Senix's Ultimate Ultrasonic Sensor Selection Guide

 Ultrasonic sensors are engineered to measure the distance to a remote object through the air without physically touching it. They determine this value by emitting high-frequency ultrasonic soundwaves toward the object being measured, then receive the reflected wave and calculate the time between emission and reception.

Due to their unique operational characteristics, these distance measurement sensors find use in a wide range of industrial and scientific applications where measuring without making physical contact is critical. As a result, ultrasonic sensor manufacturers produce sensor products in numerous variations to meet different measurement requirements and restrictions.

While this broad selection makes it possible for customers to find a sensor that suits their unique application, it can also make it more difficult to determine which one is right.

Fortunately, the experts at Senix are here to help!

Senix specializes in designing, manufacturing, distributing, and supporting high-quality ToughSonic® ultrasonic sensors. We're equipped with over 35 years of experience supplying these non-contact distance measurement sensors to end-users and original equipment manufacturers (OEMs) across a variety of industries, and have the expertise to help customers identify the right product for their needs. 

Choosing the ideal sensor depends on numerous variables, including: 

• The measurement application
• The distance of the object being measured
• The output requirements
• The environmental conditions

What Is the Measurement Application?

Ultrasonic sensors are used in various non-contact distance measurement applications, each of which carries different requirements and restrictions. The sensor you choose should fulfill the demands of your application, whether you need stainless steel sensors for corrosive environment operations, cross-talk-resistant sensors for multi-sensor operations, or wireless-enabled sensors for remote measurement operations. 

Typical applications for Senix ultrasonic sensors include:  

• Water Monitoring: Measuring levels of water to facilitate irrigation, stream, river, canal and sea monitoring, and floor and tsunami warning operations
• Tank Level Monitoring: Measuring the levels of materials within a tank to calculate the current volume and indicate if—and when—the tank needs to be refilled
• Distance Ranging: Measuring the distance to an object for dimensioning, positioning, and object ranging operations
• Object Detection: Detecting whether an object is present, rather than the distance between them and the object, within a specific distance window
• Hydrofoil & Nautical: Calculating the flying height of hydrofoil and other types of boats
• Civil Engineering: Providing vehicle positioning, tank level measurements of road resurfacing materials, road surface irregularity detection, and monitoring structural integrity

In all of these applications, it is important to consider the chemical characteristics of the object being measured when choosing the sensor design and construction. For example, if water is being measured, a ToughSonic-100 general-purpose sensor may suffice. On the other hand, if a strong chemical is being measured, a more chemical-resistant ToughSonic-200 model may be more appropriate.

What Is the Maximum/Minimum Measurement Distance?

If a sensor is too close to an object, it may not be able to measure the distance accurately. If a sensor is too far from an object, it may not detect the object at all. The sensor chosen for a distance measurement application must be properly rated for the expected minimum and maximum measurement distances.

Factors to consider when determining the useful operating range required (i.e., the material window) include: 

• Material State: Liquids and solids behave differently when hit with soundwaves, which results in different interactions with ultrasonic sensors. For liquid measurement applications, we recommend choosing a sensor with a range that is at least 25% greater than the expected maximum measurement distance. For dry measurement applications, we recommend a sensor with a range that is at least 50% greater than the expected maximum measurement distance. 
• Size, Shape, and Orientation: The size, shape, and orientation of the material affect the maximum distance at which it can be detected. Large, flat water surfaces are among the easiest to detect at a distance, while curved or granular objects are harder to detect at a sensor’s maximum range. 

Senix sensors are available with a maximum measurement distance of about 50 feet. Different models offer different maximum measurement distance ranges—e.g., general-purpose (50 feet) and chemical (35 feet).

What Sensor Output Is Preferred?

Sensor outputs are set based on the measurement reading or, in override conditions, the lack of a detected target or user-selected response algorithms. Senix ultrasonic sensors can provide one or more simultaneous outputs to various connected devices: computers, displays, programmable logical controllers, and similar devices.

The output options available are: 

• Analog: Voltage or current output signals vary proportionally to the measured distance
• Switch/Relay: Switch outputs turn on or off at set distances to start and stop certain external actions or indicators at predetermined distances
• Serial Data: Output data is transmitted sequentially to a connected device

When choosing between these three output options, it is important to consider the type of system you are plugging the sensor into and the devices connected to the sensor.  

What Are the Application Environment Conditions?

Ultrasonic sensors can offer reliable distance measurement performance in a variety of industrial environments. However, they must be engineered to withstand the conditions found in that environment.

Some of the environmental factors to consider when choosing an ultrasonic sensor include: 

• Temperature: The speed of sound varies depending on temperature, which can affect the accuracy of the distance measured between the sensor and the targeted object
• Weather: Ice, snow, dust, mud, and other environmental material buildup can block the sensor face, which can prevent the ultrasonic soundwaves from being transmitted or received. Additionally, the ingress of contaminants, such as water, can affect sensor function. ToughSonic sensor models are constructed with full epoxy potting, UV-shielded cables, and IP68 / NEMA-4X / NEMA-6P stainless steel or polymer housings to ensure durability in harsh outdoor environments
• Pressure/Vacuum: Ultrasonic sensors are not designed for use in high-pressure or vacuum applications
• Ultrasonic Noise: Ultrasonic noise generated by nearby equipment (air nozzles, pneumatic valves, and ultrasonic welders) can interfere with measurement operations. Computable programmable models can be configured to ignore these effects

Senix: Your Expert and Partner for Ultrasonic Sensor Needs

Ultrasonic sensors play an essential role in a wide range of non-contact distance measurement applications. For sensors you can rely on in your most critical operations, turn to the experts at Senix. 

Contact us at info@senix.com or click here to get started.