Interesting facts

Presence detection

Sensors with a switched output, e.g., from the mic+ sensor family can be used, depending on the size of the box or container. The mic+25/D/TC , mic+35/D/TC or mic+130/D/TC can be selected for scanning small boxes.

With larger containers you are recommended to use a mic+340/D/TC or mic+600/D/TC . If the box or container is to be scanned by several sensors, it is recommended to synchronise them with each other.

Furthermore, the pms ultrasonic sensor in hygienic design is recommended in the food industry, the pharmaceutical industry or the beverage industry.

Web edge control

The ultrasonic web edge sensors bks and edge sensor bks+ sense the edge of web-form materials which are decoiled from a spool and guided through a processing machine. The position of the edge is required in order to readjust the web run in such a fashion that the material run always remains “on track”. 

The ultrasonic web edge sensors are structured as a fork sensor and work as a through-beam barrier. A transmitter is located in the lower prong of the fork, which emits continuous ultrasound. A receiver transducer in the upper prong receives the emitted ultrasonic signal and evaluates its intensity. A web material inserted in the fork of the web edge sensor more or less covers the sound path between the transmitter and the receiver. The intensity of the receiver signal varies depending on the degree of coverage. This change is issued as an analogue signal 4-20 mA or 4–20 mA for the purpose of controlling the web run.

Double sheet control

identifies two or more sheets of material on top of each other. The  dbk+4 product range is ideal for use where paper is in use, such as sheet fed printing presses, printers, copiers or collating machines. For thicker materials, plastic sheets and coarse corrugated cardboard, the dbk+5 ultrasonic double-sheet detection is used.

Checking diameter

The diameter of a roll or coil of material can be detected by an ultrasonic sensor with analogue output and the drive adjusted or brake applied accordingly. Typical application for an ultrasonic sensor

mic+35/IU/TC for small diameters,

mic+130/IU/TC for diameters up to 2.5 m.

Installation for a foil extruder

The mic+ ultrasonic sensors with analogue output 0 – 10 V and 4 – 20 mA are ideally suited for controlling the diameter on a foil extruder.

Through-beam barrier

Ultrasonic through-beam barriers are highly suited for reliable presence control and counting of objects at high speed. The through-beam barrier consist of a transmitter and a receiver. The transmitter emits acoustic pulses on a cyclical basis which are captured by the receiver. If an object interrupts the pulses between the transmitter and the receiver, the switching output of the receiver is set.

Label detection

The esf-1 label sensor reliably detects high-transparency, reflective materials as well as metallised labels and labels of any colour. The measurement cycle time automatically self-adjusts to the sound power required. 

Foil tear monitoring

Can be implemented with all ultrasonic sensors with switching output. If the material does not lie flat, it is advisable to operate the sensor as a two-way or reflective barrier. This operating mode also works reliably when the sonic beam is deflected away by the waves in the material. All ultrasonic proximity switches with the microsonic Teach-in support the operating mode reflective barrier.

Level control

Detection of filling levels from just a few millimetres up to 8 m can be made. Ultrasonic sensors with one or two switched outputs for minimum/maximum control, or with 0-10 V and 4-20 mA analogue output are available. Chemical resistant versions are also available with pico+TF ultrasonic level sensor in M22 housing, crm+ ultrasonic sensors (M30 housing) or hps+ ultrasonic sensors (process connection).

Level control in 6 bar overpressure

are possible with the hps+ sensors. In addition, the sensors are chemically resistant and available as a version with two pnp switching outputs or analogue and switching output.

Filling level monitoring in small containers

Detection of filling levels from just a few millimetres up to 8 m can be made. Ultrasonic sensors with one or two switched outputs for minimum/maximum control, or with 0-10 V and 4-20 mA analogue output are available. Even in small containers with a diameter of less than 5 mm can be measured with the zws ultrasonic sensor + SoundPipe .

The pico+TF ultrasonic sensors are the smallest chemically-resistant ultrasonic sensors available from microsonic.They cover a measurement range of 20 mm to 1.3 m.

Detecting obstacles

Ultrasonic sensors of the mic+ family enable the contactless protection of automated guided vehicles in the driving direction. When using several sensors these can be synchronised with each other to avoid influencing each other. With a pre-alarm range and a stopping range, the vehicle can be halted smoothly before an obstacle without the impact bumper triggering the braking mechanism.

Height control of the field sprayer boom

For height control of the field sprayer boom, several wms ultrasonic sensors or mic ultrasonic sensors continuously measure the distance to the crop. The control system of the field sprayer uses the measured distance values to compensate for unevenness in the soil and different plant heights. This allows crop protection agents or fertilisers to be distributed evenly over the field.

The all-metal housing of the two sensor families is specially designed for outdoor applications on agricultural machines.

