Portable ultrasonic level sensor

Types of Portable Ultrasonic Level Sensor

Portable ultrasonic level sensor has several types. They include:

• Contact Ultrasonic Level Sensors

  These portable ultrasonic level sensors utilize a measuring technique, which is particular operationally based on the time difference in the echo return between an emitted pulse and the surface of the measured liquid or solid material. They are classified under the general category of non-invasive measurement devices as they don't necessarily have to get into contact with the materials whose level they are measuring. This distinctive feature gives it an added advantage in the sense that it can be freely used for hazardous, high-pressure, or high-temperature liquids, as well as viscous ones that tend to foam.

• Clamp-On Ultrasonic Level Sensors

  Clamp-on ultrasonic level sensors represent a convenient tool for liquid measurement. In this system, the transducers are clamped onto the outside of the container for the liquids in which level measurement is needed. These sensors generate ultrasonic waves that travel through the container wall and the liquid. It measures the level by assessing the time it took for the waves to return. This approach is most effective on materials with good acoustic coupling such as metals and dense plastics. It allows for a quick check on levels without requiring any modification.

• Submersible Ultrasonic Level Sensors

  Submersible ultrasonic level sensors are intended to be placed under the liquid surface for optimum precision. They measure liquid level by emitting ultrasonic impulses that reflect off the liquid surface and return to the sensor. The core of their design is an alloy, which is corrosion and pressure resistant so that it can be used reliably. These sensors provide great accuracy for deep tanks or containers and are effective in the Water, Wastewater, and Chemical industries.

Industrial Application of Portable Ultrasonic Level Sensor

Portable ultrasonic liquid level sensor finds application in several industries. They include:

• Water and wastewater treatment

  Ultrasonic sensors are important in the management of water and wastewater as they help measure the water levels in sewer systems and reservoirs. With increased attention on efficient resource use, accurate level readings can improve process automation, prevent overflow, and reduce waste.

• Chemical and petrochemical industries

  Since chemicals and petroleum products can be dangerous, it is a priority to get precise measurements without necessarily taking risks. Ultrasonic level sensors offer such precision without actually coming into contact with the liquids. In this sense, they reduce the risks and increase efficiency by helping in better storage and transfer.

• Oil and gas industry

  Portable ultrasonic sensors in the level measurement of oil and gases found in tanks and remote field areas. They support monitoring of levels in places that are difficult to access and do not need bulky installations, which, in turn, enhance safety and productivity in monitoring operations.

• Food and beverage industry

  Non-intrusive with high precision ultrasonic level sensors play their role in all aspects of the food and beverage industry, measuring liquid levels like water, milk, juices, and even slurries. The sensors help ensure that processes such as filling, mixing, and fermentation are accurately managed to ensure food safety and quality.

• Mining and metal industries

  In the mining and metallurgy industries, portable ultrasonic level sensors measure slurries and solids in storage bins, hoppers, and silos. They withstand harsh media such as dust and dense solids. They allow for safe measurement in hazardous or difficult environments, which helps prevent accidents like spillovers.

• Power generation

  Power generation plants use water for cooling and steam generation. There is, therefore, a need for accurate water level monitoring. Ultrasonic level sensors provide this monitoring without hazardous contact with the water.

Product Specification and Feature of Portable Ultrasonic Level Sensor

Specifications

• Measurement range: The measurement range of portable ultrasonic level sensors usually spans from 0.3 to 15 meters, depending on model and application and ambient conditions.
• Accuracy: These devices have an average accuracy of about 1% of the range, with some high-end models reaching up to 0.5% for more precise needs.
• Resolution: Most ultrasonic level sensors are equipped with a level resolution of 1 millimeter for detecting changes in level measurement.
• Beam angle: The typical value for an effective beam profile of the sensor is approximately 6° to 10°, which determines the measurement precision and spot size on the surface of the measured liquid.
• Temperature compensation: Ultrasonic level sensors have provisions for temperature changes to maintain accuracy. This is done through a compensation algorithm or materials that resist temperature variations.
• Housing rating: The general housings of portable ultrasonic sensors are IP65 or higher to provide protection against contaminating water and dust elements in industrial environments.
• Power supply: Most models of these sensors are powered by DC sources, ranging from 12V to 24V, while some advanced models are equipped with rechargeable lithium batteries for portable operating convenience.

