VEGAUltrasonic level gauge (such asVEGASON 61The series is widely used in industrial liquid and solid level monitoring due to its advantages of non-contact measurement, high adaptability, and low cost. However, its measurement accuracy and long-term stability are easily affected by environmental factors, installation methods, and maintenance measures. This article starts from technical principles and combines practical application scenarios to systematically explain the guaranteeVEGAThe key strategy for the accuracy and stability of ultrasonic level sensors.

1、 Core factors affecting accuracy and stability

1. environmental interference

Temperature fluctuations: The propagation speed of ultrasonic waves is significantly affected by temperature (per℃Change about0.17%If the temperature compensation function is not enabled, drastic changes in ambient temperature can lead to measurement errors.

Dust and Steam: In scenarios such as grain storage and chemical reaction vessels, dust or steam adhering to the surface of the medium may reflect or absorb ultrasonic signals, causing data jumps.

Electromagnetic interference: Strong electromagnetic fields (such as near frequency converters and high-voltage cables) may interfere with the operation of electronic components, leading to signal distortion.

2. Installation and mechanical issues

Verticality deviation: Sensor installation inclination exceeds±2°When the sound wave reflection path deviates, it causes errors in the calculation of the material level.

Unstable fixation: Vibration or mechanical impact (such as near pump rooms or transportation equipment) may cause the sensor to loosen, leading to measurement fluctuations.

Obstacle obstruction: Obstacles such as container walls and stirrers reflect sound waves, forming false echoes and interfering with real object level recognition.

3. Changes in dielectric properties

Sudden change in medium density: When liquid layers or solid particles are unevenly sized, the intensity of sound wave reflection changes, affecting the stability of signal reception.

Foam and liquid level fluctuation: in scenes such as fermentation tanks and sewage pools, foam or severe liquid level fluctuation causes echo signal dispersion and reduces measurement accuracy.

2、 Precision and stability maintenance strategy

1. Environmental adaptability optimization

Temperature compensation enabled: Real time correction of sound velocity changes through built-in temperature sensors or external temperature probes to ensure stable accuracy under temperature fluctuations.

Dustproof and moisture-proof design: Install dust covers in dusty environments and regularly clean the sensor surface; Selection of high humidity scenariosIP68Protection level shell to prevent condensation water from entering.

Electromagnetic shielding measures: Install away from strong electromagnetic sources, or use shielded cables to connect sensors and control cabinets to reduce interference risks.

2. Installation specifications and mechanical reinforcement

Verticality calibration: Use a laser level to ensure that the sensor axis is perpendicular to the surface of the medium, and the deviation is controlled within±1°Within.

Rigid fixation: Use stainless steel brackets or flanges to fix the sensor, avoiding vibration transmission; Install shock-absorbing pads next to transportation equipment to reduce mechanical impact.

Obstacle avoidance: through3DSimulate software to plan installation locations, ensuring that the distance between sensors and obstacles is greater than the maximum measurement distance30%.

3. Adaptation of medium characteristics

Dynamic threshold adjustment: for foam or liquid level fluctuation scenarios, enable“Dynamic echo threshold”Function: Automatically filter weak signal interference.

Multi band scanning: using18-70kHzBroadband scanning technology, suitable for different medium densities (such as switching between liquid and solid materials).

Regular calibration: every6Use standard weights or liquid level simulators for zero points every month/Range calibration, compensating for sensor aging errors.

4. Intelligent diagnosis and maintenance

Self check function enabled: throughHARTorFoundation FieldbusProtocol, regularly read sensor diagnostic data (such as echo quality, signal strength).

Historical data tracing: Using supporting software to record measurement curves, analyze fluctuation patterns, and detect potential faults in advance (such as seal aging).

Spare parts inventory management: reservePVDFMaterial probe sealing ringEPDMEnsure quick replacement of vulnerable parts such as process connectors.

3、 Typical application scenario maintenance case

1. Liquid level monitoring of chemical storage tanks

Problem: High temperature steam causes condensation on the surface of the sensor, resulting in attenuation of the echo signal.

Solution: Install a steam blowing device to keep the probe surface dry; Enable temperature compensation+Dynamic threshold function, stable measurement values.

2. Measurement of solid materials in grain silos

Problem: Dust accumulation covers the probe, causing false echoes.

Solution: Install an automatic blowback device and regularly remove dust; Adopting a four wire digital signal transmission system to enhance anti-interference capability.

3. Monitoring of sewage treatment open pool

Problem: Severe fluctuations in liquid level cause data jumps.

Solution: Enable“Average filtering”Algorithm, for continuous10Take the median of the secondary measurement values; Install anti wave plates to reduce liquid level disturbance.

4、 Conclusion

VEGAThe maintenance of accuracy and stability of ultrasonic level sensors requires a combination of four strategies: environmental control, installation standards, medium adaptation, and intelligent diagnosis. By regular calibration, dynamic parameter adjustment, and preventive maintenance, the service life of equipment can be significantly extended and the total lifecycle cost can be reduced. For example, after a certain petrochemical enterprise adopted the above scheme, the repeatability error of level measurement decreased±0.5%drop to±0.2%The annual failure rate has decreased70%Providing reliable guarantees for production safety. In the future, with the integration of IoT technology,VEGAThe remote diagnosis and adaptive calibration function of the level gauge will further simplify the maintenance process and promote the development of industrial measurement towards intelligence.