How a Laser Level Sensor Can Reduce Maintenance Costs

One of the biggest costs in any industry is the time spent on equipment maintenance, regardless of the type. In addition to halting or slowing production, many pieces of equipment need to be repaired or replaced, directly impacting a company’s financial results. 

This is why leveraging technology in production processes is indispensable in Industry 4.0. It enhances productivity, reduces errors, and maximizes profits. Besides being integrated into production routines, technology can (and should) be combined with industrial maintenance practices. 

Finding a level, distance, or volume sensor with little to no maintenance is a major challenge in the bulk transport of grains, fluids, and solids. Most sensors currently in use involve direct contact, leading to wear and even short- or medium-term failures. 

To solve this issue, a new technology was developed: laser measurement. This technology enables the measurement of a wide range of fluids and solids without direct contact, offering precision and reduced maintenance. 

Efficiency Without Maintenance 

NOVUS’s TL400 laser sensor utilizes advanced ToF (Time of Flight) technology to accurately calculate the distance between the sensor and the measurement point. 

This operational principle allows the device to remain outside the tank, and with no moving parts, there’s no need for preventive maintenance, as it’s not subject to wear or contamination over time. 

With a low-power Class 1 laser beam (safe for the human eye), the TL400 performs multiple measurements per second, ensuring precise results converted into level, volume, and distance in various units. The analog output update rate is 1 Hz, with an accuracy of up to ±3 mm. 

Additionally, the TL400 features embedded software that allows accurate measurement of both static and moving materials. It supports the registration of up to 20 custom points for irregularly shaped tanks. 

Applications 

The TL400 is highly versatile, suitable for various industries and transport types, and capable of measuring up to 4 meters in height, including: 

• Fuel tanks; 

• Tractors and self-propelled machines (measuring fuel levels or harvest quantities); 

• Buses and trucks (measuring fuel levels); 

• Fertilizer tanks; 

• Diesel generators; 

• Effluent tanks (potable water and sewage); 

• Solid reservoirs (grains, polymers, etc.). 

Durability and Safety 

The TL400 is made of UV-protected polycarbonate, with a flame-retardant polymer. Its ultrasonic sealing ensures complete protection with an IP68 rating. This means the device is durable enough for field applications and can withstand outdoor conditions for long-term stable operation. 

Thanks to its mechanical robustness, the sensor can be used in pressurized tanks up to 8 bar and operates in environments with temperatures ranging from -20 to 80°C. 

Simple and Practical Configuration 

The TL400 is fully configured via Bluetooth, eliminating the need for cables and allowing configuration from up to 10 meters away. Readings are easily obtained through a 4-20mA analog signal. 

The free SigNow Mobile configuration app is available for Android and iOS. No additional configuration interface is required; simply download the app to any smartphone. 

To learn more, visit the product page on our website.