Thick Foam Workshop Measurements Always Inaccurate? 3 Tips to Zero Out Errors – Engineer's Guide [Dayu Electronics]

When using ultrasonic level meters to measure data under thick foam conditions, the following measures can be taken to improve measurement accuracy:

1. Adjust the probe position: Ensure that the probe maintains an appropriate distance from the foam, typically around 5mm to 10mm, to avoid excessive absorption of ultrasonic signals by the foam. At the same time, the probe and the foam should be kept on a flat plane to ensure measurement stability.

2. Choose a wide-range level meter: Select an ultrasonic level meter with a range 3 times larger than the actual range to ensure accurate measurement signals even when foam covers the surface. This is because thick foam may absorb part of the ultrasonic signal, leading to measurement errors. Increasing the range can reduce the impact of such errors.

3. Add a stilling well: Install a measuring tube such as a DN150 plastic pipe at the measurement site and place the probe inside the tube for measurement. This method effectively avoids interference from foam on the ultrasonic signal, improving measurement accuracy. However, the inner wall of the plastic pipe must be smooth, and the top of the pipe should be 30 cm higher than the maximum water level plus the blanking distance. Note that measuring inside a plastic pipe may result in a slight decrease in measurement accuracy.

4. Consider alternative technologies: If the measurement performance of the ultrasonic level meter is poor under thick foam conditions, other technologies such as guided wave radar level meters can be considered. Guided wave radar level meters operate based on microwave pulses and electromagnetic wave reflection principles, and are relatively less affected by foam, thus potentially offering better measurement performance under thick foam conditions.

In summary, by adjusting the probe position, selecting a wide-range level meter, adding a stilling well, and considering alternative technologies, the measurement accuracy of ultrasonic level meters can be improved under thick foam conditions.