Understanding Non-Contact Level Sensors

Non-contact level sensors, such as ultrasonic and radar sensors, offer a convenient and cost-effective solution for precise liquid level measurement and fluid handling control. These sensors, also known as non-contact level detectors, emit signals towards the medium and then detect the reflected signals. Hence, they determine the level without physically touching the workpiece.

How Do These Sensors Work?

• The sensor emits a signal towards the substance whose level is being measured. This signal could be ultrasonic waves, microwave pulses (radar) or laser beams.
• Emitted signal interacts with the surface of the substance. It could reflect off the surface or be absorbed depending on the properties of the material.
• A sensor detects the signal that has interacted with the substance. This could involve receiving the reflected signal (in the case of ultrasonic or radar sensors) or measuring the time it takes for the signal to return (in the case of ultrasonic sensors).
• Based on the characteristics of the detected signal, the sensor calculates the distance between itself and the substance’s surface. This calculation could involve measuring the time taken for the signal to travel to and from the surface (in the case of ultrasonic sensors) or analysing the frequency shift of the signal (in the case of radar sensors).
• The calculated distance is then converted into a level measurement. This measurement is usually displayed in units, such as inches, centimetres or as a percentage of the total depth of the container or vessel.
• Non-contact level sensors can continuously monitor the level of the substance, providing real-time data to control systems or operators.

Types of Non-Contact Level Sensors

Ultrasonic Level Sensors

They measure the level of solids or liquids by emitting ultrasonic pulses and calculating the time taken for the signals to return after reflecting from the material’s surface. These non-contact liquid level sensors remain unaffected by pressure, temperature and corrosive substances. This makes them suitable for challenging environments.

• They feature automatic temperature compensation for precise level measurements.
• These Flowline noncontact ultrasonic level sensors have a PVDF transducer and 6P polycarbonate enclosure to withstand corrosive liquids.
• They offer configuration via WebCal software and a USB adapter for integration into existing systems without extensive setup time.
• These noncontact ultrasonic level sensors have a short 4 or 8-inch dead band for storage space.

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Radar Level Sensors

Radar level sensors work by emitting microwave pulses towards the measured substance, which then reflect off its surface and are detected by the sensor. The time taken for these signals to return to the sensor is used to determine the level of liquids or solids. These sensors provide continuous and precise monitoring of material levels in tanks and vessels.

• It features a pulse radar technology, utilising an electromagnetic surge to measure and monitor liquid levels.
• This noncontact radar level sensor has an accuracy of +/-3 mm, ensuring precise level measurements.
• It has a spatial resolution of 0.118 inches for detailed and accurate level detection.
• Moreover, this noncontact radar level sensor can be operated at temperatures ranging from -76 to 302 degrees F.
• It has an IP67-rated aluminium enclosure for durability and protection against moisture, dust and vibrations.
• This noncontact radar level sensor further features a beam angle of 12 degrees for precise targeting.

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Laser Level Sensors

Laser-level sensors use laser beams to measure distances with high precision. These sensors emit laser beams on the substance and detect the reflection of the beams off the surface. The time that these beams take to return to the sensor calculates the distance, providing precise level measurements. Their non-contact nature reduces the contamination risk and enables use in harsh working environments.

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Advantages of using a Non-Contact Level Sensor over Contact Level Sensor

• Non-contact level sensors are safer as they operate without physical contact with the measured material.
• They generally require less maintenance than contact sensors, which may need regular cleaning and calibration.
• Comparatively, non-contact sensors can be used in a wider range of applications and environments due to their ability to measure without direct contact with the substance being monitored.
• Non-contact sensors often provide more accurate and reliable measurements than contact sensors, especially in challenging conditions or when measuring highly reflective materials.
• Non-contact sensors are comparatively easier to install and set up.

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