Level measurement is the equivalent process to the industry compared to the blood pumping of a heart. It keeps the process and different functions align with other components of the machineries in a plant. 

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As the significance and presence of the level measurements process and instruments are so common amongst the different industries, that every single industry has found itself the most suitable working principle to do the level measurement as per their most convenient method.

One of such working principle is transit time. It can be carried out in two ways, ultrasonic-based level measurement and radar-based level measurement.

Radar-based level measurements/ Radar level transmitters can measure levels in both contact and non-contact ways. A probe is dipped into the fluid tank during the contact type of measurement, and radio signals travel to the bottom of the tank and reflect from the varying levels of fluids in the tank. 

In the non-contact type of Radar level measurement, radio waves are emitted from the top of the tank, travel to the bottom, and reflect the receiver from the various fluid levels.

The following are the most common principles of level measurement.

• Based on pressure
• Based on transit time and is divided into two types they are ultrasonic based level measurement and radar-based level measurement
• Based on attenuation and radiation
• Electrical level measurement based on conductivity
• Capacitive level measurement

Also read: 5 Ways Level Gauges Help In Chemical Industry For Level Measurement

Working Principle Of Radar-Based Level Measurement

Radar level transmitters work similarly to ultrasonic transmitters, determining the distance from the transmitter (placed at some high point) to the surface of a process material situated further down by measuring the time-of-flight of a travelling wave.

The primary difference between a radar and an ultrasonic instrument is the type the wave used: radio waves rather than sound waves.

Radar level transmitters are the ideal solution for precise level measurement when reliability and precision are critical. Since the Radar-Based working principle is based on non-contact measurement. It has various advantages over other types of level measuring. 

Advantages Of Radar-Based Transmitters/Radar-Based Level Measuring Instruments

• Superior Accuracy: Radar level transmitters reach unmatched accuracy by utilising modern signal processing techniques to produce very precise and reliable level measurements. These transmitters excel in giving exact data, optimising process control, and assuring operational efficiency even in hostile settings characterised by severe temperatures, pressure differentials, or vapours.

• Non-Contact Measurement: The ability of radar level transmitters to measure levels without making physical contact with the substance is its defining characteristic. This non-intrusive technology reduces the possibility of contamination, corrosion, or sensor damage, making it perfect for applications demanding the highest level of purity and sensitivity.

• Versatility Across Materials: Radar-level transmitters are intended to work with a wide range of materials, including liquids, slurries, granules, and powders. Their measuring precision is unaffected by changes in density, viscosity, or dielectric constant, allowing for accurate measurements in a wide range of industries and applications.

• Range Capability: Using radar technology, these transmitters have outstanding measuring ranges, allowing for exact level detection in towering tanks or deep vessels. They easily penetrate vapours, foam, or dust, ensuring accurate readings even under the most difficult operating circumstances.

Also read: Radar Level Transmitter: A new phase in contactless level measurement

Why A Radar-Based Level Measurement Is The Future?

We’ve previously discussed how significant and widespread level measuring is in the industry. In this instance, selecting the proper technology is critical for precise and dependable results. 

Among the different alternatives available, radar-based level measuring is the superior choice. This is most likely why many industry experts and professionals only consider the most reputable Radar Level transmitter manufacturers and suppliers.

• Unmatched Accuracy & Precision
• Non-Contact and Non-Intrusive
• Versatility & Adaptability to wide range of materials
• Exceptional Range Capability
• Robust Performance

Radar-based level measurement equipment has emerged as the industry’s chosen form of a level measurement instrument for accurate and consistent level measurements. Its five most advantageous characteristics are unparalleled precision, non-contact operation, material adaptability, remarkable range capabilities, and solid performance, making it the ideal choice for a wide range of applications. 

Industries may improve process control, safety, and operational efficiency by utilising radar-based level measuring technology, eventually leading to higher production and profitability. Lastly, due to its peak performance and industry favourite, there are multiple cheaper models with no proper identification and hall-mark available in the market. 

