An automated measurement of substance filling levels in storage containers is essential in Industry 4.0. For a secure and stable production process, continuous monitoring of filling levels is an absolute prerequisite. Waycon Positionsmesstechnik offers needs-based, automated monitoring of filling levels for many industries.

1. Measuring filling
levels
Measuring filling levels in automated
Industry 4.0
Waycon Positionsmesstechnik GmbH is ideally
equipped for the future
An automated measurement of substance filling levels in storage
containers is essential in Industry 4.0. For a secure and stable
production process, continuous monitoring of filling levels is an
absolute prerequisite. Waycon Positionsmesstechnik offers needs-
based, automated monitoring of filling levels for many industries.
These can be split into two main types:
• Monitoring the filling level for the feeding and timing of
the filling process as well as the retrieval of stock
status.
• Initiating safety measures (e.g. shutting down) when a
maximum or minimum filling level is reached
In the first case, we are talking about continuous filling level control.
The filling level of the monitored substance can be registered at any
time at any position in the container and ensures a continuous
reading. The advantage of this is that capacity planning can be
adapted for irregular use at any time in the production process.
In the second case, we are dealing with a “level detection”.
Predefined maximum and/or minimum filling levels are defined and
monitored throughout the production process. If the relevant level
limit is exceeded or too low, an action is initiated. This monitoring
method is best suited to continuous processes for the timely supply
or removal of necessary substances. The level detection also
serves as a safety measure, for example to avoid overfilling due to
system shut down.
The different methods of filling level measuring
Press information: 2015-09-071

2. Filling level measuring works via contact or non-contact sensors
which determine the distance between the sensor and the object
being measured.
Ultrasound filling level measuring
Classic filling level measuring works with the help of ultrasound
sensors. Measurement with ultrasound sensors is a non-contact
method and is suitable for both continuous filling level control and
level detection. Ultrasound sensors release high frequency
oscillations, which are reflected through the object being measured.
The time difference between the moments of “sending and
receiving” is calculated. The advantage of this method is that it is
not dependent on the substance used, e.g. oil or water.
Measuring filling level with the magnetostrictive principle
Magnetostrictive sensors are non-contact and free from wear.
A short, constant electrical pulse is sent via a waveguide. A freely
moving position magnet reacts to the electrical pulse with a
reversed torsion wave. Moving the position magnet produces a
different run time for the response pulse. With the help of a pulse
converter, this is finally converted into an electronic measurement
signal. The magnet is embedded in a float and guarantees
permanent registration of the filling level. Magnetostriction is non-
contact but the float must make contact with the substance being
measured.
Filling level measuring using draw wire sensors
Draw wire sensors are a contact measurement method. A stainless
steel wire is coiled in a single layer around a drum with a pre-
stressed mainspring. The measurement wire is attached to the
object being measured and the is drawn from the drum if the
position is changed. The drum’s axis is firmly attached to an
electronic element, which converts the mechanical turning
movement into a proportional electronic signal. For the filling level
measuring, the measurement wire is connected to a float which is in
contact with the measuring material.
Filling level measuring with the capacity principle
Capacity sensors measure changes in capacity. Thus the sensor
and the object being measured always create a plate, as you find
with a plate capacitor. The electronic field in between them is
recorded and changes according to the distance. This
measurement method is non-contact and is suitable for continuous
monitoring and level detection.
WayCon offers suitable measurement engineering for all uses
Press information: 2015-09-072

3. With WayCon’s intelligent sensor solutions, measuring filling levels
is easy and efficient. The Taufkirchen company’s broad production
spectrum can be used in practically any industry and for any use.
Companies are already equipped for Industry 4.0 with WayCon
sensors for their filling level measuring.
You can find more information at www.waycon.de/home/ or
Product portfolio: www.waycon.de/produkte
Author:
Graduate engineer oec.
Erik Baumeister
Press information: 2015-09-073

4. Background information
WayCon Positionsmesstechnik GmbH has been developing and
producing filling level, position and distance sensors since 1999.
With their head offices in Taufkirchen near Munich, a second office
in Brühl near Cologne and distributors in 28 countries, the
innovative company supplies its products worldwide. Our goal is to
provide our clients with optimal measurement engineering
solutions: From high quality sensors from our standard range to
client-specific solutions, from the prototype to range - for different
usage areas in industry and research. The products, manufactured
in Taufkirchen, are subject to the strictest quality requirements and
are delivered without exception with a calibration certificate.
Contact
WayCon Positionsmesstechnik GmbH
Marcus Venghaus
Mehlbeerenstraße 4
82024 Taufkirchen
Email: presse@waycon.de
Website: www.waycon.de/home/
Product portfolio: www.waycon.de/produkte
In the event of publication, we would greatly appreciate a specimen copy.
Thank you!
Press information: 2015-09-074