Features

• Non-contact measurement: Portable ultrasonic sensors measure liquid levels without coming into contact with the substance. They send an ultrasonic wave that reflects off the liquid's surface to measure the distance.
• Portability: These sensors allow easy movement from one location to another without major installations. They are often lightweight and operate on battery power, making them suitable for fieldwork.
• Accuracy and range: Ultrasonic sensors measure level with accuracy from ±1 to ±3 millimeters over a range of 0.2 to 15 meters, depending on ambient conditions and target surface.
• Tank auto calculation: The special feature of tank auto calculation allows the sensor to determine the shape and volume of the tank to convert measured levels into the volume.
• Robust design: Most sensors have robust designs with IP65 or IP67 rating housings for dust and water resistance, making them suitable for harsh environments.
• Temperature compensation: These sensors can regularly measure levels despite fluctuations in environmental temperature by correcting for any effect temperature might have on the sound waves.

How to Choose Portable Ultrasonic Level Sensor

Here are some strategies business owners can use to get portable ultrasonic sensor with accurate measurement:

• Container materials

  Sensors that can work well with the ambient materials of a given container should be selected. For instance, while clamp-on transducers are suitable for dense metals, submersible sensors are suitable for chemicals and adverse elements, as the materials used for the housing are resistant to them.

• Liquid properties

  Buyers, in this case, should consider the nature of the liquid, such as density, temperature, and corrosiveness. While some models have been designed with properties that support working at high temperatures and with dense media, others are equally designed to work with low temperatures.

• Tank shape and size

  Level ultrasonic sensors are adequately specified for irregular tanks visually. For instance, the beam angle and measurement range have been designed to provide accurate readings, even on the large or irregular tanks.

• Accuracy and resolution

  One of the most salient factors is the level of precision required. Where highly precise readings are necessary, sensors with accuracy less than 1% of the full range should be chosen. Such sensors are often equipped with fine resolutions that measure minute changes in level, further enhancing this accuracy.

• Environmental factors

  Buyers should settle for portable ultrasonic sensors that can withstand environmental elements such as dust, water, and extreme temperatures. Such elements can adversely affect the functioning of a sensor. Therefore, one should ensure that the sensor has appropriate IP ratings and a housing designed for outdoor and industrial use.

• Output options

  The selection of the output option should be based on the type of monitoring or control system that is to be utilized. In this case, there are various output types available, such as analog, digital, and Modbus. Therefore, one should ensure the output type available is compatible with the existing system.

Q&A

Q1. What limits the range of portable ultrasonic level sensors?

A1. The extreme environmental conditions surrounding the sensors affect their range, as well as the container and liquid properties. Such factors as high dust concentration or low temperature can interfere with the ultrasonic waves and, thus, have an effect on the range of sensors.

Q2. Can portable ultrasonic sensors be used for both liquids and solids?

A2. These sensors are primarily made for applying to liquids. However, there are specially designed models in the market that can measure both the solid and liquid types of samples. Such models use technology that is specially designed to measure the stockpile and surface of solids.

Q3. What maintenance do these sensors require?

A3. The good thing about portable ultrasonic level sensors is that they require little to no maintenance at all. However, regular cleaning of the transducer, as well as occasional verification of the calibration to ensure it is accurate, goes a long way in making it last longer.

Q4. What makes the readings from these sensors inaccurate?

A4. The most notable killer of portable ultrasonic level sensors is inaccurate readings caused by false returned pings bouncing off the tank walls, improper transducer positioning, or even irregular tank shapes. Other causes of errors include improper environmental compensation and the kind of liquid distortion caused by surface turbulence.

Q5. Do portable ultrasonic level sensors provide safety features?

A5. A majority of portable ultrasonic level sensors have IP ratings on their housings, which protect them from dust and water. This is especially critical for working in hazardous or outdoor areas and helps provide a safe working environment in adverse areas.