Banner Ultrasonic Sensors Provide Flexible Solutions

Advances in technology have made today’s ultrasonic sensors extremely rugged and precise. These new technologies have made ultrasonic sensors simpler, more flexible and more cost-effective. These new enhancements have opened up new applications that go beyond traditional ultrasonic sensors. Today’s ultrasonic sensors offer mechanical designers new and creative solutions for industrial applications. Years ago, ultrasonic sensors were the fallback option in sensor technology, and designers only turned to them when other sensing technologies failed, such as detecting transparent objects, sensing over long distances or when the target color changed. New technologies have made today’s ultrasonic sensors able to withstand the test of harsh environments: · Ultrasonic sensors with IP67 and IP69K protection ratings can be used in humid environments, such as bottle washing machines. · Built-in temperature compensation circuitry to calibrate when there are significant temperature changes during normal or variable operating conditions. · Teflon models have a special coating on the surface that protects against harmful chemicals. · Advanced filtering circuitry shields ultrasonic sensors from field interference. · The new sensor head has a stronger self-protection ability, can resist material damage, and adapt to relatively dirty environments Ease of use A significant feature of the new generation of ultrasonic sensors is that they are easier to use, including button settings, DIP switch programming and some multiple program options. The switch button is completely embedded in the sensor device, which makes it very easy to adjust the distance of the installed sensor. It is a simple matter to place the target in front of the sensor and press the button. This sensor can automatically master the size of the window and the distance. Easy installation means that the same sensor can be adapted to many different applications. The programming method of DIP switches means that a simple sensor can be customized for certain special applications. These personalized features include response time, output type, switch and analog selection, and special settings for level/liquid level control. Ultrasonic sensors generally include multiple output types in a single sensor. Models with two switch outputs can use one sensor to sense two objects at different distances at the same time, while models with one switch output and one analog output can be used to measure and provide alarm outputs. The above features make ultrasonic sensors more flexible and selective than sensors with other technologies. Basic principles for using ultrasonic sensors Ultrasonic sensors use the vibration of the pressure-vibration ceramic on the sensor head to generate high-frequency sound waves that are inaudible to the human ear for sensing. If the sound wave hits an object, the sensor can receive the return wave. The sensor can determine the distance of the object by the wavelength of the sound wave and the time difference between the emission of the sound wave and the reception of the return sound wave. More representatively, a sensor can have two settings, short distance and long distance, through the setting of a button. No matter which boundary the object is in, the sensor can detect it. For example: an ultrasonic sensor can be installed on a pool of liquid or a box of small balls, and send sound waves to the container. By the length of time it takes to receive the return wave, it can be determined whether the container is full, empty or partially full. Ultrasonic sensors also use models with independent transmitters and receivers. When detecting slow-moving objects, or when a fast response is required or in a humid environment, this type of ultrasonic sensor, called a split type, is very suitable. Ultrasonic sensors are the first choice when detecting transparent objects, liquids, smooth, rough and shiny surfaces, translucent materials, and irregular objects. Ultrasonic sensors are not suitable for the following situations: outdoors, in extremely hot environments, in pressurized containers, and also cannot detect objects with foam. Key points for ultrasonic sensor selection: range and size The size of the object being detected will affect the maximum effective range of the ultrasonic sensor. The sensor must detect a certain level of sound waves before it can be stimulated to output a signal. A larger object can reflect most of the sound waves to the sensor, so the sensor can sense the object to its maximum extent, while a small object can only reflect a small amount of sound waves, which significantly reduces the sensing range. The most ideal object to be detected by ultrasonic sensors should be large, flat, high-density objects, placed vertically facing the sensor sensing surface. The most difficult to detect are those with very small areas, or made of materials that can absorb sound waves, such as foam plastics, or facing the sensor at an angle. Some objects that are more difficult to detect can first teach the background surface of the object, and then respond to the object placed between the sensor and the background. When used for liquid measurement, the surface of the liquid needs to face the ultrasonic sensor vertically. If the surface of the liquid is very uneven, the response time of the sensor should be adjusted longer. It will average these changes and can read more fixedly. Using the ultrasonic sensor in retrosonic mode also makes it possible to detect irregular objects. In retrosonic mode, the ultrasonic sensor can first detect a flat background, such as a wall. When any object passes between the sensor and the wall, it will block the sound waves. The sensor senses the interruption and realizes the presence of an object. Vibration, whether it is the sensor itself or the surrounding machinery, will affect the accuracy of distance measurement. At this time, some vibration reduction measures can be considered. For example, a rubber anti-vibration device can be used to make a base for the sensor to reduce vibration. A fixing rod can also eliminate or minimize vibration. Attenuation When the ambient temperature changes slowly, the temperature compensated ultrasonic sensor can make adjustments, but if the temperature changes too quickly, the sensor will not be able to make adjustments. Misjudgment Sound waves may be reflected by some nearby objects, such as rails or fixing fixtures. In order to ensure the reliability of detection, the influence of surrounding objects on the sound wave reflection must be reduced or eliminated. To avoid false detection of surrounding objects, many ultrasonic sensors have an LED indicator to guide the operator during installation to ensure that the sensor is installed correctly and reduce the risk of errors. Typical Application Examples of Ultrasonic Sensors Ultrasonic sensors were once considered too difficult or too expensive to operate, but with the reduction in cost and convenience of use, more and more mechanical designers have incorporated ultrasonic sensors into their machine designs. Industrial applications of ultrasonic sensors include detecting filling conditions, detecting reflective objects and materials, controlling the expansion of loop ropes, and measuring distances. The following are a few application examples:

In the filling room, testing bottles

In water treatment or factory production workshops, detect liquid levels and control container filling conditions (picture using QT50U)

Ultrasonic sensors with integrated pump-in and pump-out logic can control the liquid level.

Check whether the can lid is crooked or missing in the packaging workshop

Ultrasonic sensors are rapidly gaining ground in industrial applications. This once expensive and inaccurate technology has now become easy to use, accurate and inexpensive. Ultrasonic sensors have become a common device used in process control to improve product quality, detecting defective parts, confirming the presence or absence of parts and other areas. The sensors can also improve productivity by reducing scrap and avoiding downtime due to part damage. The future development of this technology will continue this trend. This is a challenge, but there is a consensus in the industry that ultrasonic sensors have great potential for development in all areas of manufacturing, including quality control, process control and inspection.