Ultrasonic sensors applications

The possible applications of ultrasonic sensors are diverse – whether used for classic object detection, precise level measurement, or practical distance measurement.

Here you can get an exciting insight into the various applications that can be realised with ultrasonic sensors. Be inspired by the possibilities and, at the same time, discover your potential limitations.

1. Where are ultrasonic sensors used?

1.2 Three possible applications of ultrasonic sensors

2. Ultrasonic sensors for object detection

2.1 Advantages and limitations when performing object detection with ultrasonic sensors

2.2 Object detection – Application example

3. Applications of ultrasonic sensors for level measurement

3.1 Possibilities and limitations when performing level measurement using ultrasonic sensors

3.2 Level measurement – Application example

4. Use of ultrasonic sensors for distance measurement

4.2 Advantages and limitations when using ultrasonic sensors for distance detection

4.2 Distance measurement – Application example

5. Outlook: additional potential applications for ultrasonic sensors

StaalCloud key visual

For direct access to all available ultrasonic sensors:

Go to the ultrasonic sensors

1. Where are ultrasonic sensors used?

In some expert circles, ultrasonic sensors are referred to as the "Swiss Army Knives" of position sensors. This is on account of their versatility and numerous possible uses.

In contrast to optical sensors, ultrasonic sensors are able to detect a host of media, including liquids, bulk solids, and solids, as well as coloured and even transparent objects such as glass.

They are also characterised by their ability to precisely detect objects as they approach or move away. In comparison to optical sensors, ultrasonic sensors are also less sensitive to dust, dirt, and mist, and are therefore also suitable for more demanding applications.

1.2 Three possible uses of ultrasonic sensors

Ultrasonic sensors owe their name to the so-called ultrasonic principles according to which they operate. They emit sound waves and then measure the reflected waves, by recording the travel time between the emitted ultrasonic signal and the return of the reflected signal. By measuring the travel time, conclusions can be drawn regarding the object position, the distance, and the properties of the surrounding medium.

A differentiation can be made between three areas of application for ultrasonic sensors.

Object detection
Level measurement
Distance measurement

2. Ultrasonic sensors for object detection

One common application for ultrasonic sensors is real-time object detection.

Hard and smooth objects that reflect sound well offer the best conditions for this. This includes materials such as metal, ceramic, or glass. The colour and transparency of the measurement target have no influence on the sensor's ability to detect. This enables the detection of many different objects.

Soft materials such as felt and foams absorb the sound and therefore are not suitable. Particular caution is advised in case of sound-absorbing ambient conditions as measurement results are likely to fluctuate.

Aside from this, there is barely any sensor that can be put to such flexible, versatile, and also cost-efficient use for object detection as an ultrasonic sensor. Furthermore, ultrasonic sensors score points on account of their simple installation, maintenance, and handling. You simply have to make sure that it is mounted vertically to the measurement object.

2.1 Advantages and limitations when performing object detection with ultrasonic sensors

Benefits:	Limitations:	Examples for alternative solutions:
Can be used for many different media Contactless, wear-free object detection irrespective of colour and transparency Real-time measurements Coverage of various ranges Low susceptibility to interference Simple handling Simple installation and maintenance Economical solution	Unsuitable for sound-absorbing objects (e. g. felt, foam, sand) Limited detection of measurement targets that have sharp edges or are very small Limited ability to detect quickly moving objects Measurement accuracy in case of sound-influencing ambient conditions (e. g. loud noise, wind and rain, high air humidity) Requires vertical alignment and positioning in relation to the detection object	Laser sensors Radar level transmitters Camera systems

Ultrasonic sensors for object detection can be found here:

Go to the ultrasonic sensors for object detection

Fig. 1: An ultrasonic sensor used for motorcycle detection in a multi-storey car park

2.2 Object detection – Application example:
Reliable detection of motorcycles in front of a traffic barrier

Situation:

In a multi-storey car park it is not just cars but also motorcycles that have to be reliably detected in front of a traffic barrier. In the past there were instances of barriers closing or malfunctions, which caused delay and inconvenience to visitors. Incidents such as this must immediately be a thing of the past.

Our solution:

Optical sensors such as photoelectric sensors and laser sensors reach their limits when it comes to the detection of motorcycles, as the smaller surface area and higher ground clearance of motorcycles may impact detection accuracy.

Ultrasonic sensors can be of assistance here, as they effortlessly detect motorcycles, even in these types of situation. In conjunction with a timer relay, a precise point in time for the lowering of the barrier can be determined, as soon as the vehicle is no longer detected by the ultrasonic waves.

With these products, you can find the solution!

