Industrial Ultrasonic Proximity Sensor

We are the professional manufacturer of industrial ultrasonic proximity sensor. The common sensing distances are as follows: short type (20~150mm, 30~350mm and 40~500mm), 60~1000mm, 180~2000mm, 180~3000mm, 200~4000mm, and 350~6000mm. Regular shape is cylindrical or tubular. But there are also the square and rectangular. In addition, USSR can also customize the special ultrasonic proximity switch. For example, we can manufacture the anti-corrosion or explosion-proof ultrasonic proximity detectors.

Normal diameter of the round tube is M18 and M30 threaded. And available output configuration has four types. That is, switching output, analog output, analog + switching, and digital output. The first one includes the NPN, PNP and others. The second output includes current (4-20mA) and voltage (0-5v and 0-10v). And the last output includes RS485, RS232 and TTL232, Io-Link, etc.

Acoustic proximity sensor is different from double sheet sensor. The former is diffuse or reflective mode. The latter is through beam or opposed mode. It uses high-frequency sound waves to detect object proximity. Usually use Pulse-echo type technology. The sensor can measure the distance between detector and object. Its main application is in the field of industrial automation control. For example, apply it in a variety of automated production lines, as well as robots and other intelligent equipment. Ultrasonic proximity switch can measure the both distance and level.

Industrial ultrasonic sensor has many advantages such as fast response time, high accuracy and reliability. It does not need mechanical contact and apply any pressure to make the switch action. Then drive the DC motor or give control instructions to PLC.

Why choose our industrial ultrasonic proximity sensor?

In fact, we manufacture both ultrasonic sensors and ultrasonic transducers. So we can control the cost well. Our industrial ultrasonic sensor price is advantageous. Of course, the proximity switch performance is also stable.

(1) A comprehensive range of sensors to suit most conditions.

Several detection distances are available.The minimum detection range is 20~150mm. It has a small blind zone and high precision. We can apply it to small range measurement. And the maximum measuring distance is 6 meters. It can meet the long distance industrial measurement.

In addition to the regular cylindrical shape, we also offer many square or rectangular sensors. Therefore, it can meet special mounting requirements.

Ultrasonic sensors will interfere with each other. So, two sensors cannot be installed too close to each other. If you have to mount them in close proximity, our sensors with synchronisation can solve this problem.

(2) Strong customization ability to meet special requirements

Regular housings of ultrasonic proximity switch are nickel-plated copper tube. This will not be a problem in normal environments. However, it is not suitable for corrosive applications. For example, in strong acid and alkali environments, we need special housings. USSR can customize housings of special materials such as stainless steel, PTFE and ceramics. They ensure that the sensors are well sealed and corrosion resistant.

In some flammable and explosive places, we need explosion-proof sensors. USSR can customize the Ex ib Ⅰ Mb class proximity sensors. You can use it for distance measurement down the mine. It can also applicable in places with a lot of dust and other flammable gases.

In addition, some customers want the sensor to display a specific measurement distance. We can change the learning line to the digital signal line. Then connect a display module to the digital signal line. So it will display the distance. If you have special ultrasonic proximity detection requirements, please tell us.

(3) Excellent price/performance ratio

Firstly, our industrial ultrasonic proximity sensor has a cost advantage over other brands. For example, the price of one meter range Pepperl+Fuchs sensor is nearly USD200, but our price is only USD100.

Secondly, our ultrasonic proximity detector also has high performance. Last year, we manufactured and sold more than 12,000 pcs ultrasonic sensors in total. Many customers previously bought Pepperl+Fuchs sensors. But now they start to choose our products.

Below, we take a 1-meter ultrasonic distance sensor as an example. And compare the performances of our product and Pepperl+Fuchs product (test on May 27, 2024).

