…for distance measurement (e.g., distance determination, level measurement, and presence detection).
Optical sensors use light (visible or infrared) to detect objects or determine their distance. Typical applications include position detection of components, surface inspection, distance measurement, and traffic monitoring. Optical sensors work using light barriers, laser triangulation or time-of-flight (LiDAR).
SECO thinks:
Reliable measurement even in dust, fog, smoke, or spray, where optical sensors may fail.
Glass, transparent, or reflective materials can cause incorrect measurements with optical sensors.
Optical sensors can be disrupted by sunlight, shading or darkness.
Ultrasound can measure short and longer distances without relying on complex optics.
Mechanical sensors operate on the basis of direct physical contact or pressure transmission. Typical applications include level control, position and end position monitoring, and stroke and displacement measurement in industrial plants. Mechanical sensors usually operate using floats, push buttons, limit switches, or cable pull sensors.
SECO thinks:
No physical wear or contamination due to contact with media or objects.
Mechanical systems require regular cleaning and replacement of moving parts.
Ultrasound also works for bulk materials or gases and complex geometries.
Mechanical systems are slower and less precise during rapid movements.
Inductive sensors detect metallic objects without contact by changing an electromagnetic field. Typical applications include presence monitoring or position determination in machines or automation systems. Inductive sensors operate using high-frequency magnetic fields that generate field-changing eddy currents.
SECO thinks:
Inductive sensors only detect metals. Ultrasound works with liquids, solids, and gases.
No wear or contamination due to mechanical contact with the object. Maintenance- and wear-free.
Inductive sensors are unsuitable for non-metallic media. Ultrasound can be used flexibly.
Inductive sensors have a range of only a few millimeters. Ultrasound works reliably over several meters.
Capacitive sensors measure changes in electrical capacity between an electrode and an object or medium. Typical applications include level measurement in tanks and object detection in automation or the packaging industry. Capacitive sensors work by detecting changes in the dielectric constant in the electric field.
SECO thinks:
Capacitive sensors are sensitive to material properties. Ultrasound measures independently of this.
Ultrasound also works in fog, dust, or dirt. With capacitive sensors, deposits can cause incorrect measurements.
Capacitive sensors react to the surface area and shape of the object. Ultrasound is less dependent on this.
Capacitive sensors are limited to short distances (maximum 50 mm). Ultrasound covers greater distances.
Radar sensors emit electromagnetic waves (usually in the GHz range) and measure the time or frequency change of the reflected signals. Typical applications include measuring the distance between vehicles, measuring fill levels in tanks, and presence detection. Radar sensors operate using time-of-flight measurement or the Doppler effect.
SECO thinks:
Ultrasonic sensors are significantly cheaper than radar systems due to lower material and energy requirements.
Radar systems require complex antennas. Ultrasound is less complex and easy to integrate.
Radar is optimized for long distances, while ultrasound provides precise measurements at short to medium distances.
Radar can be affected by electromagnetic interference and EMC issues. Ultrasound cannot.
Sensors are essential for automation, robotics, and industrial applications. They detect distance or presence and enable precise control. The most important technologies include optical, mechanical, inductive, capacitive, radar, and ultrasonic sensors. Each technology has specific properties that determine its areas of application.
Optical sensors work with light and offer high precision and fast response times. However, they are highly dependent on environmental conditions and reach their limits in the presence of dust, fog, or transparent objects.
Mechanical sensors are robust and cost-effective, but are subject to wear and tear and are not suitable for non-contact applications.
Inductive sensors are reliable for metallic objects, but have a short range and are limited to conductive materials
Capacitive sensors also detect non-metallic materials, but are sensitive to moisture and temperature.
Radar sensors offer long ranges and work in poor visibility conditions, but they are expensive and complex.
Ultrasonic sensors emit sound waves and measure the transit time of the reflected signal. They are material-independent and detect almost all objects, regardless of color or transparency. Their resistance to dust, moisture, and darkness makes them ideal for harsh environments. They are also cost-effective, non-contact, and safe for humans. Ultrasonic sensors are versatile, reliable, and economical.
While other sensors may be superior in special cases, ultrasound remains the first choice for many industrial applications. If you are looking for a robust, universal, and cost-effective solution for distance measurement and presence detection, ultrasonic sensor technology is the ideal choice.
SECO Sensor Consult GmbH
Am Bleichanger 1
96450 Coburg
Phone: +49 (0)9561 869141
Fax: +49 (0)9561 869149
info@seco-sensor.de
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