Ultrasonic sensor microsonic lcs+340/F/A

Go to the ultrasonic sensor

Analogue multi-functional timer relay Selec 600XU-A-1-CU

Go to the timer relay

3. Applications of ultrasonic sensors for level measurement

Ultrasonic sensors are also widely used in level measurement, as they are suitable for the precise detection of the majority of media in real time.

Containers with smooth surfaces that reflect sound well, such as metal or glass containers, offer fantastic conditions for this. Some foam materials or porous contents, as well as highly reflective or sound-absorbing media may impair measurement.

It is also possible that sound-influencing ambient conditions, such as strong temperature fluctuations, vibrations, or noise may affect the performance of ultrasonic sensors. Irrespective of these manageable potential limitations, ultrasonic sensors are considered to be an effective solution for precise level measurements in various fields of industry.

Barely any other sensor is characterised by such flexibility and versatility in level detection as an ultrasonic sensor.

Thanks to their contactless function, ultrasonic sensors do not come into contact with the detection target, whereby the contamination of the medium is effectively prevented. This makes it particularly well-suited for applications within the food and pharmaceuticals industries, as stict hygiene and quality standards must be adhered to here.

The lack of contact with the medium also contributes to the wear and maintenance-free quality of the sensors.

Other properties that should be highlighted are their simple installation, provided that vertical alignment to the object in question is taken into account, and their user-friendly operation.

3.1 Possibilities and limitations when performing level measurement using ultrasonic sensors

Benefits:	Limitations:	Examples for alternative solutions:
Suitable for most media Precise, thanks to real-time measurement Coverage of large measurement ranges Work contactlessly and without wear Easy to install and maintain Cost-efficient	Measurement impairment on account of sound-absorbing liquid media and bulk solids (e.g. thick lubricants and dense heavy fuels, sludge, gravel, find sand, soil), and highly reflective objects Limited measurement accuracy on account of external ambient conditions (e.g. sound-absorbing containers, strong temperature fluctuations) In normal cases, the need for vertical alignment and positioning in relation to the medium	Level sensors Capacitive sensors Radar level transmitters Pressure transmitters

Ultrasonic sensors for level measurement can be found here:

Go to the ultrasonic sensors for level measurement

Staal Instruments radar level sensor & StaalCloud: a powerful combination for remote monitoring

Fig. 2: An ultrasonic sensor measures the fill level, without any required programming knowledge

3.2 Level measurement – Application example:
Automated pump control based on the fill level

Situation:

Do you want a simple means of level detection and monitoring for your tank, well, or pool? In addition, should the filling and drainage pump start automatically as required? But a lack of or limited programming knowledge is the reason why you have been unable to implement this project up to this point.

Our solution:

We can put your mind at rest! Making your wish a reality requires no programming knowledge whatsoever.

You can simply combine an ultrasonic sensor with a multifunctional display with a switching output. Using the sensor, the fill level of the medium is detected and transmitted as a signal to the display. This in turn interprets the measurement signal and displays the level value in real time.

The switching output is required so that you can connect your desired pump control unit. If necessary, this simultaneously opens up the ability to implement many other automated applications, such as the control of solenoid valves or the switching on and off of lights.

The areas of application are diverse.

With these products, you can find the solution!

Ultrasonic sensor ifm electronic UGT584

Ultrasonic Sensor microsonic mic+340/D/TC

Go to the ultrasonic sensor

Multi-function display WIKA 14110042 - DI32-1

Go to the multi-function display

4. Use of ultrasonic sensors for distance measurement

In comparison to classic solutions such as laser sensors, ultrasonic sensors represent a more affordable alternative to distance measurement. They enable precise real-time distance measurements over various distance ranges, and are ideally suited for the detection of objects with smooth, sound-reflecting surfaces such as metal or glass, as well as for reflective liquids such as water and oil.

Distance measurement is performed contactlessly, whereby signs of wear are kept to a minimum. On account of the lack of mechanical contact with the detection object, repair and maintenance expenses are also manageable. This is limited to routine functional checks and regular sensor cleaning, so that dirt and deposits cannot influence detection.

Ultrasonic sensors only encounter limitations when sound-impairing external influences such as strong rain, wind, temperature fluctuations or high air humidity come into play. In these cases, measurement deviations may occur.

In addition, sound-absorbing objects or media such as foam, or objects with porous surfaces, can pose challenges to the sensors and may require alternative solutions.

Another advantage of ultrasonic sensors is their simple installation, which only requires vertical alignment and an obstacle-free path to the detection target.

