{"id":23405,"date":"2026-02-04T07:20:42","date_gmt":"2026-02-04T07:20:42","guid":{"rendered":"https:\/\/www.kcsensor.com\/?p=23405"},"modified":"2026-02-04T07:20:43","modified_gmt":"2026-02-04T07:20:43","slug":"ultrasonic-sensors-with-plc-tank-level-monitoring","status":"publish","type":"post","link":"https:\/\/www.kcsensor.com\/de\/ultrasonic-sensors-with-plc-tank-level-monitoring\/","title":{"rendered":"Ultraschallsensoren mit SPS zur F\u00fcllstands\u00fcberwachung mehrerer Tanks"},"content":{"rendered":"<h2 class=\"wp-block-heading\"><strong>1. Hintergrund des Projekts<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Eine chemische Produktionsanlage ist in Betrieb <strong>f\u00fcnf vertikale Lagertanks<\/strong>, die jeweils unterschiedliche Industriefl\u00fcssigkeiten enthalten. Eine genaue, kontinuierliche F\u00fcllstands\u00fcberwachung ist erforderlich, um:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Vermeiden Sie \u00dcberf\u00fcllung oder Versch\u00fctten<\/li>\n\n\n\n<li>Steuerung von Pumpvorg\u00e4ngen und Prozessabl\u00e4ufen<\/li>\n\n\n\n<li>Bestands- und Produktionsplanung automatisieren<\/li>\n<\/ul>\n\n\n\n<p class=\"wp-block-paragraph\">Bisher f\u00fchrten manuelle F\u00fcllstandskontrollen und Einpunkt-Kontaktsensoren h\u00e4ufig zu Wartungsproblemen und Messverz\u00f6gerungen. Die Anlage ben\u00f6tigte eine <strong>zentralisierte \u00dcberwachungsl\u00f6sung<\/strong>&nbsp;unter Verwendung ber\u00fchrungsloser Sensoren.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large is-resized\"><img data-dominant-color=\"dadada\" data-has-transparency=\"false\" fetchpriority=\"high\" decoding=\"async\" width=\"1024\" height=\"1024\" src=\"https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-1024x1024.webp\" alt=\"Ultraschallsensoren mit SPS-Anschluss\" class=\"wp-image-23408 not-transparent\" style=\"--dominant-color: #dadada; width:868px;height:auto\" srcset=\"https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-1024x1024.webp 1024w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-300x300.webp 300w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-150x150.webp 150w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-768x768.webp 768w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-1536x1536.webp 1536w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-600x600.webp 600w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf-100x100.webp 100w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/\u63a5\u7ebf.webp 2000w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><figcaption class=\"wp-element-caption\"><em>Schaltplan f\u00fcr Ultraschallsensoren mit SPS zur F\u00fcllstands\u00fcberwachung mehrerer Tanks<\/em><\/figcaption><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>2. Herausforderungen bei der Messung<\/strong><strong><\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Die wichtigsten Herausforderungen waren:<\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>Mehrere Tanks mit unterschiedlichen Fl\u00fcssigkeitseigenschaften (auf Wasserbasis, chemische L\u00f6sungen)<\/li>\n\n\n\n<li>Eingeschr\u00e4nkter Zugang zu den Tank-Tops bei h\u00e4ufigen Sensorwartungen<\/li>\n\n\n\n<li>Notwendigkeit ber\u00fchrungsloser Messungen zur Vermeidung von Verunreinigungen und Sensorverschlei\u00df<\/li>\n\n\n\n<li>Echtzeit\u00fcberwachung und Alarmintegration \u00fcber SPS<\/li>\n\n\n\n<li>Raue industrielle Umgebungsbedingungen (Temperaturschwankungen, Luftfeuchtigkeit, gelegentliche Chemikalienspritzer)<\/li>\n<\/ul>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>3. L\u00f6sung<\/strong><\/h2>\n\n\n\n<p class=\"has-black-color has-text-color has-link-color wp-elements-1 wp-block-paragraph\">Die L\u00f6sung bestand aus <strong>5 <a href=\"https:\/\/www.kcsensor.com\/de\/product\/kus550-ultrasonic-water-level-sensor\/\" target=\"_blank\" rel=\"noreferrer noopener\">Ultraschall-F\u00fcllstandssensoren KUS550<\/a><\/strong>&nbsp;an den Tanks angebracht, angeschlossen an einen <strong>SPS<\/strong>&nbsp;zur zentralen \u00dcberwachung und Steuerung. Jeder Sensor misst kontinuierlich den Abstand vom Sensor zur Fl\u00fcssigkeitsoberfl\u00e4che und wandelt diesen in F\u00fcllstandsdaten um.