Detect, Measure, Communicate Ultrasonic Sensor with IO-Link for Various Applications

The ultrasonic sensor UB*-F42 from Pepperl+Fuchs is designed as an all-rounder. It can reliably detect objects as well as accurately measure fill levels. Thanks to the integrated IO-Link interface, the device can transmit not only the actual measurement values but also additional differentiated process and status data, which can be used for optimized control and targeted predictive maintenance. The range of applications extends from bulk material monitoring in dusty environments to vehicle detection and consumption measurement of roll materials in production machines.

The physics of ultrasonic technology offers a number of inherent strengths that provide significant advantages over other measurement methods. The ultrasonic sensor is based on an ultrasonic transducer, where a piezoceramic element generates short sound pulses using a membrane. At the same time, the transducer detects the echo of these pulses and uses it as a basis for measurement: the distance value to the target object is calculated by the integrated electronics from the time difference between the transmitted and echo pulse.

Unlike optical signals, sound waves are not affected by the material, color, or surface texture of the target object. Electrical fields and magnetic induction effects do not influence the measurement, nor do steam, precipitation, dust, and deposits. The sensor itself is also immune to virtually any type of contamination.

Another advantage is offered by the propagation characteristics of sound waves. The original pulse corresponds to the circular shape of the membrane, but the diameter continuously increases during propagation. This creates a so-called sound cone, which scans the target area not in a single point but over a surface.

This ensures reliable detection even with irregular surfaces, recesses, and perforated contours of the target object. Additionally, the measurement is conducted contact-free and wear-free; solid objects are detected as well as liquid levels and amorphous masses.

Sensors for the IIoT

The new ultrasonic sensors of the UB*-F42 series combine the proven strengths of the measurement principle with the option of communication via IO-Link. The integrated interface enables very simple commissioning and parameterization of the devices and also provides access to all sensor parameters as well as detailed diagnostic and process data. Via IO-Link, numerous additional parameters such as operating hours, temperature, or device status can be retrieved alongside the actual measurement values. At the same time, seamless communication between the field device and all higher-level systems is made possible. Together with the extensive range of available data, this forms the basis for integrating the sensors into IIoT and Industry 4.0 environments.

The hardware of the UB*-F42 series has also been optimized for industrial use in harsh environments. The device concept has already proven itself over many years and in numerous different applications with the products of the predecessor series of the same name as well as the conceptually identical K0 series. Key improvements were implemented in the development of the new generation. One of these is the replacement of plastic connectors with metal connections to increase mechanical stability. With an IP67 rating, the housing now offers higher protection and ensures excellent resistance to dust and moisture. However, the dimensions and installation fixtures remain unchanged; additionally, there are suitable adapter plates available for replacing the conceptually identical K0 devices. The wide selection of various output variants provides options for all common configurations. The series also features a broad range of detection distances, with measuring ranges of 500 mm (approx. 19.7 in), 2000 mm (approx. 78.7 in), 4000 mm (approx. 157.5 in), and 6000 mm (approx. 236.2 in).

Easy Commissioning, Flexible Installation

The usability of the new generation of devices has also been further improved. The direct use of the new learning input replaces the teach-in with push buttons. This makes parameterization and operation possible even without IO-Link. As the only device series of this type on the market, the UB*-F42 combines the IO-Link interface with two push-pull outputs. This allows the values of two switching outputs to be transmitted to the control system. In a fill-level application, for instance, these could be the signals for 'empty' and 'full.' This saves on wiring and integration effort, as a single sensor can handle two tasks. Two device types of the UB*-F42 series are available in addition to the standard design in the so-called sidelooker version. As the name suggests, the transducer is installed in the housing rotated 90° with the opening for the sound membrane on the narrow side. This arrangement simplifies the integration of the sensor in confined spaces. The space required for the measurement application is further reduced by the particularly short blind zone, which distinguishes all devices in the series compared to the market. Furthermore, the diameter of the sound beam can be infinitely adjusted to the application, allowing the spatial expansion of the detection area to vary. A larger diameter enables the scanning of large surfaces as well as reliable detection of objects that may appear at different points within this area. A smaller diameter minimizes the possibility of disruptive echo effects, for example, when the device is measuring the fill level in a narrow silo or an environment with protruding components on the inner walls.

Thanks to a synchronization function, multiple ultrasonic sensors of the UB*-F42 series can be operated in close proximity to each other. To avoid mutual interference of the signals, three synchronization modes are available, which can be selected according to the application. Up to ten sensors can be connected via the synchronization input on the device. Synchronization is automatic and requires no parameterization.

Versatile Application

Fill level: The devices detect the fill level of solids just as effectively as they do for liquids. They can be used in tanks, silos, and material storage facilities. The robustness of the ultrasonic signal allows universal application, as neither vapors nor dust affect the measurement. A liquid surface is reliably detected within the detection range, as is the conical surface of bulk material. For the latter, a valid average value can be derived from the signal of the wider detection area. The robust housing with a high protection rating and the weather independence of the measurement principle ensure consistently reliable performance even in open storage areas and under harsh conditions.

Access control: A UB*-F42 sensor can detect the entry and exit of vehicles at a gate passage. Detection is completely independent of the vehicle's contours, color, or reflective surfaces. Harsh environmental conditions, dust, and dirt are tolerated. With appropriate parameterization, it is possible to differentiate, for example, between vehicles and people within the detection range.

Production, material control, intralogistics: Where roll material (e.g., paper, film, sheet metal) is processed, the ultrasonic sensor can monitor consumption by measuring the distance to the roll and trigger the replenishment process upon reaching a defined threshold. In the field of production and intralogistics, the sensor can be used for numerous other control and measurement tasks. This allows a wide variety of applications to be covered with just one device type, optimizing inventory management.