Everything you need to know about radar level transmitters

Radar level sensors are becoming the primary option for level measurement in many industries. But how do they work? Where can you apply them? And what about IIoT radar devices?

You have a radar level sensor at your plant, right? If not, then this article can fill you in on how radar technology can help you out. If so, you should read the article too, to find out how the technology has evolved and understand more about IIoT radar devices.

Level measurement can be tricky sometimes. If you don’t pick the right device and set it up correctly, you’ll wind up with a headache. Of course, when you choose the right technology and configure it properly, you’ll practically forget about it because it keeps your process running smoothly.

Radar tech brings tons of benefits and has replaced many technologies in nearly all applications. Its popularity has increased as its cost has dropped, providing precise level measurement for less.

Let’s learn more about the technology and see how IIoT radars have become the tipping point for level monitoring on the market.

How do you measure levels in tanks?

The market offers an extensive list of models that use different methods to provide level measurement. How do you know which will work best for your process? As always, it depends on your process characteristics and requirements.

So what kind of sensor? Pressure, hydrostatic, capacitive, ultrasonic, something else? You could use any of those, but radar also fits in many different applications in many different ways. Pair it with IIoT and you’ll have half your work done for you!

For now, let’s dive into more details on radar devices. Later, I hope to bring you more information regarding other technologies.

How does a radar level transmitter work?

Radar level transmitters typically use one of two working principles, time-of-flight (ToF) and frequency-modulated continuous wave (FMCW). Up next – an explanation of each!

For more information, please visit radar type level transmitter.

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Time-of-flight

With this method, a radar device measures the distance from itself to the product surface by emitting radar pulses to reflect from the surface back to the device.

Its antenna receives the signal and sends it to the electronics, where all the magic happens. The microprocessor identifies the echo and calculates the time it took for the signal to return.

The distance (D) to the surface is proportional to the time of flight (t) of the pulse from the radar. Here’s the formula the microprocessor uses:

D = c · t/2

Here, c represents the speed of light.

After the device finds the distance (D), it can calculate the level (L) based on the empty distance (E):

L = E-D

Super simple!

Frequency-modulated continuous wave (FMCW)

For this method, the radar sensor emits a high-frequency signal. This frequency increases over time and it creates what we call a frequency sweep or signal sweep. This signal will reflect from the product surface to be received by the antenna and transmitted to the electronics with a time delay (t).

The frequency received differs from the frequency emitted, and the difference (Δf) is proportional to the echo curve. It applies the Fourier transform into a spectrum, as shown here:

The device then finds the level by calculating the difference between the tank height and the distance measured. This method is a bit more complex than the ToF method, but you don’t have to worry about that because the device does all the math for you.

Which frequency band?

You need to understand frequency bands or ask for expert help to determine which bands may fit your application best. You can find non-contact level sensors on the market with four different bands. Most use 6 GHz, 10 GHz, or 26 GHz.

Today, new radar sensors have come to the market with 80 GHz. These bring a lot of benefits to a process installation, as they fit well in applications where traditional radar transmitters need more room for the beam angle.

So which is the best frequency band for you? Because it depends on many factors in your application, you need to either do a lot of research or give your process information to an expert. Doing it yourself is more thorough, but the expert is faster. Up to you what you want to do.

IIoT level monitoring?

Ever heard of IIoT radar sensors? IIoT radar transmitters, such as the Micropilot FWR30 from Endress+Hauser, are the newest type of compact level sensor on the market.

This device installs easily in small tanks and can move with them if necessary. You get this portability because the radar uses battery power and wireless communication. That means you can transport a tank anywhere that has internet access and still retrieve data constantly.

You can also track this device locally, set up min/max thresholds, and receive alerts if the data changes. And because it uses the 80-Ghz frequency, you can install it easily in small containers for more reliable measurements.

Cloud-based IIoT radars like the FWR30 let you set up the device with just a few simple steps. Then you can access all your data using your , laptop, or tablet. On top of that, services like Netilion Value have excellent features such as a dashboard, history, map, notifications, and more.

When you’re ready to check things out, Netilion offers free trials. Other companies may as well, so do your research!

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