Innovation in Stacker Level Detection: Ultrasonic Sensors Replacing Contact-Based Material Hammers

Background: One of our clients operates a stone processing plant. Their original contact-based detection system using long and short material hammers for the stacker’s level detection had broken down, and the dust resistance of the original design was poor. The client wanted to find a new solution that did not require changes to the original control requirements. They decided to replace the contact-based material hammer system with a non-contact ultrasonic sensor solution from DADISICK. After the upgrade, the new detection system performed well and operated stably.

The original system for material level detection on the stacker used a contact-based long and short material hammer detection device. The working principle was as follows: when the stacker was distributing material, if the long hammer made contact with the material, it would generate a switching signal and send it to the on-site PLC (Programmable Logic Controller). The PLC would then send a signal to the stacker indicating that the material height had reached the required level and the stacker should rotate 3° to continue stacking. If the material touched the short hammer, the system would immediately stop the upstream conveyor and the stacker, and issue an alarm.

Ultrasonic sensors are designed based on the characteristics of ultrasonic waves, using piezoelectric chips as the core component. These sensors offer high accuracy, strong directionality, and perform well even in dusty environments. The sensor’s probe is equipped with temperature compensation components to ensure high measurement precision, even when the environmental temperature fluctuates.

DADISICK’s ultrasonic sensors provide not only high-precision measurements but also support multiple output modes, including proximity switch mode, window mode, reflector mode, dual-switch mode (hysteresis mode), analog output, digital output, and single/double sheet detection. These features make them suitable for various industrial applications. ^{(For more information about the output modes of ultrasonic sensors, please click here.)}