Non-Contact Measurement
Measure liquid levels and distances without touching the material, eliminating contamination risks and reducing sensor maintenance.
Ultrasonic Sensors for Level & Distance Measurement
BinMaster ToughSonic® ultrasonic sensors use non-contact ultrasonic sound waves to measure liquid levels and distances through the air. These rugged, compact sensors provide fast, reliable measurements up to 50 feet (15.2 meters) without contacting the material being measured.
ToughSonic sensors are used for liquid level monitoring, distance measurement, and object detection in industrial and environmental applications. They perform reliably in open or closed tanks, outdoor installations, and harsh processing environments.
Typical uses include inventory monitoring, batch control, high- and low-level alerts, flood monitoring, roll diameter measurement, object detection, and general industrial automation.
General-Purpose Ultrasonic Sensors
ToughSonic®-100 Series
The ToughSonic TS-100 series features heavy-duty construction designed for demanding industrial environments.
Sensors are manufactured in the USA with electronics fully epoxy-potted inside a Type 316 stainless steel housing for long-term durability. Key features include:
- Permanently attached cable connection
- Ruggedized piezoelectric transducer
- Fully epoxy-potted electronics
- Designed for harsh industrial environments
TS-100 sensors are commonly used in industrial plants, environmental monitoring systems, mining equipment, and factory automation.
- Liquid level measurement in tanks and mixers
- Industrial process tanks
- Environmental water monitoring
- Distance measurement on heavy equipment
- Conveyor and production line object detection
Chemical-Resistant Ultrasonics
ToughSonic®-200 Series
The ToughSonic TS-200 series is designed for applications involving chemical exposure or corrosive environments.
Electronics are epoxy-potted inside a chemical-resistant PVDF housing (Kynar®) that protects the transducer and electronics from harsh process materials.
- Heavy-duty epoxy-potted electronics
- Designed for corrosive or chemical environments
- Suitable for indoor and outdoor installations
TS-200 sensors provide reliable non-contact liquid level measurement in harsh processing environments where chemical resistance is required.
- Chemical storage tanks
- Plastics processing
- Wood products and paper processing
- Agricultural liquids and storage tanks
- Food and beverage processing
| ToughSonic TS-100.03 | ToughSonic TS-100.14 | ToughSonic TS-100.30 | ToughSonic TS-100.50 | |
|---|---|---|---|---|
| Maximum / Optimum Range | 3 ft. (0.9 m) / 24 in. (0.6 m) | 14 ft. (4.3 m) / 10 ft. (3 m) | 30 ft. (9.1 m) / 20 ft. (6.1 m) | 50 ft. (15.2 m) / 33 ft. (10 m) |
| Deadband | 0-1.75 in. (0-44 mm) | 0-4 in. (0-102 mm) | 0-10 in. (0-254 mm) | 0-12 in. (0-303 mm) |
| ToughSonic TS-200.14 | ToughSonic TS-200.20 | ToughSonic TS-200.35 | |
|---|---|---|---|
| Maximum / Optimum Range | 14 ft. (4.3 m) / 10 ft. (3 m) | 20 ft. (6.1 m) / 13 ft. (4 m) | 35 ft. (10.7 m) / 25 ft. (7.6 m) |
| Deadband | 0-3.5 in. (0-89 mm) | 0-8 in. (0-203 mm) | 0-12 in. (0-303 mm) |
ToughSonic® Ultrasonic Sensor Features
Precise Target Ranging
Sensors capture the exact distance to a target rather than simply detecting presence, allowing operators to monitor precise position/level.
Distance-Proportional Output
The sensor output signal changes proportionally with measured distance for seamless integration with PLCs, controllers, and monitoring systems.
High-Resolution Measurement
ToughSonic sensors detect very small changes in distance, making them ideal for applications requiring precise position or level measurement.
Immunity to Optical Conditions
Ultrasonic sound wave technology is unaffected by ambient lighting conditions, object color, surface transparency, and reflectivity or shine.
Rugged Industrial Construction
Design offers a long service life in demanding environments: solid-state electronics, rugged transducers, and epoxy-potted components.
High-Frequency Technology
How ToughSonic® Ultrasonic Sensors Work
- The sensor emits an ultrasonic pulse toward the target surface.
- The sound wave reflects off the liquid surface or object.
- The sensor receives the returning echo.
- The time required for the signal to return is converted into a distance measurement.
Because the speed of sound in air is known, the sensor calculates the distance to the target surface with high accuracy.
The measured distance can then be used to determine liquid level in a tank, distance to an object, position of moving equipment, or diameter of a roll or coil.
ToughSonic® Mounting Options
Proper installation ensures reliable ultrasonic performance. ToughSonic sensors can be mounted above tanks, vessels, equipment, or open areas, depending on the application.
Top-of-Tank Mounting
Commonly used for liquid level measurement in tanks or vessels. The sensor is mounted above the liquid surface and aimed downward toward the target.
Bracket Mounting
Mounting brackets allow installation on structural frames, walls, or equipment for distance monitoring or object detection.
Open-Air Mounting
Sensors are mounted above the monitored surface to provide continuous distance measurement.
This includes environmental monitoring applications such as flood monitoring, water level monitoring, or reservoir and canal measurement.
Common Ultrasonic Sensor Applications
Ultrasonic sensors are ideal where non-contact measurement, rugged construction, and simple installation are required.
Liquid Level Monitoring
Process Monitoring
Storage Tanks
Chemical Tanks
Food Ingredient Tanks
Environmental Monitoring
Flood Monitoring Systems
Reservoir or Canal Level Monitoring
Wastewater Treatment Facilities
Industrial Automation
Conveyor Belt Object Detection
Roll Diameter Measurement
Distance Measurement for Heavy Equipment
Position Detection in Manufacturing Systems
Why Choose Ultrasonics?
Both ultrasonic and radar level sensors provide reliable non-contact measurement, but each technology performs best under different conditions.
Choose ultrasonic sensors when:
- Measuring liquids in tanks, channels, or open environments
- The application requires cost-effective non-contact measurement
- Tanks are relatively short (typically under 50 feet)
- The environment has minimal dust or foam
- You need distance measurement or object detection
When Radar is Required
Choose radar sensors for applications where you're:
- Measuring solids in dusty environments
- Applications involve tall silos or vessels
- There is heavy vapor, foam, or turbulence
- Maximum measurement reliability is required in harsh process conditions
BinMaster offers multiple continuous level measurement technologies so customers can select the best solution for their application.
This includes 80 GHz radar transmitters, 3D level scanners, guided wave radar, laser, and SmartBob cable-based systems.
Selecting the Right ToughSonic® Ultrasonic Sensor
Choosing the correct ultrasonic sensor depends on the environment, installation conditions, and material being measured. Consider these factors:
Measurement Range
Select a sensor capable of measuring the required distance. ToughSonic sensors measure up to 50 feet (15.2 meters).
Environmental Conditions
Use TS-100 stainless-steel models for rugged industrial environments. Use TS-200 PVDF sensors for corrosive or chemical applications.
Mounting Location
Sensors need clear line of sight to the surface/object. Avoid mounting near obstructions that may interfere with the ultrasonic signal.
Application Type
There are best-suited ToughSonics for tank measurement, water monitoring, distance ranging, object detection, and industrial automation.
Unsure Which Sensor is Best for Your Application?
BinMaster application specialists can help select the optimal ultrasonic sensor and mounting configuration for your operation.
