Ultrasonic level transmitters are widely used in industrial fields, mainly for non-contact level measurement, such as chemical, petroleum, food, water treatment and pharmaceutical industries. By accurately measuring the level of liquid, solid or powder media, it ensures the safety, stability and quality of the production process, which is of vital importance for industrial production.
Ultrasonic level transmitter introduction
Ultrasonic level transmitters utilize the propagation characteristics of ultrasonic waves to achieve liquid level measurement. Its working principle is based on the fact that the speed of ultrasonic wave propagation in the medium is related to the nature of the medium, and the liquid level height is calculated by transmitting ultrasonic pulses and measuring the time of their propagation in the medium. The sensor is usually composed of a transmitter and a receiver, the transmitter sends out ultrasonic pulses, which are received by the receiver after passing through the medium, and the time difference is measured to determine the liquid level height.
The structural features of ultrasonic level transmitters include precision ultrasonic transmitters and receivers, built-in electronic control modules, and protective enclosures. Its transmitter and receiver are usually made of high-frequency piezoelectric crystals or magnetostrictive materials, which provide high sensitivity and stability and are suitable for various industrial environments. At the same time, its compact structural design makes it easy to install and maintain, high reliability, and can adapt to the harsh environmental conditions of long-term operation.
Ultrasonic level transmitter has many advantages, firstly, it is non-contact measurement, no need to contact the medium directly, avoiding the risk of contamination or corrosion of the sensor, suitable for a variety of media and container types. Secondly, the measurement accuracy is high, can realize millimeter level measurement, suitable for application scenarios that require high level accuracy. In addition, the ultrasonic technology of the AK2000E ultrasonic liquid level sensor and the AK7000E ultrasonic level transmitter has good anti-interference capability, less influence on changes in medium density, temperature and pressure, and high stability and reliability.
Applicable scenarios include chemical, petroleum, water treatment, pharmaceutical and other various industrial fields. In these fields, ultrasonic level transmitters can be used for level monitoring and control of various liquid, solid or powder media, such as level measurement in storage tanks, reactors, pipelines and other equipment to ensure the safety, stability and efficiency of the production process. Its wide applicability and reliable performance make it an indispensable and important tool in industrial automation and process control.
Calibration of ultrasonic level sensors
When different types of errors occur in ultrasonic level sensors, appropriate calibration methods are required to correct these errors. The following is a specific explanation of the various calibration methods:
Zero error calibration
Zero error is when the sensor’s output signal is not zero under no level conditions. To resolve this situation, install the sensor in a vessel with no liquid level and adjust the sensor’s output signal so that it is zero when there is no liquid level.
Distance error calibration
Distance error refers to the deviation of the sensor measurement distance from the actual liquid level. Under the condition of known liquid level, by adjusting the distance calibration parameter of the sensor, the measuring distance of the sensor will be consistent with the actual liquid level.
Time delay error calibration
Time delay error refers to the existence of error in the time required for the uplink signal to be transmitted to the downlink. Adjust the time delay parameter of the sensor to correct the time delay of the sensor by sending a standard test signal and recording the transmission time of the uplink signal and downlink signal.
Linearity error calibration
Linearity error refers to the linear deviation between the sensor output signal and the actual liquid level. Carry out multi-point calibration, record the output signal of the sensor at different liquid levels, and adjust the linear calibration parameters of the sensor to make its output signal linear with the actual liquid level.
Stability error calibration
Stability error refers to the fluctuation or instability of the sensor output signal. By monitoring the stability of the sensor output signal and adjusting the stability calibration parameters of the sensor, the stability and accuracy of the sensor output signal can be improved.
Environmental impact error calibration
Environmental impact error refers to the impact of environmental factors on the sensor measurement. Adjust the compensation parameters of the sensor according to the actual environmental conditions, such as temperature, humidity, etc., in order to improve the accuracy of the sensor measurement.
Regular calibration and maintenance of ultrasonic level sensors
Regular calibration and maintenance of ultrasonic level transmitters is essential to ensure their stable and accurate operation. First of all, regular calibration can ensure that the sensor’s measurement results and the actual liquid level to maintain consistency, to avoid inaccurate measurements due to the accumulation of errors. Secondly, maintenance can extend the service life of the sensor, improve its stability and reliability, and reduce production interruptions and losses due to malfunctions.
It is recommended to calibrate the ultrasonic level transmitter regularly, the calibration frequency can be determined according to the specific application and the manufacturer’s recommendations, it is generally recommended to calibrate every 6 months to 1 year. During the calibration process, attention should be paid to check whether the parameters of the sensor are in line with the standard requirements, including zero point, distance, linearity and stability and other parameters.
In addition, regular maintenance of the ultrasonic level transmitter is crucial. Maintenance steps include cleaning the surface of the sensor, checking whether the power supply and signal line connections are loose, and checking whether the sensor is affected by dirt or foreign objects. Regular maintenance can effectively prevent malfunctions and maintain the stability and reliability of the sensor.
Finally, it is recommended that when carrying out calibration and maintenance work, the operation manual and instructions provided by the manufacturer should be strictly followed to ensure the accuracy and safety of the work. Regular calibration and maintenance work can not only improve the performance of the ultrasonic level transmitter, but also reduce the risk and cost of the production process, to ensure the smooth progress of production.
Summary
Regular calibration and maintenance of ultrasonic level transmitters is essential. Calibration ensures that measurements are consistent with the actual level and avoids the risks and losses associated with inaccurate measurements. Maintenance, which includes cleaning the sensor, checking connections and removing dirt, improves the stability and reliability of the sensor.
Apure offers ultrasonic level transmitters as well as magnetic level meters, capacitance level meters, radar level meters and level switches. Please contact us if you have any questions.