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Guangdong Kaidi Energy Technology Co., Ltd. Christmas GiftIlluminating warmth with technology, safeguarding every reunion with craftsmanship.As Christmas starlight adorns the night sky and the warmth of reunion fills our hearts, we understand that behind every sparkle lies the quiet pulse of energy; behind every act of warmth, the silent guardianship of technological craftsmanship.Guangdong Kaidi Energy Technology Co., Ltd. aspires to be the most reliable light among the festive illuminations—empowering the future of energy with innovation, making reunions brighter and winters more consistently warm.Like our level gauges, precise, dependable, and always online, safeguarding the security of every industrial process.This holiday season, Kaidi wishes to be your most steadfast “guardian”—measuring with pinpoint accuracy, ensuring blessings return in abundance.Wishing you and your team a Merry Christmas and a prosperous New Year. May your endeavors rise steadily like liquid levels, reaching new heights!Thank you for your trust and choice this past year. Our “cooperative liquid level” remains consistently stable and abundant. We look forward to continuing ourjourney together in the new year. Merry Christmas and prosperous business!

In industrial control, security surveillance, and smart device applications, RS-485 communication is widely adopted in various instrumentation systems due to its high interference immunity, long transmission distances, and support for multipoint communication. However, when debugging RS-485 communication, many engineers frequently encounter a question: Why must a 120-ohm terminating resistor be added at both ends of the bus? This article will thoroughly analyze the function and principles of terminating resistors by integrating instrumentation applications with real-world operating conditions.I. Introduction to RS-485 CommunicationRS-485 communication is a differential transmission method, whose main characteristics include:Strong anti-interference capability: Differential signals effectively suppress electromagnetic interference (EMI).Long transmission distance: RS-485 supports a maximum transmission distance of up to 1200 meters.Multi-point communication: RS-485 supports communication among up to 32 devices (nodes) on a single bus.In practical applications, the RS-485 communication bus typically adopts a bus-type structure. Impedance matching at both ends of the communication line requires special attention, which is the key consideration in terminal resistor design.II. The Necessity of Termination ResistorsIn RS-485 communication, termination resistors are not optional but an essential component for ensuring communication quality. Specifically, the role of termination resistors is reflected in the following aspects:Preventing Signal Reflection: During data transmission, signals encountering impedance mismatch at the end of the transmission line may reflect back onto the bus. This reflection introduces interference on the bus, compromising data integrity and causing communication instability.Achieving Impedance Matching: The characteristic impedance of RS-485 communication cables is typically around 120 ohms. To ensure effective signal transmission and prevent reflections, a 120-ohm terminating resistor must be used to absorb excess signal energy, thereby matching the cable's characteristic impedance.Ensuring Data Integrity: Without a terminating resistor, reflected signals superimpose onto the original signal, causing waveform distortion that leads to data errors or communication interruptions. This issue becomes particularly pronounced during long-distance or high-speed transmission.III. Why Choose 120 Euros?The RS-485 communication standard specifies that the characteristic impedance of the communication cable is approximately 120 ohms. Therefore, adding 120-ohm terminating resistors at both ends of the bus effectively achieves impedance matching, thereby ensuring stable communication.What happens if there is an impedance mismatch?Excessively high resistance: Signal reflections remain unabsorbed and continue to interfere with communication.Excessively low resistance: Signal energy loss becomes excessive, adversely affecting transmission distance.Therefore, the 120-ohm terminating resistor has been proven through extensive practical testing to be the optimal choice. It delivers the best matching effect—simple and effective.IV. Correct Procedures in PracticeTerminating resistor placement: Terminating resistors should only be added at both ends of the bus, not at intermediate nodes. Each node does not require additional resistors, as this may affect impedance matching and cause unnecessary signal loss.Common resistor selection: For most applications, 120-ohm, 1/4-watt metal-film resistors suffice. While termination may not be mandatory for short-range communication (e.g., within a few meters), it remains critical for long-distance transmission or high-speed communication.V. Practical Case Study: The Importance of Termination ResistorsA chemical plant initially failed to install termination resistors when using an RS-485 bus for long-distance sensor data transmission. This resulted in data packet loss and frequent alarm issues, with communication stability significantly deteriorating as the number of nodes increased. After adding termination resistors, signal reflection phenomena disappeared, and data transmission became more stable and reliable. This case vividly demonstrates the critical role termination resistors play in ensuring the stability of 485 communication.VI. Common MisconceptionsEach node requires a terminating resistor: Incorrect! Terminating resistors should only be placed at both ends of the bus. Resistors should not be added between nodes, as this would compromise overall impedance matching.Short-distance communication does not require terminating resistors: While communication may sometimes function normally over short distances, terminating resistors still enhance reliability when signals face interference or operate at higher transmission rates.Terminating resistors can have arbitrary values: Incorrect! The resistor value must match the bus's characteristic impedance; selecting 120 ohms is best practice.VII. Summary and RecommendationsAlthough seemingly insignificant, the terminating resistor is a critical component in RS-485 communication, ensuring stable and reliable data transmission. When designing and debugging RS-485 communication systems, it is imperative to connect 120-ohm terminating resistors at both ends of the bus in accordance with standards. Particular attention should be paid to this design detail during long-distance transmission or multi-node communication to prevent potential communication instability. Properly configuring the terminating resistor significantly enhances the overall communication quality of the system, ensuring the stable operation of instruments and control equipment.

