Measurement and Level Monitoring

Measurement and Level Monitoring

Accessing accurate fill level data from tanks and other storage containers is critical to managing inventory, securing contents, and assuring quality and safety. Broad variations in contents and containers, as well as location and environmental conditions, can challenge the accuracy and timeliness of data from these assets, compromising its value. Banner solutions for measuring and monitoring fill levels are available in a range of sensing technologies to optimize detection for each unique target. Used in combination with our wireless products, these solutions can provide accurate, real-time data from assets deployed in remote and hard-to-access areas.

Monitor Fill Level of Liquid in Mobile Drum

    • Mobile drum fill level monitoring
    • Non-contact and wireless ultrasonic sensor
    • Epoxy is a highly viscous adhesive

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Liquid Level Monitoring

Banner’s U-GAGE QT50U ultrasonic analog long distance sensor has a narrow sensing beam that works in confined areas, such as the tank, without interference from the tank walls and senses with an extended range up to 8 m. The ultrasonic sensor can be mounted to the center so that the beam spreads over the tank to detect the fluid level without interference, while signaling when to pump out excess liquid and pump in additional liquid.

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Liquid in Container Detection

Banner combined the technology of WORLD-BEAM QS30 opposed mode sensors, which provide high excess gain, with a 1450 nm infrared sensing beam—specially tuned to an absorption band of water, to create the QS30H2O Water Sensor. In this application, the powerful sensing beam of the QS30H2O will burn through the opaque plastic of the container. At 1450 nm, water absorbs 1,000 times the energy of alternative wavelengths, preventing the beam from burning through the liquid within the container.

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Measuring Wear Patterns on Conveyor Belts [Success Story]

Elevators, escalators and moving sidewalks are major investments in any facility’s infrastructure. This equipment is expected to operate safely and reliably for many years and with minimal downtime for maintenance. To meet these expectations, a large-scale manufacturer of vertical and conveyor transport equipment performs rigorous tests on all system components. The data that is collected helps the company estimate component life expectancy and plan service schedules.

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Bottle Fill Level Detection

The Q4X analog sensor is set up in trigger mode and uses the averaging feature to provide a more consistent fill level measurement. Banner’s Q3X sensor, whose output wire is tied to the Q4X’s remote input wire, is used to detect the leading edge of the pill bottle and has a one-shot output timer setup based on the conveyor speed to determine when and how long the Q4X will measure.

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Inspecting Small Connectors [Success Story]

An automotive supply company makes a range of vehicle systems. Their seating systems combine structure and design with features that enhance comfort and safety. Weight sensors installed on the underside of the seats work in coordination with vehicle safety systems to determine the size and position of a seat occupant. These factors affect how or if airbags will be deployed in the event of an accident.

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  1. Sheet Metal Thickness Measurement
  2. The LH laser displacement sensor is a perfect solution because it is highly accurate and measures thickness at micron levels. The L-GAGE LH Series can also consistently look at dark targets on these levels. The LH’s 1024 pixel CMOS linear imager is capable of micrometer-level resolutions ranging from 1-10 microns, which gives it the ability to measure thickness of sheet metal quickly and accurately.
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Level Monitoring for Washdown Environments

Banner’s U-Gage QT50U ultrasonic sensor excels at the most challenging level applications, bouncing sound off any solid surface—even those that may vary in consistency or contrast. The sensor is available with a Teflon-coated transducer cover, making it resistant to harsh chemicals and suitable for the food and beverage industry. Ultrasonic sensors are able to provide accurate monitoring of pump-controlled tanks by sending a continuous signal to measure the current tank depth.

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Level Monitoring On Rotary Filler System

Banner’s SureCross wireless system can easily transmit temperature, pressure and fill levels to a local PLCs. The wireless system will seamlessly alert operators if bottling is occurring below the desired fill level. This helps prevent errors and leads to greater consistency in bottled beverages. Consistent fill levels mean no recalls—and no wasted products. Using a wireless system also eliminates the need for slip rings on the rotary filler, which in turn reduces maintenance costs.

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Day Tank Level Monitoring

Using a wireless level monitoring system, day tank fill levels are now monitored continuously so that materials are maintained at a specific quantity. Because these tanks are slowly filled or depleted, ultrasonic sensors can be used to measure the tank levels without false readings or tank wall interference. With a SureCross Wireless Network, FlexPower™ Nodes are deployed at each tank without the need to run cables for power or I/O data transmission. Banner’s unique power management capability enables a Node equipped with a T30UF ultrasonic analog level sensor to operate for years on a single DX81 battery power supply. Remotely located tank sensor readings can be forwarded to a host system for data tracking, sending e-mail alerts, or to trigger specific events, such as refilling the tank. Tank resources are only filled when necessary to maintain customer-defined levels. Time is no longer wasted performing routine refills on tanks that did not need to be refilled.

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Sensors to Measure Movement Range

During assembly, inspections are conducted to measure seat height adjustment, forward and rearward movement, and upright and recline motion. Two sensors are used for each inspection. The sensors are deployed off the conveyor line to ensure easy access to and the free movement of the seats. At its maximum range during inspection, a seat may be as far as a meter away from the sensors.

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Carton Stack Height

The two-point teach option on the Q4X analog laser measurement sensor is used to teach the full and empty magazine. Manual adjustment can be used to fine tune the output. The analog output provides a real time gauge of the stack height. This allows the cartoner machine to have several “call for parts” set points without having to manually move the sensor. The Q4X is a robust, rugged stainless steel sensor ideal for use in many industrial, factory environments.

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Monitoring Flammable Fluid Levels in a Recycling Facility

Alternative data collection solutions are possible with Banner’s DX99 900 MHz radios in CID1 housings and the B/W Prostick magnetostrictive level devices. Using the appropriate antenna barrier, the result is a Class 1 Division 1 wireless monitoring solution that provides real-time data anywhere within the facility. With the battery powered DX99 units and the loop powered Prostick, installation into the 8' flanged tanks takes only a few minutes.

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Case Stacker Inventory and Presence Detection

The two point teach option on the analog setting can be used teach the front of the flat cases as the 20 mA point and can easily be adjusted for a manual set of the 4 mA to the end of the cases. This helps gauge how many flat cases are left, so more cases can be added when the case count is getting low. The digital output can also be used for presence detection. This helps ensure there is a case available to be picked up, and also ensures only one box is picked up at a time.

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Remote Fill Level Indicator

A brew pub uses EZ-LIGHT indicator lights as a remote display of the status of the levels in the brew tanks. The indicators are connected to ultrasonic sensors within the tanks that cannot be monitored easily.

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