Pepperl+Fuchs vs USSR

Test Item	P+F Catalog Data	P+F Practical Test Data	Our Catalog Data	Ours Practical Test Data
Detection Range	70-1000mm	45-1250mm	60-1000mm	7-1080mm
Adjustment Range	90-1000mm	45-1250mm	60-1000mm	57-1080mm
Blind Zone	0-70mm	45mm	60mm	7mm
Standard Test Objective	100mm*100mm	Yes	100mm*100mm	Yes
Sensor Frequency	About 255kHz		About 200kHz	200kHz
Response Delay	About 125ms	128ms	100ms	80ms
I (Output Type)	4-20mA	3.99-19.98mA	4-20mA	3.97-19.97mA
U (Output Type)	0-10V		0-10V	3mV-10.00V
E4 (Output Type)	NPN		NPN	Push_pull
E5 (Output Type)	PNP	PNP[2000]	PNP	PNP
I/U Resolution	0.35mm	0.2mm	0.5mm	0.17mm
E4/E5 Voltage Drop	≤3V	0.9V[2000]	/	E4：1V；E5：1.8V
E4/E5 Switching Frequency	Max 3Hz	3.9Hz	/	6Hz
I/U Characteristic Curve Deviation	Full Scale ±1%	Pls check below curve	＜1%	Pls check below curve
I/U Repetition Accuracy	Full Scale ±0.1%	Pls check below curve	Full Scale ±0.3%	Pls check below curve
E4/E5 Repetition Accuracy	≤1%	-0.04，-0.29，0，-0.27，-0.08，-0.1， -0.4，-0.4，-0.1，-0.51，MAX: -0.51mm[2000]	0.3% of Full Scale	0.02，-0.12，-0.48， -0.45，-0.48，-0.61，-0.5， -0.62，-0.74，-0.63，Max:-0.74mm
I Load Impedance	0-300Ω	350Ω@10V@19.84mA	0-300Ω	200Ω@19.84mA
U Load Impedance	＞1kΩ		≥1kΩ	≥700Ω@9.9V
Temperature Drift	Full Scale±1.5%	5.50%	0.05%/℃	2.50%
Coverage	Pls check the below picture (The sample coverage map of our ultrasonic proximity switch sample is smaller)
Pulse Group Interference	/	>3.2kV	/	1.7kV
Detection Range of 25mm Diameter PVC Pipe	/	45-800mm	/	30-900mm

Note: Test sample for Pepperl+Fuchs is UB1000-18GM75-I-V15. [2000] for P+F is square model UC2000-L2-E5-V15. Our product comparison model: USUB1000-18GM85-I/U10/E4/E5-V1/V15.

Key Comparison Differences:

① Detection range: our industrial ultrasonic proximity sensor has smaller blind zones;

② Temperature rise: Pepperl+Fuchs has greater power consumption and higher temperature rise;

③ Anti-pulse group interference: Pepperl+Fuchs has stronger anti-interference ability;

④ Upgrade function: our 1 meter sensor can be upgraded through the serial port. And you can change the output and function.

⑤ Taper Adjustment: Pepperl+Fuchs has taper selection function;

⑥ Other differences: please check the table and pictures above;

How to select a right ultrasonic proximity switch?

Correct selection is related to the normal progress of industrial production activities. Therefore, we must have a basic understanding of ultrasonic proximity sensor.

(1) Clarify the function or role

First of all, we have to determine what functions we want to fulfil, such as distance measurement, presence measurement, counting, and so on. It is important to note that ultrasonic sensors are not suitable for all objects. For example, it cannot measure the level of volatile liquids. This is because the volatile material will stick to the transducer. As a result, it will affect the measurement.

(2) Define the measurement range

We know that all industrial ultrasonic sensors have a blind zone. Different measuring distances, different blind spots. For example, our 150mm range sensor has the blind zone of 20mm. And our 6000mm range sensor has the blind spot of 350mm. If the sensor is too close to the object, it may not be able to measure the distance accurately. In addition, we need to verify if the absolute accuracy of the sensor meets the requirements.

