The hottest ultrasonic sensor escorts the packagin

2022-08-08
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Ultrasonic sensors escort packaging

a few years ago, ultrasonic sensors did not have durable precision sensing capabilities. Now, scientific and technological progress has made this function of ultrasonic sensors increasingly powerful. These new technologies make ultrasonic sensors easier to use, more flexible and cheaper. Compared with the traditional ultrasonic sensor design, these new functions greatly expand its application range

nowadays, ultrasonic sensors can help mechanical designers find innovative solutions in many industrial fields to reduce costs, improve quality control efficiency, and enhance the inspection function to reduce weight by more than 50%. And its application in the field of packaging is more and more in-depth

more comprehensive protection

now, the ultrasonic sensor adopts several advanced technologies, which enable it to be used in areas where traditional equipment cannot work:

● the ultrasonic sensor adopts protective covers with protection levels of IP67 and ip69k, which can detect in wet environments (such as bottle washing machines)

● the built-in temperature compensation circuit can compensate for the severe temperature changes that may occur during normal day and night shift operation

● the special coating on the sensor surface can prevent the erosion of harmful chemicals

● advanced filter circuit enables the ultrasonic sensor to be free from the influence of factory ambient noise

● the new converter design greatly enhances its loss prevention performance and can be used in dirty environments

more convenient to use

● the new generation of ultrasonic sensor is more convenient to use, with the following characteristics: the button is designed on the sensor shell, which is easier to set the far and near sensing range; Just put the target in front of the sensor and press the button once; The sensor can automatically distinguish the window size and target distance; The setting is simple, and the same sensor can be used in different environments

● dip switch programming, a sensor can be customized for special purposes. Other programmable functions include: response time, output type, analog or discrete, and other special settings for detecting liquid level

● ultrasonic sensors usually have multiple outputs contained in a single sensor. One sensor can have two separate discrete outputs, so one sensor can detect the distance between two different intelligent manufacturing service platforms. For other sensors, there are both discrete and analog outputs in the same sensor to achieve the purpose of measuring and providing alarm output

these functions make the ultrasonic sensor flexible and applicable, and can replace other sensor technologies. Because ultrasonic sensor is easy to use and flexible in application, it can make a great contribution to significantly improve productivity and quality in the field of industrial automation

operating principle of ultrasonic sensor

there is a frequency converter in the ultrasonic sensor. When the converter element vibrates, the frequency converter will send inaudible high-frequency sound waves in one direction. If the sound wave touches the object and reflects back, the converter can receive the echo signal. The sensor determines the distance from the object according to the time from sending the ultrasonic pulse to returning the echo signal. Generally, the sensor can set the range of distance through the button. The sensor determines whether there are objects within the range of these settings

for example, when the ultrasonic sensor installed on the top of the liquid tank or pallet sends sound waves to the inside of the container, the length of time 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 bi-directional mode ultrasonic sensor is suitable for situations requiring edge detection or faster response time, or for use in humid environments

when detecting transparent objects, liquids, dense materials on any surface (rough, smooth, bright) and irregular objects, ultrasonic sensors should be the first choice. However, the ultrasonic sensor is not suitable for outdoor, extremely hot environment or pressure tank, nor can it be used to detect foam objects

the following are important considerations when applying ultrasonic sensors:

● range and size. The size of the object to be detected directly affects the maximum range of the ultrasonic sensor. The sensor must detect a certain sound level before it can output. Large components can reflect most of the sound to the ultrasonic sensor, so that the sensor can detect this component at its farthest sensing distance. Small parts can only reflect a small part of the sound, resulting in a greatly reduced sensing range

● object to be detected. The ideal object for ultrasonic detection should be large, flat and high-density, and perpendicular to the front of the converter. The most difficult objects to detect are small objects made of sound-absorbing materials (such as foam rubber), or objects at a certain angle to the converter. Some objects that are difficult to detect can be detected by allowing the sensor to detect the surface of the background and then reacting to the detection target object between the sensor and the background

if the liquid level is static 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, so as to take the average value of the fluctuation change to obtain a more consistent reading. However, the ultrasonic sensor can not accurately detect the liquid with the surface of foam, because the foam will make the direction of sound propagation deviate

the reverse ultrasonic mode of the ultrasonic sensor can be used to detect objects with irregular shapes. In reverse ultrasonic mode, the ultrasonic sensor will detect a flat background, such as a wall. Any object passing between the sensor and the wall will block the sound wave. The sensor can detect the interference to identify the existence of objects

● vibration. Whether the vibration of the sensor itself or the vibration of nearby machines may affect the accuracy of distance measurement. Rubber anti vibration devices can be used when installing sensors to reduce such problems. Sometimes guide rails can also be used to eliminate or greatly reduce component vibration

● attenuation. The sensor is also designed with temperature compensation function to adjust the slow change of ambient temperature. However, it cannot adjust the temperature gradient or the rapid change of ambient temperature

● false test results. Nearby objects (such as guide rails or fixed rods) may reflect sound waves. In order to accurately detect the target object, the influence of the nearby sound reflection surface must be reduced or eliminated. In order to avoid mistakenly measuring nearby objects, many ultrasonic sensors are equipped with LED indicators to indicate the operator during installation, so as to ensure the correct installation of sensors and reduce the risk of mistakenly measuring

new uses

in the past, it was difficult and expensive to use ultrasonic sensors in some fields. Now, due to low cost and convenience, mechanical designers have gradually begun to use ultrasonic sensors in these fields. In industrial applications, ultrasonic sensors can be used to detect liquid level, detect transparent objects and materials, control tension and measure distance. The industries that use ultrasonic sensors include packaging, bottling, material handling and automotive industries. The following are some examples of uses:

● used to detect bottles in bottling plants

● used in food processing plants to detect and control the liquid level in liquid tanks

● on the packaging line, the tension between the two rollers is monitored to control whether the transmission of materials can hold the transmission speed of the downward trend of the industry

● detect the pin on the automobile engine set

today, the industrial use of ultrasonic sensors is expanding rapidly. This once expensive but unreliable technology is now simple to use and cheap. Ultrasonic sensors are now routinely used in process monitoring to improve product quality, detect defects, determine whether there are any and other aspects. These sensors can also improve productivity by reducing waste generated by damaged components and the resulting downtime. This technology also continues to be developed in this direction. Usually, during the experiment, a certain number of other equipment is required to be equipped as auxiliary or mechanical testing equipment to develop new products

at present, how to make all walks of life realize the application potential of ultrasonic sensors in various fields of manufacturing industry is a major challenge we face, including quality control, process control and inspection

source: international packaging information

Lee kielblock, Senior Application Engineer of Bonner Engineering International Co., Ltd

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