4.2 Advantages and limitations when using ultrasonic sensors for distance detection

Benefits:	Limitations:	Examples for alternative solutions:
Compatibility with many objects and media Reliable real-time detection Broad coverage of distance ranges Contactless, and consequently wear-free distance detection Simple installation and maintenance Affordable solution	Measurement inaccuracies in case of highly reflective objects or sound-absorbing detection targets (e. g. foam, felt, porous concrete blocks) Possible measurement deviations in case of sound-impairing ambient conditions (e. g. strong wind, rain, noise, temperature fluctuations, high air humidity, surrounding concrete blocks) Detection limitation in case of very fast-moving objects Need for precise vertical and obstacle-free alignment and positioning in relation to the detection object	Laser sensors Photoelectric sensors Capacitive sensors Radar level transmitters Camera systems

Ultrasonic sensors for distance detection can be found here:

Go to the ultrasonic sensors for distance measurement

Fig. 3: Alternatives to a distance sensor: Ultrasonic sensors

4.2 Distance measurement – Application example:
Reversing assistant for lorries when loading

Situation:

For lorry drivers, the view to the rear often poses a challenge, with reversing at times proving particularly difficult. Accidents or damage can often occur, especially when loading.

But this need not remain the case. However, before equipping a host of lorries with costly reversing assistants, a more affordable solution can be of assistance.

Our solution:

In order to improve reverse manoeuvring, ultrasonic sensors can be used as a reversing assistant. These are installed along the loading ramps and precisely measure the distance between the lorry and the ramp. They then forward the data in real time, to a signal tower for example.

In combination with a signal tower, the distance can be visually displayed to the driver. For instance, a green light indicates that the distance is OK, while a red light indicates that the lorry is getting too close to the ramp. In case of a signal tower with acoustic indicators, the different steps of the manoeuvre can also be guided by means of acoustic signals.

With these products, you can find the solution!

Ultrasonic sensor microsonic mic+600/IU/TC

Go to the ultrasonic sensor

Complete signal tower device Eaton 171424 - SL7-100-L-RG-24LED

View signal towers

Compatible items:

Mounting Bracket Eaton 171446 - SL7/4-FW

Coupling Relay PHOENIX 2903370 - RIF-0-RPT-24DC/21

Acoustic Alarm Eaton 171281 - SL7-AP24

5. Outlook: additional potential applications for ultrasonic sensors

Fig. 4 Examples of ultrasonic sensor applications

You have now learned a few examples as to how ultrasonic sensors are used. However, these only provide a brief insight into the potential offered by the sensors. The wide range of possible applications is almost limitless. Here is another preview of possible tasks that can be performed using ultrasonic sensors:

Measurement of diameters e.g. of pipes, cables, or cylindrical objects
Measurement of objects with regard to their height and width
Edge detection in case of flat objects, for precise positioning in production processes
Rope/cable breakage checks in the heavy goods transport and shipping industry or in elevators, to increase safety
Robot positioning in medical technology or production automation
Use at the sheet extruder to guarantee perfect thickness and quality
Monitoring of load carriers or transport containers to ensure cargo security

These stated examples make clear the incredible versatility and wide range of uses of ultrasonic sensors.

From presence monitoring in the most diverse of scenarios to the quality checking of various materials – the versatility of these sensors is evident in the wide range of applications. There are practically no limits when it comes to the versatility of ultrasonic sensors.

Whether used for object detection, fill level or distance measurement – ultrasonic sensors are genuine all-rounders that are suitable for use in many different applications. You don't always need expensive solutions - see for yourself the flexible possibilities that affordable ultrasonic sensors offer. You are now aware of the limitations, but also the diverse potential that the sensors offer when it comes to implementing unconventional solutions to meet your requirements, without having to resort to traditional and often also more expensive products. Discover the possible uses of ultrasonic sensors in your projects and revolutionise your measurement processes today!

Discover all ultrasonic sensors

Get advice from the Support team

Back to the overview

Ultrasonic sensors applications

1. Where are ultrasonic sensors used?

1.2 Three possible uses of ultrasonic sensors

2. Ultrasonic sensors for object detection

2.1 Advantages and limitations when performing object detection with ultrasonic sensors

2.2 Object detection – Application example: Reliable detection of motorcycles in front of a traffic barrier

Situation:

Our solution:

3. Applications of ultrasonic sensors for level measurement

3.1 Possibilities and limitations when performing level measurement using ultrasonic sensors

3.2 Level measurement – Application example: Automated pump control based on the fill level

Situation:

Our solution:

4. Use of ultrasonic sensors for distance measurement

4.2 Advantages and limitations when using ultrasonic sensors for distance detection

4.2 Distance measurement – Application example: Reversing assistant for lorries when loading

Situation:

Our solution:

5. Outlook: additional potential applications for ultrasonic sensors

2.2 Object detection – Application example:
Reliable detection of motorcycles in front of a traffic barrier

3.2 Level measurement – Application example:
Automated pump control based on the fill level

4.2 Distance measurement – Application example:
Reversing assistant for lorries when loading