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img data-dominant-color=\"46615f\" data-has-transparency=\"false\" style=\"--dominant-color: #46615f;\" decoding=\"async\" width=\"1024\" height=\"575\" src=\"https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-1024x575.webp\" alt=\"\" class=\"wp-image-23406 not-transparent\" srcset=\"https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-1024x575.webp 1024w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-300x168.webp 300w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-768x431.webp 768w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-1536x862.webp 1536w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-2048x1150.webp 2048w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-5-600x337.webp 600w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Systemkonfiguration:<\/strong><\/p>\n\n\n\n<ul class=\"wp-block-list\">\n<li>5 Ultraschall-F\u00fcllstandssensoren vom Typ KUS550 (einer pro Tank)<\/li>\n\n\n\n<li>Vertikale Montage an Tankoberseiten<\/li>\n\n\n\n<li>SPS-Einheit mit Analog-\/Digital-Eingangsmodulen<\/li>\n\n\n\n<li>RS485-Ausgang von jedem Sensor zur SPS<\/li>\n\n\n\n<li>Lokales HMI-Panel zur Echtzeit\u00fcberwachung und Alarmanzeige<\/li>\n\n\n\n<li>Schutzhalterungen und Spritzschutzvorrichtungen gegen Chemikalien nach Bedarf<\/li>\n<\/ul>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>3.1 Wichtige technische Spezifikationen<\/strong><strong><\/strong><\/h3>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><td><strong>Parameter<\/strong><strong><\/strong><\/td><td><strong>Spezifikation<\/strong><strong><\/strong><\/td><\/tr><tr><td>Messbereich<\/td><td>0,2\u20133 m<\/td><\/tr><tr><td>Genauigkeit<\/td><td>\u00b10,51 TP3T ~ \u00b111 TP3T<\/td><\/tr><tr><td>Ausgabe<\/td><td>RS485 \/ 4\u201320 mA<\/td><\/tr><tr><td>Schutz<\/td><td>IP65 (SPS); IP68 (KUS550)<\/td><\/tr><tr><td>Betriebstemperatur<\/td><td>-20 \u00b0C bis 60 \u00b0C<\/td><\/tr><tr><td>Einrichtung<\/td><td>Vertikal, oben montiert<\/td><\/tr><tr><td>Anzahl der Sensoren<\/td><td>5 pro SPS<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<h3 class=\"wp-block-heading\"><strong>3.2 Umsetzungsprozess<\/strong><strong><\/strong><\/h3>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Einrichtung<\/strong><br>Jeder KUS550-Sensor wurde mithilfe verstellbarer Halterungen in der Mitte des jeweiligen Tankdeckels montiert, um die Signalreflexion zu optimieren. Zum Schutz vor Chemikalienspritzern wurden Schutzabdeckungen angebracht.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>SPS-Integration<\/strong><br>Die RS485-Ausg\u00e4nge der Sensoren wurden an die RS485-Kommunikationsmodule der SPS angeschlossen. Die F\u00fcllst\u00e4nde der Tanks wurden in der SPS abgebildet, und es wurden Schwellenwerte f\u00fcr Hoch- und Tiefalarm festgelegt.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><strong>Betrieb und \u00dcberwachung<\/strong><br>Das SPS-Display erm\u00f6glicht die direkte Steuerung der Sensoren vor Ort, einschlie\u00dflich der manuellen Aktivierung und Deaktivierung jedes einzelnen Sensorger\u00e4ts. Au\u00dferdem unterst\u00fctzt es die Echtzeitanpassung wichtiger Messparameter wie der oberen und unteren Messgrenzen sowie der oberen und unteren Schwellenwerte f\u00fcr Alarmausl\u00f6sungen. Dar\u00fcber hinaus speichert das SPS-System alle historischen Messdaten, die direkt auf dem Display angezeigt und bei Bedarf zur weiteren Datenanalyse und Archivierung exportiert werden k\u00f6nnen.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img data-dominant-color=\"535275\" data-has-transparency=\"false\" style=\"--dominant-color: #535275;\" decoding=\"async\" width=\"1024\" height=\"575\" src=\"https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-1024x575.webp\" alt=\"\" class=\"wp-image-23407 not-transparent\" srcset=\"https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-1024x575.webp 1024w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-300x168.webp 300w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-768x431.webp 768w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-1536x862.webp 1536w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-2048x1150.webp 2048w, https:\/\/www.kcsensor.com\/wp-content\/uploads\/2026\/02\/PLC550-\u539f\u56fe-6-600x337.webp 600w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>4. Projektergebnisse<\/strong><\/h2>\n\n\n\n<figure class=\"wp-block-table\"><table class=\"has-fixed-layout\"><tbody><tr><td><strong>Leistungskennzahl<\/strong><strong><\/strong><\/td><td><strong>Ergebnis<\/strong><strong><\/strong><\/td><\/tr><tr><td>Messgenauigkeit<\/td><td>\u00b11%<\/td><\/tr><tr><td>Verf\u00fcgbarkeit der Daten<\/td><td>99,71 TP3T-Verf\u00fcgbarkeit<\/td><\/tr><tr><td>Wartung<\/td><td>Nur viertelj\u00e4hrliche Reinigungsinspektionen<\/td><\/tr><tr><td>Reaktionszeit<\/td><td>&lt; 1 Sekunde bei SPS-Alarm<\/td><\/tr><tr><td>Effizienz der Bediener<\/td><td>Verbesserung durch zentralisierte \u00dcberwachung<\/td><\/tr><\/tbody><\/table><\/figure>\n\n\n\n<p class=\"wp-block-paragraph\">Durch das System aus SPS und KUS550 entfielen manuelle Kontrollen und die Kosten f\u00fcr den Austausch von Sensoren konnten gesenkt werden.