In recent years, radar level gauges have been progressively replacing ultrasonic level gauges as the more prevalent non-contact level measurement technology in field measurement applications across industries such as chemical, petrochemical, power generation, food and beverage, wastewater treatment, and powder storage and transportation. This trend is driven not by a single factor but by a combination of factors, including: differences in physical principles, environmental adaptability, measurement accuracy and stability, process compatibility, digitalization and intelligent diagnostic capabilities, and improvements in total cost of ownership.While ultrasonic level transmitters retain competitiveness in low-cost and simple operating conditions, radar level transmitters are poised to become the mainstream technology in future developments. This study reviews the differences and application boundaries between the two technologies, synthesizing key considerations for selecting appropriate measurement techniques based on academic research and engineering practice.                                                                                                                                      Radar Level Transmitters and Ultrasonic Level TransmittersI. Physical Characteristics Differences Between Electromagnetic Waves and Sound WavesUltrasonic level transmitters measure distance by timing the propagation of sound waves, making them highly susceptible to temperature, humidity, gas composition, and turbulence. For instance, in high-temperature steam environments, fluctuations in the speed of sound through air can cause measurement errors. Simultaneously, foam and mist can absorb or scatter ultrasonic signals, generating false echoes.In contrast, radar level transmitters emit microwave or millimeter-wave electromagnetic signals. Electromagnetic waves are virtually unaffected by temperature and humidity in gaseous phases, enabling effective penetration through steam, mist, and dust. Both manufacturer reports and academic studies indicate that radar echo stability significantly outperforms ultrasonic performance in steam clouds, dust-filled enclosed compartments, and agitated vessels.                                                                                                                  Radar level gauges demonstrate significant advantages in anti-interference performance.II. High-frequency and FMCW technologies enhance measurement resolution.Traditional pulse radar has limited resolution, but with the development of 24 GHz and 80 GHz high-frequency bands and FMCW (Frequency Modulated Continuous Wave) technology, the resolution and interference resistance of radar level gauges have significantly improved.High-frequency radar features a narrower beam angle, reducing wall echo interference;80 GHz technology enables smaller antenna sizes, making it more suitable for compact vessels;FMCW delivers higher signal-to-noise ratio and dynamic range, enabling detection of weak echoes—particularly advantageous for liquids with low dielectric constants.These advancements enable radar to perform exceptionally well in containers with complex geometries, narrow tanks, and agitated conditions.                                                                                                                                    Level measurement in mixing tanks is more stable and reliable.III. Reduced Blind Spots and Installation FlexibilityUltrasonic probes typically have a ±10mm “blind zone,” making accurate measurement difficult when liquid levels are too close to the container top. In contrast, high-frequency radar can often reduce the blind zone to just a few centimeters, significantly enhancing feasibility for small tanks or shallow tanks.This eliminates the need for engineers to install bypass pipes or extension tubes to reduce the blind zone, simplifying installation complexity and reducing maintenance points. For industries requiring frequent cleaning, such as food and pharmaceuticals, this simplified installation is particularly crucial.IV. Measurement Reliability Under Foam and TurbulenceIn fermentation, dairy, papermaking, and chemical reaction processes, liquid surfaces are often covered by foam or bubbles. Ultrasonic waves scatter energy within foam, frequently causing signals to be completely attenuated and interrupting measurements.Radar, however, relies on dielectric constant differences. Even when a foam layer exists on the liquid surface, it can identify the true liquid surface echo in most cases. Through signal processing algorithms, radar distinguishes between foam reflections and liquid surface reflections, enhancing data reliability.                                                                                                                           