PDC sensor for solid level
An ultrasonic sensor for solid level measurement is a non-contact device that monitors the level of bulk materials, powders, and granular substances in silos, bins, and hoppers. It uses sound waves to measure the distance to the material surface, providing continuous level data for inventory management and process control. This guide covers the operating principles, challenges, and applications of ultrasonic sensors for solid level measurement.
An ultrasonic sensor for solid level measurement is a non-contact device specifically designed to monitor the level of bulk materials, powders, and granular substances in silos, bins, and hoppers. The UL-SLD ultrasonic sensor from ABM is the ideal solution for solid material level applications. The non-contact ultrasonic sensor provides continuous level measurement up to 100 feet (30.5 meters) with 4-20 mA output standard and simple push-button calibration. Ultrasonic sensors are suitable for measuring the level of both solid and liquid materials in various storage vessels, including silos, tanks, and bins. They are commonly used in the milling industry for monitoring grain levels, flour, and other powdered or granular materials. The technology is unaffected by dielectric constant, density, or humidity.
PDC Sensor
The working principle of an ultrasonic solid level sensor follows the same time-of-flight principle as liquid level sensors. A transducer emits sound pulses, measures the echo return, and converts distance to level or volume with built-in temperature compensation. The technology works on liquids and, with a clear acoustic path, some bulk solids. Ultrasonic sensors use sound waves to measure the distance between the sensor and the material surface, emitting high-frequency sound waves toward the material. The sensors are useful because nothing touches the medium, making them ideal for corrosive, abrasive, sticky, or hygienic processes. The Prosonic FDU91F ultrasonic sensor provides continuous, non-contact, and maintenance-free level measurement of fluids, pastes, sludges, and powdery to coarse bulk materials. The sensor can also measure the flow in open channels and at weirs.
Solid level measurement presents unique challenges that ultrasonic sensors are designed to address. Angled surfaces are formed in silos for bulk solids, which can cause the ultrasonic signal to be laterally reflected and lead to a reduced signal intensity. The measuring range starts where the ultrasonic lobe meets the bottom of the silo, and in dished or torsipherical heads or conical outlets, levels below this point cannot be detected. The sensors are unaffected by buildup due to the self-cleaning effect of sensors by diaphragm vibration. Ultrasonic sensors are suitable for coarse to fine-grained materials in silos, on belts, stockpiles, and in crushers, as well as rough process conditions including vibration, buildup, corrosion, and abrasion. The sensors automatically remove condensation and build-up from the transducer face.
Advanced ultrasonic sensors for solid level measurement incorporate self-adjusting technology for reliable performance. Self-adjusting sensors continually monitor conditions in the environment and automatically adjust the transmitted energy, transmitted pulse amplitude and duration, and receiver sensitivity to match to the current tank conditions. This technique allows the receiver to detect only one echo from the measured media while all false echoes are pushed under the noise level and eliminated. The self-adjusting technique also gives the same amplitude of wanted echoes regardless of distance to the target. With one echo only, signal processing is very simple and the certainty of the measured echo being the target is 100%. This makes the sensors very accurate and reliable, enabling very fast response for fast-moving applications such as conveyor belts. The sensors have very narrow and uniform polar patterns and a very wide frequency bandwidth that produces uniform echoes, short ringing, and wide temperature operation.
The applications of ultrasonic solid level sensors are extensive across industries. Continuous level sensors deliver long-term, precise performance to ensure bulk material is properly accounted for in tanks, silos, and conveyors. Ultrasonic Level Sensors are suitable for measuring the level of both solid and liquid materials in various storage vessels, including silos, tanks, and bins. They are commonly used in the milling industry for monitoring grain levels, flour, and other powdered or granular materials. The sensors are also used in process tank level and control, inventory level in storage tanks, bins, silos, and for overflow prevention. The self-adjusting nature means there is no need for mapping or profiling the environment or downloading several parameters. Operation is plug-and-play, with the sensors automatically adapting without user involvement. Measuring ranges up to 100 feet (30.5 meters) are available, with simple push-button calibration and various power and communication options.
