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80 GHz Conquers the World

For more than 20 years, Vega has been the market leader in the area of level measurements with radar. The world’s first two-wire radar sensor was launched in 1997, and just a year later the company had already sold 6,300 units worldwide. But this number holds no comparison to current sales figures. In 2018 nearly 100,000 radar level measuring instruments were sold. This breakthrough is thanks to the Vegapuls series, which has unlocked many application areas with its higher frequency range of 80 GHz and its narrow measuring beam, surpassing other measuring principles. Both Vegapuls 69 for bulk solids and Vegapuls 64 for liquids have now proved themselves as genuine problem solvers.

Radar Level Measurement

Vega Are Already Very Close to the 100,000 Mark with their 80 GHz Radar Level Sensors

“Vegapuls masters level measurement tasks that could not be dealt with by anybody before, or where companies could only deliver solutions with a great deal of effort that involved very expensive equipment,” explains Development Manager Deck. This unit can also measure e.g. in very small containers, as the sensors have a very low dead zone. In addition, the sensors can defy aggressive vapors that adhere to surfaces, such as in the production facility of a French titanium dioxide manufacturer, who only received very inadequate measurement data with the previous systems, despite considerable outlay on maintenance. Further examples of extremely aggressive applications that could be managed thanks to 80 GHz technology include the measurement of hydrofluoric acid or preparation processes in platinum production. With PTFE-plated versions of the instruments, it is even possible to use standard sensors here.

Managing Raw Materials

Level measurement technology plays a special role in inventory management. The VMI (Vendor Managed Inventory) solution from Vega is a web-based software for data acquisition and for the visualization of level data, for example in storage tanks and silos. It enables users to optimize logistics for their raw materials — from suppliers right through to production. “With this technology we can look directly into the silos of the customers and trigger orders when new supplies are needed. This means that companies can outsource responsibility for their raw materials management,” explains Deck.

In some ways this has preempted Industry 4.0 — after all, the VMI solution from Vega was created long before Industry 4.0 started to take shape. The principle has remained the same in the process, but the method of data transfer has changed. Whereas the data used to be sent via modem, it can now be uploaded directly from the sensor to the cloud, where it can be processed directly by the supplier, who for example initiates delivery of a product. In the process, there are more conceivable options than just inventory management. The data can also be further processed and used in ERP systems. Typical applications include the delivery of a wide range of different types of flour to industrial bakeries, delivery of additives like Adblue to filling stations, internal product deliveries within chemical parks or the use of mobile silos in the building materials industry.

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Incidentally, a further development has been initiated for this last application. The external radio unit for Hart sensors Plicsmobile needed to be equipped with robust, durable rechargeable batteries in order to ensure reliable operation on building sites. “Although this may initially appear to be of secondary importance, ultimately it is vital that the accessories are just as reliable as the sensors themselves,” emphasizes Deck.

Embarking into the World of Industry 4.0

There’s no doubt about it: Measuring instruments play an important role in the digitalization process. After all, not only do they supply the information on which the open and closed-loop control systems of processes rely, but they are also essential for the development of further concepts in the sense of Industry 4.0. But Deck is certain: “We are not talking about digitalization at all costs here. Instead, the key must always be to generate benefits for the user.” As examples, he mentions the introduction of the Bluetooth interface for Vega measuring devices.

First and foremost, this was about finding a solution for delivering the measured data directly to the user. In this context it is important to know that e.g. level sensors are often located in potentially explosive atmospheres, in containers with toxic or abrasive products or at dizzying heights in silos. This means that reading off measurements directly from the instruments is just as difficult as routing cables. With the aid of Bluetooth, this can be done wirelessly via smartphone, tablet or laptop. The Development Manager also assures us that implementation is straightforward: “Unscrew the lid, set up the Plicscom display and adjustment module and screw the lid back on — done!”

Exclusive Interview: Milestone Instrumentation

Technology Leadership Means Thinking about the Long Term

In particular the development of the Bluetooth interface and the option for operating the units via apps — i.e. directly from a smartphone or tablet — are good examples of how things are taken a step further at Vega. “We will continue to respond flexibly to the demands of the market and need to be able to quickly implement new technical requirements in the measuring instruments,” explains Deck. “It is all about remaining agile, but of course without neglecting safety and reliability.” And, of course, the factor “cost” also needs to be taken into account.

Whether level or pressure measurements — for both measuring principles, Deck believes that the trend will continue toward smaller measuring devices and simpler operation. “We have already established a good cornerstone here in the past with the Plics concept. These aspects will become increasingly more important in future, when we are looking at integration in Industry 4.0 environments.” Deep in the Black Forest, in the tranquil town of Schiltach, the measurement technology experts are well set-up for the future.

Additional Information

Editorial Statement: That's Why Vega Deserves This Milestone

“We love radar” — the fact that this is not just a brand claim, but actually a lived spirit at Vega becomes immediately clear as soon as you enter the company headquarters in Schiltach. It is something I have already experienced repeatedly in the last 20 years of my “PROCESS life” — namely whenever we were able to present an exclusive of another milestone in level measurement — a privilege of the trade press. Whether the world’s first two-wire radar, the Plics concept or, of course, most recently Vegapuls 64: It always was and still is fascinating to see how the “yellow ones” keep managing to excite themselves, but of course also the users, for their technology. These are the genes that characterize true technology pioneers. And this deserves to be recognized as a milestone in measurement technology!

* The author is a freelancer at PROCESS.

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