Easily identify foam levels, with measurements as reliable as ever.V. Long-Range and High-Precision PerformanceFor large tanks or silos exceeding 20 meters in height, ultrasonic signal attenuation and sound velocity fluctuations significantly reduce measurement accuracy. Radar, with its superior signal penetration and interference resistance, maintains stable measurements across ranges of 30–120 meters or even longer.Additionally, radar typically achieves accuracy within ±1–2 mm, whereas ultrasonic systems generally maintain only ±5–10 mm precision. In chemical reactors, batching processes, or industries requiring strict inventory management, this accuracy gap can directly impact production quality and economic efficiency.VI. Intelligent Systems and Remote DiagnosticsModern radar level transmitters widely support industrial protocols such as HART, Modbus, and Profibus, while progressively integrating Bluetooth and wireless communication. This enables engineers to perform parameter configuration, waveform diagnostics, and firmware upgrades from safe zones or remote workstations.In contrast, while ultrasonic level transmitters also offer digital versions, they lag behind in waveform processing, diagnostic algorithms, and remote upgrade capabilities. Academic research indicates radar level transmitters hold greater advantages in intelligent diagnostics and Industry 4.0 integration.VII. Cost and Lifecycle ConsiderationsHistorically, radar level transmitters were limited by their higher cost. However, with the mass production of integrated 80 GHz chips and antennas, prices have significantly decreased. Many plants conducting lifecycle cost assessments have found that while radar level gauges have a higher unit price than ultrasonic gauges, they offer superior overall economics by reducing false alarms, downtime, and maintenance costs.Consequently, in applications demanding high safety and reliability (such as petrochemical tank farms and hazardous chemical storage tanks), an increasing number of enterprises are opting for radar level gauges.VIII. Application Boundaries and Selection RecommendationsNot all scenarios require radar. In budget-sensitive, open-environment applications where measurement accuracy is not critical—such as open channels in water treatment plants or small reservoirs—ultrasonic technology remains a cost-effective solution.Scenarios where radar is preferred: High-temperature environments, condensing steam, foaming conditions, dusty atmospheres; large tanks, deep silos, remote operations; process control points requiring high precision and continuous monitoring.Scenarios where ultrasonic is preferred: Low-cost water tanks/channels, simple operating conditions, low-risk storage tanks.Hybrid strategy: Deploy radar at critical points and ultrasonic at secondary points to optimize overall investment and operational efficiency.ConclusionRadar level gauges are gradually replacing ultrasonic level gauges, driven by the convergence of mature technology, enhanced adaptability to operating conditions, and the trend toward industrial intelligence. With the widespread adoption and decreasing cost of 80 GHz high-frequency FMCW technology, this replacement trend will accelerate. Ultrasonic technology will retain its market share in certain low-cost, low-risk applications, but radar level gauges are undoubtedly the future mainstream.

With the rapid advancement of technology, smart and intelligent solutions have become key drivers for transformation and upgrading across all industries. In the power sector, the concept of smart power plants has emerged, representing not only technological innovation but also a profound vision for future energy management. By integrating advanced information technology, automation, artificial intelligence, and other technologies, smart power plants achieve efficient energy utilization and environmentally friendly emissions, marking the future direction of power plant development.In response to the wave of intelligent transformation sweeping the power industry, a series of innovative solutions have been introduced to support the construction and development of smart power plants. These solutions not only encompass traditional level measurement technologies but also integrate cutting-edge technologies such as advanced 3D imaging, high-frequency radar, and AI algorithms, bringing innovation and transformation to the level measurement and control models of smart power plants.Typical CasesI. Fuel Supply ProcessCase Background: In thermal power plants, fuel supply is a critical factor in ensuring stable plant operation. After coal is transported to the plant site, it is first stored in the coal yard. Here, the coal is processed by crushers to achieve the appropriate size before being conveyed to the coal silo. Within the silo, the coal is ground into pulverized coal, stored in the pulverized coal silo, and ultimately delivered to the boiler via the pulverizer for combustion. This process ensures the continuity and stability of the power generation cycle.Application Scenario: Coal Stockpile YardChallenges in Measurement: Coal piles typically exhibit irregular shapes and may become unevenly distributed due to factors like wind and rain, making it difficult to accurately measure their height and volume. The quantity and configuration of coal in stockyards can change frequently, requiring measurement systems to have real-time updating capabilities.Recommended Product: 3D Laser Disc Gauge Application Scenarios: Coal bunkers, pulverized coal bunkersMeasurement Challenges: Coal accumulation within coal bunkers is uneven, and its form is easily influenced by various factors such as angle of repose and bulk density, making traditional measurement methods prone to inaccuracies. Additionally, the presence of