IoT Pressure Sensors
Pressure Sensor- G1/4 12-36V 4-20mA 0-600bar industrial
Pressure sensors measure the pressure of gasses or liquids and convert the measurement into an electrical signal. These sensors are essential for monitoring and controlling pressure in various industrial and consumer applications.
Types of Pressure Sensors
Piezoelectric Sensors
1D22 27 mm Diameter Piezoelectric Discs
Piezoelectric sensors generate an electrical charge in response to pressure changes. Piezoelectric sensors utilize the piezoelectric effect to measure changes in pressure, acceleration, temperature, strain, or force by converting them to an electrical charge. These sensors are widely used due to their high sensitivity, excellent linearity, and wide frequency response.
Applications of Piezoelectric Sensors
- Shock and impact sensing in automotive crash testing.
- Medical devices such as ultrasound transducers.
- Pressure sensors in aerospace applications for turbine monitoring.
Strain Gauge Sensors
Foil Strain Gage
Strain gauge sensors measure the deformation of a diaphragm under applied pressure, providing a proportional electrical signal. The deformation of the diaphragm causes a change in the resistance of the strain gauge. The resistance of a typical strain gauge varies from about 120 ohms to 350 ohms, although values can be as high as 1000 ohms or more for specialized applications. The change in resistance is converted into an electrical signal, which can be measured and correlated to the applied pressure. Strain gauges can typically measure strains from 0.5% (5000 microstrain) up to about 10% (100,000 microstrain) depending on the type and material of the gauge.
Applications of Strain Gauge Sensors
- Structural health monitoring in buildings, bridges, and other infrastructure.
- Load measurements in scales and weighing systems.
- Torque measurement in rotating shafts and motors.
Advantages of Pressure Sensors
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Accuracy
High-end pressure sensors, such as piezoelectric or capacitive types, can achieve accuracy levels of ±0.1% to ±0.25% of full-scale output, which is crucial in applications like fuel injection systems or medical ventilators. -
Wide Range
Pressure sensors can measure from as low as 0.001 bar (0.1 kPa) up to 1000 bar (100 MPa), enabling their use in varied industries from automotive tire pressure monitoring systems (TPMS) to deep-sea exploration. -
Durability
Many pressure sensors, especially those made from stainless steel or ceramic, are highly durable and can operate reliably in extreme conditions, including temperatures from -40°C to 150°C and exposure to corrosive environments like oil and gas pipelines.
Disadvantages of Pressure Sensors
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Complexity
Installing pressure sensors often requires careful consideration of factors like the type of fluid or gas, pressure range, and environmental conditions. Additional components, such as signal conditioners or temperature compensation circuits, are often necessary to ensure accurate readings. -
Susceptibility to Drift
Pressure sensors, particularly those exposed to high pressures or extreme temperatures, can experience drift over time. For example, a sensor might lose 0.1% of accuracy per year, requiring periodic recalibration to maintain performance, especially in critical systems like aircraft altimeters or industrial automation.
IR Sensors
IR Sensors-TSOP Sensor with IR Receiver Metal Covering
IR sensors, or infrared sensors, detect infrared radiation emitted from objects and convert this detection into an electrical signal. Objects emit infrared radiation based on their temperature and IR sensors are used to detect this radiation.
Types of IR Sensors
Active IR Sensors
IR Active Infrared Sensors
In active IR sensors, a light source emits the IR light. The emitted IR light travels until it hits an object. The light is then reflected back to the sensor or is interrupted by an object passing through the beam. The photodetector in the sensor captures the reflected or interrupted IR light and measures it to determine the distance to an object or detect motion.
Applications of Active IR Sensors
- Object detection in industrial automation for machinery safety and operation control.
- Counting and sorting systems in manufacturing processes.
- Barcode scanning in retail and logistics.
Passive IR Sensors (PIR)
PIR (Passive Infrared) Sensors
Passive Infrared (PIR) sensors do not emit any radiation themselves. Instead, they detect the infrared radiation naturally emitted by warm objects, such as humans and animals. At the core of a PIR sensor is a pyroelectric material. When a warm object moves within the sensor's field of view, it causes a fluctuation in infrared levels, leading to a change in the electrical charge generated by the pyroelectric material. This differential detection allows PIR sensors to effectively identify motion.
Applications of Passive IR Sensors
- Motion detection in security systems for residential and commercial properties.
- Lighting control systems to switch lights on or off based on occupancy.
- Automatic doors in commercial buildings and public spaces.
