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Enhancing the ultrasonic waveguide sensor's fluid level sensitivity using through-transmission and pulse-echo

Abhishek Kumar1, Suresh Periyannan1

  • 1Department of Mechanical Engineering, National Institute of Technology, Warangal 506004, Telangana, India.

The Review of Scientific Instruments
|October 20, 2023
PubMed
Summary

This study introduces a U-shaped ultrasonic waveguide sensor for accurate fluid level measurement. The novel design improves accuracy and enables monitoring in challenging industrial environments.

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Sensor Technology

Background:

  • Accurate fluid level monitoring is crucial in various industries.
  • Traditional sensors face limitations in hostile or inaccessible environments.
  • Ultrasonic waveguide techniques offer potential for non-invasive level sensing.

Purpose of the Study:

  • To develop and evaluate a U-shaped ultrasonic waveguide sensor for fluid level measurement.
  • To compare the performance of U-shaped waveguides with straight waveguides.
  • To explore the simultaneous use of multiple wave modes for enhanced sensing capabilities.

Main Methods:

  • Utilized Finite Element Method (FEM) for simulating wave propagation in U-shaped waveguides immersed in different fluids.
  • Employed through-transmission (TT) and pulse-echo (PE) techniques with a single shear transducer.
  • Developed a level sensor based on amplitude drop and time-of-flight changes in TT and PE signals.
  • Investigated sensor sensitivity using first and second pass signals (TT1, PE1, TT2, PE2) across various fluid levels and types.
  • Compared U-shaped (TT) and straight (PE) waveguides, analyzing signal attenuation and dead-end reflections.

Main Results:

  • The U-shaped waveguide sensor achieved an average error of 3.5% in level sensing, outperforming straight waveguides (5.6% average error).
  • The U-shaped design minimizes dead-end reflections, allowing for greater fluid depth measurements by focusing on wave leakage.
  • Simultaneous sensing using three wave modes [L(0,1), T(0,1), and F(1,1)] was demonstrated.
  • Signal attenuation analysis identified differences between straight and U-shaped sensors related to surface interaction and dead-end regions.

Conclusions:

  • The U-shaped ultrasonic waveguide sensor offers a more accurate and reliable method for fluid level measurement compared to straight waveguides.
  • The sensor's design effectively mitigates reflection issues, enhancing its capability for deep fluid level monitoring.
  • This technology is suitable for continuous fluid level monitoring in demanding industrial settings, including power plants and the oil/petrochemical sectors.