significant dust within pulverized coal bunkers can interfere with measurement results.Recommended Product: 3DPro2300 Radar Scanning RobotApplication Scenario: CrusherMeasurement Challenges: Crushers handle large volumes of material, with rapidly changing material levels and flow patterns causing measurement instability. The crushing process generates significant dust, interfering with the accuracy of optical sensors or mechanical measurement devices. High humidity environments may lead to condensation, sensor signal attenuation, and other measurement errors.Recommended Product: 3DPro2300 Radar Scanning Robot/Radar Level GaugeII. Fuel Delivery Process Case Background: At thermal power plants, coal transported by rail to the plant site is unloaded by a car dumper into the coal stockyard, then conveyed via belt conveyors to the coal silos. Consequently, monitoring the belt conveyors is of critical importance, as it not only ensures the continuity of coal supply but also guarantees the efficient operation of the entire fuel delivery system.Application Scenario: Conveyor Belt MonitoringMeasurement Challenges: Vibration, noise, and temperature fluctuations during conveyor belt operation can compromise sensor measurement accuracy and stability. Real-time processing and analysis of large data volumes are critical for providing early warnings and decision support, which increases the complexity of system design and implementation.Recommended Products: 2D Belt Laser Flow Meter / Automatic Belt Alignment System / Belt Inspection RobotIII. Steam System Monitoring Process Case Background: The steam system monitoring process is primarily responsible for real-time monitoring of steam generated by boilers to ensure steam quality and flow rate meet operational requirements. Through the monitoring system, critical parameters such as steam pressure, temperature, and flow rate can be detected, enabling timely identification of potential issues to safeguard equipment safety and efficiency.Application Scenario: Boiler Drum Liquid Level MonitoringMeasurement Challenges: Steam drums operate under high temperature and pressure, requiring durable and precise measurement equipment. Water level must be accurately measured to prevent dry firing or excessive water accumulation. Pressure within the steam drum fluctuates with boiler load, demanding stable and accurate pressure measurement devices.Recommended Product: High-Temperature, High-Pressure Guided Wave Radar Level TransmitterApplication Scenario: Deaerator/Heat Exchanger Liquid Level MonitoringMeasurement Challenges: These devices typically operate under extreme conditions, demanding high temperature and pressure resistance from monitoring equipment. Monitoring media may include steam, condensate, and other chemicals. The physical properties of these media can vary with temperature and pressure, affecting measurement accuracy.Recommended Product: Guided Wave Radar Level TransmitterApplication Scenario: Steam Pipeline MonitoringMeasurement Challenges: High temperatures and pressures, coupled with complex environmental conditions, often involve factors such as vibration and humidity in steam pipeline environments, significantly increasing measurement difficulty.Recommended Products: Level Switches / Temperature Sensors / Pressure TransmittersIV. Flue Gas Treatment Process Case Background: The flue gas treatment process primarily handles exhaust gases generated during combustion to reduce harmful emissions and ensure compliance with environmental standards. This involves technologies such as flue gas desulfurization, denitrification, and dust removal to eliminate pollutants like sulfur dioxide, nitrogen oxides, and particulate matter, thereby minimizing environmental impact.Application Scenario: Flue Gas Desulfurization System MonitoringMeasurement Challenges: In flue gas desulfurization systems at thermal power plants, lime slurry serves as the primary desulfurization agent for removing sulfur dioxide from flue gas. However, lime powder exhibits strong adhesive properties and readily accumulates on measurement probes, leading to measurement errors. Additionally, high dust levels within lime silos may interfere with measurement signals, compromising equipment stability and service life.Recommended Products: Density Meter / Mass Flow Meter / Radar Level TransmitterApplication Scenarios: Flue Gas/Flow/Pressure MonitoringMeasurement Challenges: Flue gas temperatures are typically very high, requiring sensors to possess high-temperature resistance. Additionally, particulate matter in the flue gas can easily clog or wear down sensors, while chemical components may corrode sensor materials.Recommended Products: Flow Meters / Temperature Sensors / Pressure TransmittersLooking AheadKaidi's smart power plant solution transcends isolated technological innovations by establishing a comprehensive intelligent management platform. By integrating advanced sensors, IoT, big data, and artificial intelligence technologies, this platform achieves holistic optimization of the power generation process. It not only enhances power generation efficiency and operational intelligence but also ensures process safety and environmental sustainability, providing robust support for the power industry's transition toward a smarter, greener future.