Height and distance detection of rows of trees or trellises

The wms ultrasonic sensors or mic ultrasonic sensors measure the lateral distance to vines or trellises. With the measured distance values, the control system automatically adjusts the line of the harvesting platform.

The continuous height detection of the rows of trees or trellises allows the spraying areas to be identified. Thus, spraying areas can be added or removed automatically via the control system. This minimises the use of crop protection agents and ensures even distribution.

Height and width measurements

By using several mic+ ultrasonic sensors (M30 housing), pico+ ultrasonic sensors (M18 housing) or zws ultrsonic sensors (small cubic housing), three-dimensional scanning of any size box can be made. There are sensors with different detection ranges available.

Edge detection of flat objects

Very flat objects on a conveyor belt can often be detected via an "indirect" reliable measurements: An ultrasonic sensor with switching output measures the edge of the object in an incline compared to the conveyor transport direction. The edge of the object forms a triple reflector with the conveyor belt and reflects the sound waves back to the sensor.

People detection

If the task is to detect the presence of persons, you are recommended to choose a ultrasonic sensor with an operating range well in excess of the required scanning distance. The greater the operating range of a sensor, the lower is its ultrasonic frequency. And the lower the ultrasonic frequency, the easier it is to detect absorbent clothing materials such as wool.

Robotic sensing

Owing to their compact dimensions pico+ ultrasonic sensors with an M18 threaded sleeve or the zws sensors in square housings are ideal for positioning robot arms.

Positioning

When scanning panes of glass or other smooth, flat surfaces, care should be taken to ensure that the ultrasonic sensor scans perpendicular to the surface.

Quality control

on a packaging machine. A broad spectrum of ultrasonic sensors are available for the detection of objects during fast processes: the zws ultrasonic sensors in square-shaped housing, the  sks sensors in miniature design, the pico+ultrasonic sensors in the M18 threaded sleeve with optional angled head and IO-Link interface, the pms ultrasonic sensor in hygienic design and the lpc+ sensor family with 2 output stages and 4 scanning distances.

Loop control

In this case an ultrasonic sensor with analogue output scans from above into the loop and adjusts the material feed depending on the depth of the loop. If a loop of material tends to swing sideways, the sound waves are very easily deflected away when scanning from above. In such cases it is recommended to scan the loop from below, as shown in the diagram.

Splice detection

The esp-4 splice sensor reliably detects splices and also labels. It is available both in M18 housings, as well as in M12 with external receiving transducer.

Wire break detection

during the winding/unwinding of wires. Depending on the size of the drum, a mic+130/D/TC with 1,300 mm operating range or a mic+35/D/TC with 350 mm operating range can be used. If the position of the wire on the drum should be recorded, there are ultrasonic sensors with analogue output available. Recommended sensors are

Stacking height control

Whether wooden boards, panes of glass, sheets of paper or coloured plastic panels, ultrasonic sensors are ideal for detecting the height accuracy to millimetre precision.

Monitoring of trays

A solution with the sensor operating as a two-way or reflective barrier should always be preferred when the object to be scanned absorbs the sound waves or, due to its shape or position in the tray, deflects the sound waves away. In this situation an additional reflector is positioned behind the actual object to be scanned. An ultrasonic sensor with switched output and operating in window mode emits a signal as soon as the object obscures the reflector. The lpc+ in the M18 threaded housing is ideal for this purpose.

Ultrasonic barrier

It is easy to set up a two-way or reflective barrier using an ultrasonic sensor operating in window mode. To do this, a permanent reflector is positioned behind the objects to be scanned. When an object obscures the reflector, a switching signal is generated.

Sonic reflector

The sonic beam can be redirected via a reverberant, smooth reflecting surface. There are 90° sonic reflectors available as accessories for this. These can be used to advantage in certain confined installations.

Vibration feeder

Ultrasonic sensors, such as the pms sensor in Hygienic Design, continuously measure the level in the vibratory feeder. If the sensor detects a level that is too low, the feed rate is increased. Conversely, if the sensor detects a level that is too high, the control system reduces the product feed to ensure a consistent process.

pms ultrasonic sensors in Hygienic Design

zws ultrasonic sensors in small cubic housings

Crate inspection

The mic+ ultrasonic sensors, the pico+ ultrasonic sensors and the pms ultrasonic sensor in hygienic design were specially developed for applications such as checking whether crates are filled or empty, or scanning empty plastic bottles on a conveyor belt. The synchronisation, which is integrated in both sensor families, simplifies the design of a sensor line.

Volume flow

ultrasonic sensors, as the pms in hygienic design, can be used for continuously detecting the filling level of objects on a conveyor belt. When the sensor detects minimum filling level, the feed rate will be increased. On the contrary, when the sensor detects a maximum filling level, the control unit will reduce the feed rate in order to provide a smooth filling level process.