Precise Solvent Level Control: Analysis of Dayu Electronics' Externally Mounted Ultrasonic Level Switch Application
In the automated production processes of industries such as chemical, pharmaceutical, and precision manufacturing, there is a growing demand for miniaturized and highly safe closed containers. For example, in small stainless steel solvent tanks with a wall thickness of 3 mm, dimensions of 250×150 mm, and a liquid depth of 30 mm, conventional invasive level gauges often encounter problems such as insufficient installation space and a risk of leakage. Dayu Electronics' newly launched externally mounted ultrasonic level switch uses a non-contact, 'non-invasive' monitoring method, providing a safe and efficient solution for the automatic refilling needs of such small tanks.
This solution eliminates the need to drill holes or perform hot work on the tank. Simply attach the sensor directly to the outer wall of the tank to achieve precise monitoring. This not only eliminates the risk of medium leakage from the source but also avoids production capacity losses caused by shutdowns for retrofits. Furthermore, the device's operation is entirely unaffected by medium pressure, temperature, or corrosiveness, making it particularly suitable for the demanding working environment of sealed solvent tanks.
However, to ensure the long-term stable operation of the automatic refilling system, two key medium characteristics must be considered in practical applications:
The first is the tendency of the liquid to foam. The externally mounted ultrasonic switch determines the level status based on the reflection characteristics of sound waves as they penetrate the tank wall and propagate inside. If the solvent generates a large amount of foam during flow or refilling, the foam layer will absorb and scatter the acoustic energy, potentially weakening the signal or even creating a measurement blind spot. Therefore, it is crucial to determine in advance whether the medium is prone to foaming.
The second is the concentration and purity of the liquid. Highly concentrated solutions or media containing a significant amount of suspended particles will also cause considerable attenuation of ultrasound. In such complex working conditions, our technical team can ensure measurement accuracy by adjusting the device's operating frequency or gain parameters and recalibrating the signal thresholds.
Every industrial site has its unique process characteristics. To ensure a foolproof solution, customers are advised to provide detailed medium composition data and on-site operating condition information before selection. Dayu Electronics, leveraging its profound acoustic underlying technology and full-chain R&D system, offers targeted acoustic testing and signal commissioning services to ensure that every level measurement is accurate and reliable.