Ultrasonic sensors have a variety of variants and specifications to meet different measurement standards and restrictions. This increases the likelihood that customers will find sensors suitable for their unique applications, but it also increases the potential complexity.
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Choosing a suitable ultrasonic sensor requires consideration of many variables, including measurement application, output requirements, object distance and environmental conditions.
Measurement application:
Each non-contact distance measurement application may have different requirements and constraints. Ultrasonic sensors can be stainless steel for operation in corrosive environments, for example, a wireless function that supports remote measurement, or an anti-crosstalk function for multi-sensor processes.
When deciding the design and structure of the sensor, the chemical characteristics of the object to be measured must be considered. Where you want to measure water, you may need to use a general-purpose sensor. Or, in the case of measuring strong chemicals, use a more chemically resistant model.
Maximum/minimum measuring distance:
If the sensor is too close to the object, it may not be able to accurately measure the distance. Conversely, if the sensor is too far away from the object, it may not be able to detect the object.
In the case of selecting a sensor for a distance measurement application, it is necessary to properly evaluate the expected minimum and maximum measurement distances.
Many factors should be considered when determining the required useful work range.
Such as the state of matter.
When interacting with sound waves, the behavior of solids and liquids will be different. In turn, this will result in a different interaction with the ultrasonic sensor. For liquid measurement applications, the most appropriate choice is the range of the sensor at least 25% greater than the expected maximum measurement distance.
Sensors with a range that is at least 50% larger than the expected maximum measurement distance are most suitable for dry measurement applications.
There are also size, shape and direction.
These three variables will affect the maximum distance the ultrasonic sensor can detect the material. For example, a large pile of flat water will have a certain distance from the easiest surface to detect.
In contrast, curved or granular items will be more difficult to detect within the maximum range of the sensor.
Sensor output:
The output of the ultrasonic sensor is established based on the measurement readings. In certain situations, such as coverage conditions, it can be determined based on the likelihood that the target has not been detected or the response algorithm selected by the user.
There are three options for output:
First, the analog quantity, voltage or current output signal will change with the change of the measured distance.
Second, serial data, output data will be transmitted to the designated connection device in turn.
Third, the switch/relay, the switch output is turned on or off according to the set distance, and then the specific external action or indicator light is started and stopped according to the preset distance.
This is very relevant considering the type of system the sensor will be inserted into, and the equipment to be connected to the sensor. When choosing the three output options, this should be used as part of the decision-making process.
Application environmental conditions:
In order to provide reliable distance measurement performance in various industrial environments, ultrasonic sensors need to be designed in accordance with the specifications under relevant environmental conditions.
When choosing an ultrasonic sensor, there are many environmental factors to consider.
temperature factor
Depending on the temperature, the speed of sound will also change, which may affect the accuracy of the distance calculation between the sensor and the target object. This may affect the calculation accuracy of the distance between the sensor and the target object.
climate
The accumulation of environmental materials, such as snow, mud, dust, and ice, may obstruct the sensor surface. This may hinder the transmission or reception of ultrasonic waves.
pollutant
Contaminants may enter the ultrasonic sensor and affect its function. The ToughSonic sensor series adopts a full epoxy resin potting structure. The cable adopts ultraviolet shielding and adopts NEMA-4X/IP68/NEMA-6P or polymer or stainless steel shell to ensure flexibility in harsh outdoor environments.
Pressure/vacuum
Ultrasonic sensors cannot be used in vacuum or high pressure applications.
Ultrasonic noise
Ultrasonic noise from nearby equipment, such as air nozzles, ultrasonic welding machines, and pneumatic valves, can hinder the measurement operation. Computable, programmable models can be configured to remedy these effects.
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