Ultrasonic sensor working principle and industrial application - Database & Sql Blog Articles

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Principle of use of ultrasonic sensors

The ultrasonic sensor has a frequency converter that emits an inaudible high frequency sound wave in one direction when the transducer element vibrates. If the sound wave hits the object and reflects back, the converter can receive an echo signal. The sensor determines the distance to the object based on the time between the issuance of the ultrasonic pulse and the return of the echo signal.

For example, when an ultrasonic sensor mounted on the top of a plastic melt tank or plastic pellet chamber emits sound waves into the interior of the container, the length of time that the echo returns can indicate whether the container is full, empty or half full.

Some ultrasonic sensors use a transmitter and a receiver converter, respectively. This two-way mode ultrasonic sensor is suitable for applications where edge detection is required or where faster response times are desired or when used in wet conditions.

Ultrasonic sensors should be preferred when detecting transparent objects, liquids, dense materials and irregular surfaces of any surface (rough, smooth, shiny). However, ultrasonic sensors are not suitable for outdoor, hot environments or pressure tanks, nor for detecting foam objects.

Ultrasonic sensor used in food processing plants to realize closed-loop control system for plastic packaging inspection

Innovation in ultrasonic sensing technology

Today, ultrasonic sensors introduce several innovative technologies that make them useful in areas where traditional equipment does not work:

• Covers with IP67 and IP69K protection for detection in wet environments such as bottle washers.
· Built-in temperature compensation circuit can compensate for the severe temperature changes that may be encountered in the normal plastic molding factory during shift operation.
• A special coating on the sensor surface prevents the attack of harmful chemicals.
Advanced filtering circuitry allows the ultrasonic sensor to be unaffected by factory environmental noise.
· The new converter design greatly enhances the damage prevention performance and can be used in unclean environments.

The ultrasonic sensor controls the material transfer speed by monitoring the tension between the two rollers on the packaging line.

New use

With the continuous introduction of new technologies, some areas where ultrasonic sensors cannot be used have begun to use more ultrasonic sensors. Ultrasonic sensors can be used to detect liquid levels, detect transparent objects and materials, control tension and measure distance. Its application industries include packaging, bottle making, material handling, plastics processing, and the automotive industry.

Ultrasonic sensors are now routinely used for process monitoring to improve product quality, detect defects, determine presence, and more. These sensors also reduce waste generated by damaged parts and the resulting downtime, which increases productivity. At present, how to make all walks of life realize that the application potential of ultrasonic sensors in various fields of manufacturing is a major challenge, including quality control, process control and inspection.

Range and size

The size of the object to be detected directly affects the detection range of the ultrasonic sensor. The sensor must detect a certain level of sound before it can be output. Large parts reflect most of the sound to the ultrasonic sensor so that the sensor can detect the part at its farthest sensing distance. The widget can only reflect a small portion of the sound, resulting in a much smaller sensing range.

The object to be detected

Ideal objects that are probed with ultrasound should be bulky, flat, and dense, and perpendicular to the front of the transducer. The most difficult objects to detect are objects that are small and made of sound absorbing materials (such as foam rubber), or objects that are at an angle to the transducer.

If the liquid level is stationary and perpendicular to the sensor surface, it is easy to detect the liquid. If the liquid level fluctuates greatly, the response time of the sensor can be extended to take the average of the fluctuations to obtain a more consistent reading. However, ultrasonic sensors are not able to accurately detect liquids that are foamy on the surface because the foam deflects the direction of sound propagation.

An inverse ultrasonic mode of the ultrasonic sensor can be used to detect irregularly shaped objects. In reverse ultrasound mode, the ultrasonic sensor detects a flat background, such as a wall. Any object that passes between the sensor and the wall blocks the sound waves. The sensor can detect the presence of an object by detecting the interference.

vibration

Whether it is the vibration of the sensor itself or the vibration of a nearby machine, it may affect the accuracy of measuring distance. A rubber anti-vibration device can be used to reduce such problems when installing the sensor. Rails can sometimes be used to eliminate or reduce component vibration.

attenuation

The sensor is also designed with temperature compensation to regulate slow changes in ambient temperature. However, it does not adjust for rapid changes in temperature gradients or ambient temperatures.

False test result

Nearby objects (such as rails or poles) may reflect sound waves. To accurately detect a target object, the effect of the nearby sound reflecting surface must be reduced or eliminated. To avoid false detection of nearby objects, many ultrasonic sensors are equipped with LED indicators that are used to indicate the operator during installation to ensure proper sensor installation and reduce the risk of misdetection.