 22mm ultrasonic sensors can be classified according to their configuration, detection range, output type, operating mode, and environmental compatibility.
Proximity sensors
22mm ultrasonic proximity sensors are designed for short-range detection. These sensors can accurately detect the presence of an object in the range of a few centimetres to a few decimetres. They are widely used in applications where immediate object detection is required, such as in robotic positioning or in triggering actions on assembly lines.
Long-range sensors
Long-range ultrasonic sensors are built to measure distances accurately over extended ranges. They can detect objects several metres away, making them suitable for applications requiring broader spatial awareness. These sensors are commonly employed in inventory management systems, outdoor robotics navigation, and industrial automation, where keeping a considerable distance from an object is essential for safety or operational efficiency.
Cylindrical sensors
Cylindrical sensors have a circular sensing zone, emitting ultrasonic waves in all directions. They are, therefore, ideal for detecting the position of objects within a workspace and monitoring fluid levels in tanks and containers. The 360-degree detection capability makes these sensors a reliable choice for applications requiring quick and accurate object location within a confined area.
Rectangular sensors
Rectangular ultrasonic sensors, unlike their cylindrical counterparts, are better equipped to detect the edges of objects than vast, flat surfaces. They are widely applied in measuring the level of liquids in tanks or monitoring the distance to large objects. The paddle shape of the ultrasonic waves allows these sensors to provide precise readings, particularly in scenarios where the target has a sizeable planar surface.
Various 22mm ultrasonic sensors are designed to meet specific needs, from proximity detection requiring just a few inches to long-range measurements covering several feet. By selecting the right sensor for the application, businesses can ensure accurate and reliable distance measurement.
Short-range sensors
Short-range sensors can detect distances of less than 1 metre, while average-range sensors can go up to 6 metres. Users typically apply them in proximity detection, such as robotics and automation, where tasks require detecting objects that are very close.
Medium-range sensors
Medium-range ultrasonic sensors can detect distances approximately between 0.5 to 6 metres. These sensors are widely applied in general industrial monitoring, level measurement, and such other applications where detection does not require long distances.
Long-range sensors
Long-range sensors are capable of detecting distances of up to 10 metres or more. These sensors are typically employed in outdoor robotics, stock management, and other industrial processes that call for longer distances.
22mm ultrasonic sensors are equipped with different output types, such as analogue voltage, current, and digital output. These output types are selected based on the measurement accuracy required and the system integration needed.
Analogue output sensors
These sensors provide a continuous voltage or current signal proportional to the measured distance. These sensors are widely applied in processes requiring constant monitoring and control, like adjusting motors or valves based on real-time distance data.
Digital output sensors
Digital ultrasonic sensors typically use a high/low signal that corresponds to preset distance thresholds. This output type is mainly used in applications requiring simple object detection or condition monitoring, such as in safety systems or conveyor belt monitoring.
Switching output sensors
Switching output sensors send a switch signal when the detected object is within the range of the sensor. These sensors are often used in counting objects, giving clear signals when reaching certain distances, and offering basic presence detection in machinery.
There are different operational modes that the 22mm ultrasonic sensors can support. These operational modes enable a sensor to be used flexibly in diverse applications.
Continuous mode
The continuous mode has an active emission of ultrasonic waves, constantly measuring the distance to the target. This mode is widely used in applications requiring real-time monitoring, such as robotic navigation and object avoidance. The sensor keeps sending data, thereby providing a constant stream of distance information that allows machines to respond quickly to changes in the environment.
Instantaneous mode
This mode takes a single measurement when needed, such as when an external trigger requests data. It is energy-efficient and suitable for infrequent measurement tasks, such as checking the level of materials in silos or measuring distances in a static environment. This mode can be applied in such applications where periodic sensors are needed.
Eco mode
Eco mode emits ultrasonic pulses in a low-power, energy-saving manner. This operational mode is highly useful and applicable in battery-powered systems and other energy-conserving applications. By reducing power consumption while still measuring distance, eco mode helps extend the life of battery-powered devices and reduces the cost of operating equipment.
Waterproof sensors
Waterproof 22mm ultrasonic sensors are housed in NEMA-rated casings. Such rating protects the sensors from moisture, dust, and other harsh environmental elements. These sensors are widely applied in outdoor monitoring, marine research, and industries where a sensor's exposure to water or extreme environmental conditions is likely.
High-temperature sensors
High-temperature 22mm ultrasonic sensors are specially designed to operate in extreme heat conditions. These sensors are ideal for industries such as oil and gas, metal smelting, and foundry operations. In such situations where ambient temperatures could damage standard sensors, high-temperature variants ensure continuous and reliable distance measurement.
Explosion-proof sensors
Explosion-proof 22mm ultrasonic sensors are designed and built to operate safely in hazardous areas. These sensors are commonly applied in the oil and gas industry, chemical processing, etc. In these situations, the explosive gases or dust could cause standard sensors to fail or become unsafe.
These are critical parameters as they define the performance of a 22mm ultrasonic sensor in various applications.
Sensing range
This range can determine the shortest and farthest distances at which a sensor can effectively measure. Most 22mm ultrasonic sensors have a typical sensing range of 0.15 to 6 metres. Some long-range models can measure distances larger than 10 metres.