Note: If the object is not ideally flat, it is recommended to select twice the distance. The same is true for measuring the roll diameter. For example, if you need to measure 50cm, please choose the model of 100cm. Then it ensures that it is possible to measure. The price difference of the two ultrasonic proximity sensors is not significant.

(3) Need to know the output type of industrial ultrasonic sensor

Below are the common outputs of our sensors.

[E0]:1*3 line, PNP switch output, always On	[E1]:1*3 line, NPN switch output, always Off
[E2]:1*3 line, PNN switch output, always On	[E3]:1*3 line, PNP switch output, always Off
[E4]:1*3 line, NPN switch output, always On/always Off	[E5]:1*3 line, PNP switch output, always On/always Off
[E6]:2*3 line, PNP switch output, always On/always Off	[E7]:2*3 line, PNP switch output, always On/always Off
[E8]:1*3 line, NPN switch output, Hysteresis mode	[E9]:1*3 line, PNP switch output, Hysteresis mode
[A2]:2*3 line, PNP switch output,1 always On+1 always Off	[I]: Analog current 4-20mA output
[U5]:Analog voltage 0-5V output	[U10]:Analog voltage 0-10V output
[R2]:RS232 interface	[8B]:8-bit data output,parallel-direction
[R4]:RS485 interface	[H3]: External processing unit
[TTL]:TTL232 interface, Command response	[TTL1]:TTL232 interface, Keep firing
[3E0]:3 route NPN switch output	[IU]:Analog output I and U
[IE0]:Analog current I plus NPN switch output, two route output
[IE2]:Analog current I plus PNP switch output, two route output

(4) Considering environmental factors

① We usually apply the sensors indoors. Of course, it can also be used outdoors. However, it will affect the effect if there is strong rain, freezing, or strong wind.

② Our ultrasonic proximity switch passes the IEC minimum requirements for interference. However, the customer's equipment may leak electricity. Strong electromagnetic interference exists in the environment. This may affect the ultrasonic echo signal. Eventually, the distance and energy measurement will be incorrectly determined. In this case, we can solve most of the interference by insulating the housing.

③ Some occasions have anti-corrosion or explosion-proof requirements. This requires special customization.

④ Temperature variations may affect the speed of sound. For every 1°C increase in temperature, the speed of sound increases by about 0.17%. Of course, our sensors have built-in temperature compensation.

⑤ Normal dust does not affect the ultrasonic measurement. However, if there is too much dust, it may have an effect. Excessive dust must not accumulate on the sensor surface. Otherwise it will affect the detection distance. Or affect the aftershock. Make it think that there is always a target at the nearest distance.

(5) Other selection factors

① If two sensors are installed too close to each other, they may interfere with each other. At this time, it is necessary to use the synchronous function. ② We also need to consider other points, such as response time, connection type, etc. Connection type is usually pin and cable.

Common ultrasonic proximity sensor applications

Industrial ultrasonic sensor can be applicable in various industries. Here are some examples of common applications.

(1) Material & Liquid Level Detection

Ultrasonic sensors are the optimal solution for material and liquid level detection. Our USUB450-30GK85-R2T-V1C-RN sensor is used for feed detection. Its detection range is 150~450mm and the output is digital RS232.The sensor housing uses plastic material PBT. It has high repeatability ~ 0.6% of full scale value. This is the main reason why customers choose this sensor.

In addition, we also often apply the sensor to powder granule packaging machine. It can monitor the material level of the granules in the hopper in real time. The main users of this kind of packaging machine are coffee, milk tea, beverage preparation manufacturers.

(2) Plastic film blowing machine

Our USUB500-18GM75-U-V15 ultrasonic sensor is widely used in film blow moulding machines. There are usually 3~4pcs in each machine. Customers use sensors to detect the diameter of film bubbles. After the detection signal is processed, PLC control the inlet and outlet airflow. Ensure that the bubble diameter is within a certain range. Generally it is ±3-5 mm. It is not affected by film reflections and colours.

Here, the customer uses the internal synchronisation function. Connect the synchronisation lines of different ultrasonic proximity sensors. It can avoid mutual interference between them.

