Ultrasonic Sensor 2484809 for VÖGELE Asphalt paver(Vogele Asphalt paver)
| Name |
Part number |
Weight |
Compatible models |
| Ultrasonic Sensor |
2484809 |
1kg |
S2500 S1203 S1900-2 S2100-2 S1603-1 S1803-1 S700 S800 S1900-3 S2100-3 S1603-2 S1803-2 S700-3 S800-3 S1100-3 S1300-3 S1900-3L S2100-3L S1800-1 S1803-3 S1103-3 S1303-3 S1600-2SJ S1800-2SJ S1603-3 S1800-2 S1100-3 S1300-3 S1800-3SJ S1600-2L S1880L S1880-3L |
Jinan Jinxiu Engineering Machinery Co., Ltd. specializes in the production of paving machine level gauges, sensors, balance beams, edge control computers, and connecting cables.
The function and principle of the Vögele S1880-3L Paver Material Level Sensor (Part No. 2484809):
Function of the Material Level Sensor (2484809):
- Monitor Material Height in the Hopper: Its core function is to continuously measure the height of hot asphalt mix within the hopper (also called the material trough or feed zone) located immediately in front of the auger conveyor.
- Provide Feedback Signal: It converts the detected material height into an electrical signal (typically a continuous analog voltage or current signal).
- Control the Auger Conveyor: This electrical signal is transmitted to the paver's central control system (usually an Electronic Paving Control unit or similar module). Based on this signal:
- Regulate Auger Speed: If the material height falls below the preset target value, the controller increases the rotational speed of the auger conveyor (rotating either clockwise or counter-clock depending on the side), causing the auger flights to transport material from the sides towards the center more rapidly, thereby increasing the material volume in the center of the hopper. Conversely, when the material height reaches or exceeds the target, the controller decreases the auger speed or even stops rotation to prevent material overflow.
- Control Auger Direction (on some models/configurations): In more advanced systems or specific operating modes, the controller may also command the auger to reverse direction, precisely supplementing material to areas experiencing shortages.
- Maintain Constant Material Level: Through this closed-loop control cycle (Detect -> Feedback -> Adjust -> Re-detect), the sensor's primary objective is to keep the material height in the hopper stable at a pre-defined optimal level.
- Ensure Uniform Paving Quality: A stable material level is critical for paving quality:
- Guarantee Compaction and Smoothness: Excessively high or low material levels cause uneven force on the screed. A high level increases resistance to screed movement, potentially causing "bumps" or uneven compaction. A low level results in insufficient support for the screed, leading to a thinner, less compacted mat, surface tearing ("streaking"), and significantly compromised smoothness and density.
- Reduce Operator Intervention: Automatic material level control drastically reduces the operator's need for constant manual adjustment of the auger, allowing greater focus on other paving parameters and steering.
- Improve Paving Efficiency and Consistency: Maintaining constant paving conditions enhances operational efficiency and ensures uniform, consistent mat quality.
Summary of Function: The Level Sensor 2484809 acts as the "eyes" and "signal provider" of the system. It constantly monitors the height of material in front of the screed and informs the "brain" (control system) if there is too much or too little material. The brain then commands the "material movers" (auger conveyor) to speed up, slow down, or change direction as needed. The ultimate goal is to ensure the screed always has the precisely optimal amount of material directly in front of it, enabling the paving of a smooth and dense mat.
Principle of Operation (Typical for 2484809 on Vögele S1880-3L):
Part number 2484809 typically corresponds to the Ultrasonic Material Level Sensor commonly used on Vögele pavers. Its operation is based on the Ultrasonic Time-of-Flight Measurement Principle:
- Ultrasonic Pulse Emission: The sensor's transducer (probe), usually mounted on the hopper's front or side wall facing the material surface, contains an ultrasonic transducer (piezoelectric crystal). Driven by its internal circuitry, this transducer emits a short, high-frequency burst of ultrasonic waves.
- Wave Propagation & Reflection: The ultrasonic pulse travels through the air at the speed of sound (approx. 340 m/s). Upon striking the surface of the material within the hopper, it is reflected back.
- Echo Reception: The same transducer (or a dedicated receiver in the probe) detects the reflected ultrasonic signal (echo).
- Time-of-Flight Measurement: The sensor's electronic circuit precisely measures the time interval (Δt) between the emission of the pulse and the reception of the echo.
- Distance Calculation: Using the known speed of sound (v) and the measured time interval (Δt), the vertical distance (d) from the transducer face to the material surface is calculated using the formula: Distance (d) = (v * Δt) / 2. Division by 2 accounts for the pulse traveling to the surface and back.
- Conversion to Level Height: The sensor's mounting position is fixed relative to a reference point (e.g., the hopper floor). Therefore, the actual material height (H) is determined by subtracting the measured distance (d) from the known mounting height (H0): H = H0 - d.
- Standard Signal Output: The sensor's internal circuitry converts the calculated material height (H) into a standardized, continuous electrical output signal (most commonly a 4-20mA current loop or a 0-10V voltage signal). The magnitude of this signal is proportional to the measured level (e.g., 4mA = empty/min level, 20mA = full/max level).
- Signal Transmission & Processing: This standardized signal is transmitted via cable to the paver's Electronic Paving Controller or main control unit. The controller compares this signal representing the actual material height to the target height value set by the operator on the control panel.
- Closed-Loop Control Output: Based on the difference (error) between the actual and target levels, the controller calculates the required control signal (e.g., current, voltage, PWM signal) to send to the auger conveyor drive system (hydraulic proportional valve or frequency inverter). This signal dynamically adjusts the auger's rotational speed (and/or direction), driving the actual material height towards the target setpoint.
Key Features (Ultrasonic Sensor)
- Non-Contact Measurement: Does not touch the material, eliminating wear and preventing material buildup on the sensor.
- High Accuracy: Modern ultrasonic sensors typically achieve centimeter or even millimeter-level accuracy, sufficient for paving requirements.
- Environmental Sensitivity: Measurement accuracy can be affected by extreme temperatures, air turbulence (wind, engine airflow), steam/dust in the hopper, and material surface reflectivity. Vögele's designs incorporate features like specific frequency selection, temperature compensation, and specialized probe designs to mitigate these effects.
- Requires Regular Cleaning: The transducer face must be kept clean to prevent dust, oil, or asphalt adhesion from interfering with ultrasonic wave transmission and reception. Many sensors include features like automatic air purge systems or are designed for easy manual cleaning.
(Note: Alternative Type - Mechanical Paddle Sensor)
While the S1880-3L almost certainly uses the ultrasonic sensor (2484809), older or simpler pavers might use a mechanical (paddle arm) sensor with a different principle:
- A pivoting arm or paddle extends into the hopper.
- Rising material pushes the arm, causing it to rotate.
- This rotation mechanically alters a potentiometer (variable resistor) or rotary angle sensor.
- The change in resistance or angle signal corresponds to the material height and is converted into an electrical signal for the control system.
- Pros: Simple, low-cost. Cons: Contact measurement prone to wear, jamming, material buildup; generally lower accuracy and reliability than ultrasonic sensors.
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