Output type
Commonly used output types for non-contact metal sensors include voltage, current, and switch outputs. The output type should be selected based on how the sensor system needs to be integrated with other electronic components.
Operating temperature
This range is important as it defines the temperature range in which the sensor can operate reliably. Most 22mm ultrasonic sensors can work within a temperature range of -25°C to 70°C. However, high-performance models are capable of operating in broader temperature ranges.
Housing rating
IP67-rated sensors are totally protected against dust and immersed in water. This property makes such sensors ideal for harsh industrial environments, including chemicals, dust, or extreme weather conditions.
Frequency
Most 22mm ultrasonic sensors operate at frequencies between 40kHz and 200kHz. This frequency range enables these sensors to send and receive ultrasonic sound waves for distance measurements. A sensor's frequency can, to some extent, affect its precision and the type of target it can detect.
Automation and robotics
22mm ultrasonic sensors are used in most robotics for object avoidance, path planning, and distance measuring. These non-contact distance sensors provide accurate and real-time environmental data, allowing robots to navigate complex spaces. In automation, the sensors monitor positions, fill levels, and other key parameters in industrial processes. Their reliability and precision make them indispensable in increasing efficiency and safety in many robotic and automated operations.
Hopper and conveyor belt
Ultrasonic sensors are used in many industries for reliable and accurate measurement and monitoring of material levels and flow. They can easily measure the level of bulk materials in hoppers and silos by sending ultrasonic pulses. Continuous monitoring of the material's level ensures timely alerts for reordering or preventing overflow.
Liquid level measurement
Non-contact ultrasonic sensors accurately measure liquid levels within tanks and containers. They are largely applied in oil and chemical industries, where maintaining precise liquid levels is crucial for safety, efficiency, and inventory management. These sensors are preferred over contact methods due to their ability to handle varying tank shapes and sizes while providing real-time data.
Industrial equipment safety
These sensors are critical for monitoring and ensuring safety in industrial equipment. Placement of sensors around machinery or critical areas can avoid dangerous conditions by detecting the presence of operators or other equipment. They can also be used to monitor distances or speeds that are potentially unsafe to provide real-time feedback to control systems and stop operations.
Agriculture
Ultrasonic sensors are applied in modern farming systems for various purposes, such as measuring crop height for precision irrigation, estimating livestock feed levels in troughs, and monitoring distances for farm equipment. In this space, they provide reliable measurements with the ability to operate under different weather conditions.
Waste management
These sensors help improve efficiency and reliability in waste management. They are attached to waste collection vehicles to measure fill levels in containers and provide data for optimizing collection routes. Distance sensors offer real-time feedback on levels, enabling proactive management of waste.
Mining and mineral exploration
In these industries, they are used for distance measuring, including the measurement of mineral levels in underground deposits, ore sorting, and monitoring truck position. Working without contact, ultrasonic sensors are well-suited to harsh outdoor work environments.
Non-contact measurement
Ultrasonic sensors measure the distance to an object by emitting an ultrasonic sound wave and then calculating the distance using the time taken for the wave to return. This distance allows them to be used in many applications, such as industrial automation, conveyor systems, etc. The non-contact measurement ensures that these sensors are crucial for environments where safety, hygiene, or the condition of the object needs to be considered.
High precision and repeatability
These stay consistently accurate through various environmental conditions and different types of targets. Most typically, their measuring range stays accurate to within a few millimetres. Good resolution prevents the sensor from detecting small variations in distance, an important feature in manufacturing.
Wide sensing range
This is one of the most valuable features of 22mm ultrasonic sensors. While some are capable of measuring distances ranging only from 15 centimetres to 6 metres, others can measure distances over 10 metres. This wide range makes ultrasonic sensors versatile and suitable for many applications.
IP67 rating
The most recent 22mm ultrasonic sensors feature IP67 ratings, making them dustproof and waterproof. Thus, such sensors are well protected against solid particles and water as much as 1 metre deep over a period of 30 minutes. Because of this property, the sensors can work under harsh conditions in outdoor spaces and industrial environments.
Versatile applications
The 22mm ultrasonic sensors are used in many fields, such as level measurement, object detection, and presence sensing. They fit into automation and robotics, offering distance measurement for navigation and avoiding obstacles.
A1. An ultrasonic sensor works by sending out an ultrasonic sound wave, which then counts the time taken for the wave to return. This technological advancement has enabled distance measurements without direct contact with the object being measured.
A2. They are widely used in industrial automation for distance measuring, level monitoring, and object detection. Other boring applications include robotics, where they help with navigation and avoiding obstacles, and in the logistics sector for managing stock and tracking packages.
A3. The sensor emits an ultrasonic sound wave that travels through the surrounding medium until it strikes an object. A portion of the wave is reflected back to the sensor, where the time taken by the wave is counted and converted to distance using a simple formula.
A4. The major benefit is that it ensures safe operation in hazardous, sterile, or delicate environments. It helps measure object distances without damaging the object or risking injury in dangerous industrial contexts.
A5. They are dustproof and waterproof and, therefore, are well protected against solid particles and water as much as 1 metre deep over a period of 30 minutes. Because of this property, these sensors can work under harsh conditions in outdoor spaces and in both and industrial environments.