(3) Die cutting & digital punching machine

These machines are mainly used for die-cutting, creasing, laminating of sheets. The main materials are paper products, non-metallic materials, stickers, electronics, mobile phone pads, etc. Die-cutting machine uses tool steel knives, hardware molds, and steel wires. It can roll and cut the cardboard into a certain shape.

In this case, each die-cutting machine uses 3pcs of USUB100-F77-E0-V31 ultrasonic sensors. We use them to detect PVC film. Use two F77 sensors to detect whether the PVC film enters the machine for die-cutting. The other is used to detect if there is residual PVC film in the machine.

F77 series ultrasonic sensor has a very high cost performance. The shape is square. And it is more compact than ordinary sensors. It has stronger anti-interference ability to environmental noise.

Ultrasonic proximity sensors advantages and disadvantages

There are various types of proximity switches, such as ultrasonic, infrared, photoelectric, capacitive, inductive, etc. Next we take the infrared proximity sensor as an example. Compare and analyse the difference with ultrasonic type: ir proximity sensor vs ultrasonic.

① Different measuring ranges

Both of them are suitable for short distance measurements. Currently, the latter generally measure up to 8 meters. However, the latter has a blind spot. In this zone, there is no way to detect objects.

② Different anti-interference capabilities

The IR sensor is not subject to electromagnetic interference. But it can be disturbed by light sources. Ultrasound sensor is just the opposite. It is susceptible to electromagnetic interference. However, the light source has no effect on it. We can use it in low light or complete darkness. In addition, it will be affected by temperature changes.

③ Application ranges are different

The former cannot be used to measure transparent objects or liquids, but the latter can.

④ Different prices

Infrared sensors are cheap. And ultrasonic sensors are much more expensive.

How does an ultrasonic proximity switch work?

The principle of its distance measurement is as follows: sound waves will be reflected on the object surface. We can know the target distance by calculating the propagation time in the air.

Ultrasonic proximity sensor is a kind of non-contact switch. It is composed of ultrasonic transducer and control circuit and so on. Ultrasonic wave is a kind of mechanical wave with vibration frequency higher than sound wave. The common frequencies of our proximity switches are 58KHz, 75KHz, 112KHz, 200KHz, 400KHz. Transducer chip vibrates under the excitation of voltage. So it will generate the ultrasound waves. It has the features of high frequency, short wavelength, small bypass phenomenon. Its advantage is good directionality. The penetration ability of liquid and solid is great. Ultrasonic waves touching the object will produce a significant reflection to form an echo.

Different objects have different ability to reflect ultrasonic waves. The standard detection object is 100*100mm flat plate. Generally represents the farthest detectable range. The dark colour indicates the detectable range of 25mm diameter PVC pipe.

Often the higher the ultrasonic frequency, the smaller the blind spot. Detectable range is closer and response is faster. At the same time, the resolution and accuracy is higher.

How to set the detection range of industrial ultrasonic sensor?

Let's take the model USUB2000-30GM85-E4-V1 as an example.

(1) Working modes:

A1 and A2 can be learnt separately. It can select the working mode by setting the position of A1 and A2 points. There are 5 working modes as follows:

① Window mode, normally open, A1<A2; ② Window mode, normally open, A1>A2; ③ Single switching point mode, normally open; ④ Single switching point mode, normally closed; ⑤ Target presence detection: Target detected, switch closed; Target not detected, switch open;

Note: A1 or A2 distance → ∞: it indicates that when learning, no target is detected.

(2) Setting the A1 and A2 points of ultrasonic proximity switch

Firstly power up the sensor. The green light on the back of the sensor will light up

Setting the A2 point:

1) Put a measured object at the place where you need to set the distance;

2) Connect the learning cable to the power supply. The blue light will keep blinking. It indicates that it has entered the learning state. During this time, if the object is captured, the yellow light will blink. This state will last for 2~3 seconds. Afterwards, disconnect the learning cable. At this tiime, the A2 point is successfully set. If no target is detected during the setting period, the red lamp will light up;

Setting point A1:

1) Put a test object at the place where you need to set the distance;

2) Connect the learning cable to the negative side of the power supply. Repeat the above steps.

