Level sensors play a huge role in many industries, including the food, beverage, and pharmaceutical sectors. These factories would keep using large and heavy machines to measure things if not for level sensors. Thankfully, we now have access to advanced ultrasonic sensors that can do the same job with ease. But what if you need to measure fluid levels in more challenging environments?
Advanced ultrasonic fluid level sensors and other acoustic and optical technologies come in handy in these scenarios. These sensors are ideal for tough applications as they are non-contact and can withstand residue accumulation.
Here are some of the most challenging level sensing applications and how modern tools can solve them.
Level Measurement of Foamy Liquids
Foamy liquids can present a significant challenge when trying to measure levels accurately. A traditional ultrasonic sensor to detect water levels may fail to get past the foam, resulting in incorrect readings. In applications where tank overflow is a risk, this can lead to problems with the product or inventory.
You can use guided wave radar technology to overcome this challenge. This technology uses direct measurements to calculate the distance to the product’s surface. It does this by measuring the time it takes for a microwave signal to reflect from the target.
By using special algorithms, this technology can accurately measure the level in foamy liquids.
Level Measurement of Viscous Liquids
Another complex application is the level measurement of viscous liquids. The thicker the liquid, the more time it takes for sound waves to travel through it. Longer response times can lead to inaccuracies in measurements. The delay can trick the sensor into thinking the tank is lower than its actual level.
Advanced optical sensors can overcome this challenge by using signal processing techniques that consider the delay in sound waves. Taking the pauses into account allows for accurate measurements of viscous liquids even in challenging applications.
Level Measurement in Solids
Detecting the level of solids in an industrial environment can be difficult. Solid levels are harder to see with traditional ultrasonic level detectors. There are several reasons why this is so:
- Dusty products used in industries can reduce the signal strength of ultrasound waves.
- Transparent solids can be challenging because they scatter light and create inaccurate measurements.
The solution to this problem is using either regular or mono-probe tuning forks. When the fork detects material, the frequency changes, this frequency shift indicates that the material has reached a certain depth.
However, tuning forks can only detect one range level. You might need several forks installed in a tank to detect different levels.
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However you use your level sensors, you should get them from a reliable source. We are a leading provider of ultrasonic fluid level sensors. Get in touch today for more information about its products.
