Level sensors Manufacturers online

Level sensors are used to measure the level of liquids, bulk materials or solids in containers, tanks or silos.

They are used in various sectors such as the chemical industry, food production, water management and automation technology.

Below you will find the functionality and use of level sensors as well as a brief outlook on future developments:

How level sensors work:

There are various measuring principles that are selected depending on the medium, measuring accuracy and operating conditions:

Sensors for continuous level measurement:

These sensors provide a precise measured value over the entire range:

1. Hydrostatic sensors: Use the pressure of the liquid column to determine the level.
2. Ultrasonic sensors: Transmit sound waves and measure the transit time until reflection.
3. Radar sensors: Work similarly to ultrasonic sensors, but use microwaves for greater precision.
4. Capacitive sensors: Detect changes in electrical capacitance between two electrodes.
5. Guided radar sensors (TDR - Time Domain Reflectometry): Utilize a guided radar along a probe for accurate measurements.

Level limit sensors:

These sensors detect whether a certain level has been exceeded or fallen below:

1. Float switch: Mechanical contact is triggered by buoyancy of the float.
2. Vibration sensors: A vibrating rod stops when it comes into contact with liquid or bulk material.
3. Optical sensors: Measure light refraction or reflection at a boundary surface.
4. Mechanical sensors: The rotation of a shaft is stopped when a defined fill level of bulk material is reached.

Use of fill level sensors:

1. In the chemical industry:
monitoring aggressive or hazardous liquids in containers and pipes.

2. In the food industry:
Checking fill levels of liquids, e.g. in bottling.
monitoring of storage tanks and silos.

3. In the oil and gas industry:
Measuring fill levels when storing fuels and combustibles in tanks.

4. Water and waste water management:
For measuring levels in wells and gauges of streams and rivers.
For level monitoring in sewage treatment plants.

Future developments in the field of level sensors:

• Integration into smart tank systems.
• Level monitoring via cloud systems.

Level sensors are important components for the precise control and monitoring of processes in various industries. Choosing the right type of sensor depends heavily on the specific requirements of the application.

Here are the most important aspects to look out for when purchasing level sensors:

When purchasing level sensors, numerous technical, economic and logistical aspects must be taken into account. The right choice not only influences measuring accuracy, but also process reliability and long-term operating costs.

• What technical requirements must the level sensor meet?
• The type of medium: liquid, solid, bulk material, foam or aggressive media.
• Determine the min. and max. temperature of the medium and the environment.
• what is the prevailing pressure in the tank or container?
• Determine the suitability of capacitive or conductive sensors.
• Dust and moisture resistance is particularly important in the food, chemical or cement industries.
• Different sensor types are more suitable depending on the application:
• For continuous measurement, for example, radar, ultrasonic or hydrostatic sensors are suitable for precise level indicators.
• Float switches or vibration sensors are suitable for limit level measurement and safety shutdowns.
• The measuring accuracy depends on the medium, the measuring principle and the application.
• What installation options are possible? Top, side, bottom or externally via a measuring line.
• Please note the cleaning and maintenance requirements. This is particularly important for applications with dirt or deposits
• The mechanical load capacity and vibration resistance should also be taken into account. It may be necessary to provide protection against mechanical impacts.
• Pay attention to a good price-performance ratio. It's not just the purchase price that counts, but also the service life
• Low energy consumption can reduce operating costs in the long term
• Sensors with low maintenance increase operating efficiency
• Ensure long-term availability of spare parts.
• Pay attention to the communication interfaces and the possibility of integration into existing systems such as SCADA, PLC or DCS systems.
• For analog signals, 4...20 mA, 0...10 V are the standard in many industrial applications.
• Digital interfaces such as Modbus, HART, Profibus, IO-Link are the standard for smart systems and IoT applications.
• Prefer radio or wireless sensors for measuring points that are difficult to access.
• Depending on the industry, level sensors must meet certain standards and certifications:
• ATEX certification (explosion-protected areas).
• Hygiene certificates (food and pharmaceutical industry, e.g. EHEDG, FDA).
• IP protection class (e.g. IP67, IP69K for high dust or water exposure).
• SIL (Safety Integrity Level) for safety-critical applications.
• A reliable supplier not only offers products, but also good advice and service.
• Pay attention to the warranty conditions and the availability of spare parts.
• Look out for suppliers with good customer support and fast delivery times.

When purchasing level sensors, both technical and economic factors are decisive. The best choice depends on the specific application, environmental conditions, system compatibility and long-term operating costs. Careful consideration of these criteria helps to avoid failures and increase process efficiency.

Level sensors can be purchased from various suppliers. Comprehensive information about manufacturers and suppliers of Level sensors from all over the world can be found on Exportpages.