<\/p>\n\n\n\n<h2 class=\"wp-block-heading\"><strong>5. Schlussfolgerung<\/strong><\/h2>\n\n\n\n<p class=\"wp-block-paragraph\">Diese L\u00f6sung zeigt, wie <strong>mehrere Ultraschall-F\u00fcllstandssensoren vom Typ KUS550 in Kombination mit einer SPS<\/strong>&nbsp;aktivieren <strong>zuverl\u00e4ssige, zentralisierte \u00dcberwachung mehrerer Industrietanks<\/strong>. Die ber\u00fchrungslose Messung sch\u00fctzt die Sensoren vor Verschlei\u00df und chemischen Einfl\u00fcssen und verringert die Wartungsh\u00e4ufigkeit.<\/p>\n\n\n\n<p class=\"has-black-color has-text-color has-link-color wp-elements-2 wp-block-paragraph\">F\u00fcr weitere technische Details, Schaltpl\u00e4ne oder Hinweise zur Modellauswahl klicken Sie bitte hier <strong><a href=\"\/de\/contact-us\/\" target=\"_blank\" data-type=\"link\" data-id=\"https:\/\/www.kcsensor.com\/contact-us\/\" rel=\"noreferrer noopener\">hier<\/a><\/strong> Um mehr zu erfahren oder unser technisches Team zu kontaktieren.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\"><\/p>","protected":false},"excerpt":{"rendered":"<p>1. Project Background A chemical processing facility operates five vertical storage tanks, each containing different industrial liquids. Accurate, continuous level monitoring is required to: Previously, manual level checks and single-point contact sensors caused frequent maintenance issues and measurement delays. The plant required a centralized monitoring solution&nbsp;using non-contact sensors. 2. Measurement Challenges The key challenges were: [&hellip;]<\/p>\n","protected":false},"author":6,"featured_media":23581,"comment_status":"closed","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"site-sidebar-layout":"default","site-content-layout":"","ast-site-content-layout":"default","site-content-style":"default","site-sidebar-style":"default","ast-global-header-display":"","ast-banner-title-visibility":"","ast-main-header-display":"","ast-hfb-above-header-display":"","ast-hfb-below-header-display":"","ast-hfb-mobile-header-display":"","site-post-title":"","ast-breadcrumbs-content":"","ast-featured-img":"","footer-sml-layout":"","ast-disable-related-posts":"","theme-transparent-header-meta":"","adv-header-id-meta":"","stick-header-meta":"","header-above-stick-meta":"","header-main-stick-meta":"","header-below-stick-meta":"","astra-migrate-meta-layouts":"set","ast-page-background-enabled":"default","ast-page-background-meta":{"desktop":{"background-color":"var(--ast-global-color-4)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"ast-content-background-meta":{"desktop":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"tablet":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""},"mobile":{"background-color":"var(--ast-global-color-5)","background-image":"","background-repeat":"repeat","background-position":"center center","background-size":"auto","background-attachment":"scroll","background-type":"","background-media":"","overlay-type":"","overlay-color":"","overlay-opacity":"","overlay-gradient":""}},"footnotes":""},"categories":[294],"tags":[],"class_list":["post-23405","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-cases"],"acf":[],"_links":{"self":[{"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/posts\/23405","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/users\/6"}],"replies":[{"embeddable":true,"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/comments?post=23405"}],"version-history":[{"count":0,"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/posts\/23405\/revisions"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/media\/23581"}],"wp:attachment":[{"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/media?parent=23405"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/categories?post=23405"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.kcsensor.com\/de\/wp-json\/wp\/v2\/tags?post=23405"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}