Electromechanical Level Measurement

Electromechanical Level Measurement

Electromechanical level measurement is used for continuous level measurement in bulk solids. The principle is contact-based and mechanical: a sensing weight (often referred to as a “plumb bob”) is lowered into the vessel until it meets resistance at the material surface, and the traveled distance is used to infer level. This approach is particularly associated with tall silos and bins where a direct physical reference to the surface is valuable.

A major benefit is that it is largely independent of dielectric constant, dust, and headspace conditions that can complicate radar or ultrasonic signals. Because the measurement references a physical “touch” event, it can provide repeatable results across a wide range of dry bulk materials - even when product properties vary. For inventory-centric applications, electromechanical systems can deliver dependable trending and fill-level reporting without requiring extensive signal conditioning for changing solids characteristics.

The tradeoffs are those typical of moving mechanical systems: wear components, periodic inspection, and sensitivity to obstructions or internal vessel geometry. Material that bridges, rat-holes, or forms hard crusts can interfere with the contact event. The measurement cycle also takes time compared to instantaneous electronic methods, so the design should consider fill/empty dynamics, potential for cable swing, and whether a stilling pipe or guide is needed to keep the drop path repeatable.

Electromechanical level is commonly applied in grain, flour, feed, sugar, cement, lime, plastics pellets, and other solids stored in silos - especially where dust loading is high and non-contact technologies struggle without specialized configurations. It is also used in mining/minerals applications for powders and granulates, and in distribution terminals where a robust inventory signal supports logistics and planning.

Selection typically considers required measurement distance, mechanical robustness for the specific bulk solid, enclosure and hazardous-area approvals, and integration into plant monitoring systems. Maintenance planning (inspection intervals, wear-part replacement) should be treated as part of the lifecycle design so performance remains consistent over years of operation rather than only at commissioning.

George E. Booth Co., an exclusive authorized representative of sales and service for Endress+Hauser.