Note: Learning mode is not available until 5 minutes before power up.

Install the ultrasonic proximity sensor

Ultrasonic sensors are directional, so you need to pay attention to the installation position. It is recommended that the installation position be perpendicular to the object. This will achieve better relative accuracy.

Wiring connection

Connect the brown wire to the positive terminal of the power supply; And connect white wire to learning wire; Connect the black wire to output wire; Connect the blue wire to the negative terminal of the power supply;

Use precautions

① The main reasons for temperature drift are as follows: The sensor will heat up when it is initially powered on. This will cause the internal temperature measurement deviation of the sensor. Finally causes the distance measurement deviation. But it will reach stability after about half an hour.

② Do not input a voltage other than the normal working voltage. Otherwise, the industrial ultrasonic sensor will burn out and fail.

③ Do not connect the wrong wires. Avoid ultrasonic proximity switch burnout and failure.

④ Please avoid pulling the sensor lead wires hard. Otherwise, the electrical connection of the sensor will be damaged.

⑤ Forbid covering the surface of the sensor transducer. Otherwise, it will affect the detection range.

⑥ When using, avoid strong mechanical vibration. In addition, the working environment should not have strong electromagnetic interference. There should be also no rapid air circulation.

⑦ Please do not disassemble the sensor privately. If the sensor does not work properly, please contact the after-sales service in time.

Troubleshooting of ultrasonic proximity switch

Ultrasonic sensors have the following commone problems. We can learn how to solve them.

(1) False alarm

In addition to product issues, customer installation will have an impact.

① There is a object very close to the target. At this time, there will be a constant output;

② The installation is not aligned. So sensor cannot detect the target. Or it can detect it for a while and not for a while;

③ Some electricians connect the wires according to conventional thinking. They mistakenly think that the red wire is connected to the positive power supply. And think that the black wire is connected to the negative power supply (ground). But the ultrasonic proximity switch is different. It is in accordance with the IEC standard. We should connect the brown wire to the positive power supply. And connect the blue wire to the negative power supply;

④ During installation, the learning line touched the power line. This will cause A1\A2 to be set to other values;

⑤ During learning, after setting, we may not disconnect the learning line first, but directly turn off the power. This will cause the set value to not be recorded;

(2) Anti-interference issues

Industrial ultrasonic sensors mainly face two types of interference problems.

① Strong electromagnetic interference (EMI)

At the site of use, there are motors with high power or too many types of motors. Even inferior power supplies are possible. The problem manifests itself as random digital jumps.

Solution: Shield the motor. Or use a gasket to separate the metal housing and the metal bracket;

② Vibration sound and air disturbance There are many mechanical structures or exhaust pipes with high-frequency vibrations in the environment. The problem is also manifested by random vibrations.

Solution: There is no solution except to change the environment.

(3)  Large residual vibration

Generally, the problem manifests itself as no output or a fixed output value. In fact, this problem is less likely to occur.

FAQ

Q1: What is the lead time for your ultrasonic proximity sensors?

A1: For normal models, the delivey time is 3 days. For For special models, it needs about 7~10 days. If you want to customize a new sensor, the time will be much longer.

Q2: Do your industrial ultrasonic sensors have Io-link function?

A2: No. IO-link is a data interaction method for industrial control devices. It enables data collection and control. At present, our sensors have no this function. But we can customize it if need.

Q3: Is there any performance difference between rectangular and cylindrical sensors?

A3: If the measuring distance is same, there is no performance difference. Sensor shape depends on customer installation conditions.

Q4: Do different housing materials have an effect on the performance of the ultrasonic sensor?

A4: Generally there is no effect. But sometimes, the customer equipment leakage is serious. This can cause conducted interference. Using a plastic housing can reduce or solve the interference problem.