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Radar Technology: a High-flyer

“Ultimately, it's not the measurement process that counts, but the willingness to find a solution to the user's problem.” Head of the Development Department at Vega

In the field of level measurement technology, radar technology has emerged as a real high-flyer in recent years. The Development Manager explains the reasons: “This measuring technique is largely independent of external influences like condensation, temperature, pressure, foam or dust. But that is not everything. Users require robust measuring instruments. This is why we have invested a great deal in the development of highly integrated, power-saving electronic components, in high-performance microcontrollers and high-performance plastics,” adds Deck, explaining the work that has been carried out in recent years. “Ideally, the market would prefer a single physical measuring principle that can cover the majority of measurement requirements. We can meet this challenge very well with our current Vegapuls series.”

Nonetheless, the company from Schiltach also offers many other physical measuring principles, including capacitive level measurement or guided wave radar. “I think that one of the things that really sets us apart at Vega is that we work together with our customers to find the best possible solution for their specific problems,” underlines Deck. “Although we are the market leader in radar technology, if a different measuring technique is more appropriate in a particular situation then we won’t hesitate to recommend it to the customer.” After all, it is not the measuring technique itself that matters, but the willingness to find the right solution for the problem of the user.

And whether curved antennas, antenna extensions or applications in which the guided radar beam is deflected via a metal reflector — the experts from the Black Forest are happy to think outside of the box if necessary. All around the world, Vega has dedicated itself to a mission of “problem solving,” which is also reflected by an export share of 80 percent. Vega measurement technology can be found all around the globe, from South Africa to the Polar Circle, from Asia to Australia and the USA.

Rigorously Tested

The company from Schiltach never cuts any corners when it comes to the reliability of its equipment. Emphasizing the company’s special responsibility, Deck adds: “All our employees are aware that fault-free performance of our measuring equipment is not only essential for the continued commercial success of our company, but that the safety of people and the environment often also depends on it, e.g. in chemical processes or in water supplies.” Even state-of-the-art instruments can struggle under the harsh application conditions that are often encountered. This is why every device is carefully prepared for its future area of application and subjected to extensive tests. Some units need to withstand temperatures between -196 °C and +450 °C, while others must be able to cope with relative humidity of 100 percent, or others in turn need to remain unphased by pressures of up to 1,000 bar. Some sensors need to stay relaxed in the face of vibrations up to 2,000 Hz or lightning strikes up to 100 kA — and only units that can pass this acid test will be approved for use in the field.

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Two examples of sensors that like it hot: Vegaswing 66, a vibrating level switch for liquids, works absolutely reliably even under extreme process temperatures and pressures, as does the TDR (Time Domain Reflectometry) sensor Vegaflex 86 for continuous level and interface measurements of liquids, which covers an extremely wide range of temperatures.

“The major advantage is that we have a wide range of very different testing methods available directly here on site for the equipment tests, for example a 3D X-ray microscope, EMC simulation measurement technology or a bursting pressure test device for up to 6,000 bar,” explains Deck. “On the one hand, the distances are short for dealing with questions, while on the other we save time and can therefore bring new devices to market more quickly.” Incidentally, one very unusual test environment is the company’s own in-house hydroelectric power plant, which is powered by the Kinzig river, which flows straight past the company site. For over 20 years it has met a large proportion of Vega’s energy demands, while serving at the same time as a test field for the company's own level and pressure sensors.

Short Delivery Times

Speed was also the issue when the building block system Plics was introduced more than ten years ago — another milestone in the history of the company. For better understanding: Vega manufactures between 1,500 and 2,000 units every day, which adds up to around 418,000 measuring instruments per year. “Here, we have 180 basic devices and up to 100,000 variants of these devices — which is a big challenge, particularly for a medium-sized company,” explains Deck. The Plics solution: Every measuring device is assembled from pre-fabricated individual components after the order is received. In other words: Every Vega device is a customer-specific device, particularly given that every customer wants different, individualized equipment features.

Every device from the Plics series is assembled from five modules: A sensor is connected via a process fitting with a housing made of plastic, aluminum or stainless steel. In this is the heart of the device: an individually programmed electronics module. The head is always the same display and adjustment module. This means that anyone who has ever operated a Plics device is also capable of operating any other Plics device. As the individual component modules are always kept in stock, Vega can offer very fast delivery times to customers.

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