Industrial automation systems often need to detect objects or measure distances accurately while processes are running continuously.

However, sensing tasks can become difficult when:

• Objects vary in colour or surface finish
• Materials are transparent
• Environments contain dust or vapour
• Surfaces are irregular or reflective

These factors can make consistent detection challenging for some sensing technologies.

For automated production systems, unreliable sensing can affect process stability and product quality.

Ultrasonic sensors operate by emitting sound waves and measuring the time it takes for the echo to return from an object.

Because detection is based on sound rather than light, ultrasonic sensors can detect objects independent of colour, transparency, or ambient lighting conditions.

This allows them to provide consistent sensing in many industrial environments where detection conditions may vary.

Microsonic ultrasonic sensors are designed to deliver precise non-contact measurement and reliable object detection for automation systems.

Ultrasonic sensors are used across a wide range of industrial processes where reliable detection and measurement are required.

Presence Detection on Conveyors

Sensors such as the mic+ series can detect boxes or containers moving along conveyor systems.

Multiple sensors can also be synchronised to detect larger containers or scan wider areas of a conveyor line.

Web Edge Control

Ultrasonic web edge sensors monitor the position of material edges in processes involving continuous materials such as film or paper.

The system can automatically adjust positioning to maintain proper alignment during operation.

Double Sheet Detection

In printing, packaging, and collating machines, ultrasonic sensors can detect when multiple sheets are present instead of a single sheet.

This helps prevent process interruptions such as misfeeds or jams.

Level Measurement

Ultrasonic sensors can measure the level of liquids, powders, and bulk materials without making contact with the material.

Typical level measurement applications include:

• Tank and vessel monitoring
• Silo and hopper measurement
• Water and wastewater systems

Measurement ranges can extend from a few millimetres up to several metres depending on the sensor.

Quality Control and Inspection

Ultrasonic sensors can also support inspection processes in automated production systems.

They can detect objects during fast processes or verify product presence during packaging or manufacturing operations.

Microsonic ultrasonic sensors are available with several output and communication options to suit different automation systems.

These include:

• Digital switching outputs
• Analogue outputs such as 4–20 mA or 0–10 V
• IO-Link communication

Sensors with IO-Link enable remote configuration, diagnostic monitoring, and simplified commissioning.

This can improve visibility within automation systems and help streamline setup and maintenance.

Choosing the correct ultrasonic sensor depends on the application and installation environment.

Key considerations include:

Measurement range
The sensor must operate reliably within the required detection distance.

Target characteristics
Surface shape and material properties can influence how sound waves reflect.

Environmental conditions
Temperature, vapour, and pressure can affect sensing performance.

Mounting position
Adequate space is required to install the sensor and avoid interference within the detection zone.

Control system compatibility
The output type should match the requirements of the PLC or automation system.

Ultrasonic sensors provide reliable, non-contact detection across many industrial applications. Their ability to detect objects regardless of colour or transparency makes them suitable for challenging sensing tasks.

Pacific Automation supplies the full range of Microsonic ultrasonic sensors and supports customers with selecting the right sensor for their application.

The goal is simple: helping ensure reliable sensing in automated industrial systems.