Advantages of IR Sensors
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Non-Contact Measurement
Infrared (IR) sensors detect thermal radiation emitted by objects, allowing for non-contact temperature measurement and object detection. This feature is especially valuable in applications like industrial equipment monitoring and medical thermography, where contact is not feasible. -
Versatility IR sensors operate effectively across a broad spectrum of wavelengths, typically between 0.7 to 14 micrometers (µm), enabling their use in various applications, from proximity sensing in consumer electronics to environmental monitoring in smart homes.
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Speed
With response times as fast as a few microseconds, IR sensors are ideal for applications requiring quick detection, such as automotive collision avoidance systems and gesture recognition technologies.
Disadvantages of IR Sensors
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Limited Range
The detection range of IR sensors is typically short, often limited to 2-5 meters, which can constrain their use in larger spaces. High-power IR sensors can extend this range to 10 meters or more but at an increased cost and power consumption. -
Sensitivity to Interference
IR sensors can be susceptible to interference from ambient light sources, especially direct sunlight, which can cause false readings. Additionally, environmental factors like fog, smoke, or dust can attenuate IR signals, reducing their effectiveness. -
Material Limitations
IR sensors may have difficulty accurately detecting certain materials, such as transparent surfaces like glass or highly reflective metals, as these can either pass through or reflect IR waves, leading to potential inaccuracies in applications like object detection or distance measurement.
Position Sensors
Position Sensors- Non Contact Linear Position Sensors
Position sensors detect the position of an object and convert this information into an electrical signal. Position sensors use various principles such as magnetic fields, light, or resistance to determine the position of an object. They are vital in applications requiring precise control and monitoring of object location.
Types of Position Sensors
Linear Position Sensors
PIPS Linear Displacement Sensors
Linear position sensors are devices that measure the linear displacement of an object or position of an object along a single axis. These sensors come in various types, including potentiometric, inductive, capacitive, and magnetic, each with distinct characteristics. For digital communication integration, digital outputs using protocols like I2C, SPI, RS-232, RS-485, or CAN bus are common.
Applications of Linear Position Sensors
- Robotics for precise movement control of robot arms and joints.
- Automotive industry, including suspension systems and automatic braking systems.
- Energy sector, including solar panel positioning and oil drilling equipment.
Rotary Position Sensors
SP-2801 308 000 001 ROTARY SENSOR
Rotary position sensors, also known as rotary encoders or angle sensors, are used to measure the angular displacement or position of an object. Rotary position sensors measure the angular position of a rotating part, converting angular mechanical position into an electrical signal. These sensors are crucial in applications where precise angular measurement is necessary, such as in automotive steering systems, industrial automation, and robotics.
Applications of Rotary Position Sensors
- Automotive steering angle measurement for advanced driver-assistance systems (ADAS).
- Wind turbines for blade pitch control to optimize energy generation.
- Aerospace applications for monitoring the position of aircraft flaps and rudders.
Advantages of Position Sensors
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High Precision
Position sensors, such as optical encoders, can achieve resolutions as fine as 0.1 microns or 0.0001 degrees, making them indispensable in precision applications like CNC machining, robotics, and medical devices. -
Wide Application Range
These sensors are used across various industries to measure linear or angular displacement. For example, linear variable differential transformers (LVDTs) can measure displacement over ranges from a few millimeters to several hundred millimeters, while rotary encoders can track rotations with resolutions up to 65,536 pulses per revolution (PPR). -
Durability
Many position sensors, particularly non-contact types like magnetic encoders, are designed to withstand harsh conditions, including temperatures from -40°C to 125°C, and are resistant to environmental factors like dust, vibration, and moisture, ensuring reliable operation in demanding environments such as automotive and aerospace.
Disadvantages of Position Sensors
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Complexity in Integration
Integrating position sensors can be challenging, as it often requires precise alignment, calibration, and sometimes the incorporation of additional signal processing units to interpret sensor outputs, adding complexity and cost to the overall system. -
Susceptibility to Wear and Tear
Position sensors with moving parts, like potentiometers or certain types of mechanical encoders, are subject to mechanical wear over time, which can degrade accuracy. For example, a potentiometer may lose linearity or become noisy after a few million cycles, necessitating periodic maintenance or replacement to maintain system performance.
Level Sensors
Level Sensor-Siemens Switch Level Capacitance Flow Sensor
Level sensors detect the level of liquids, solids, or granular materials within a container and convert this detection into an electrical signal. They are essential for monitoring and controlling fluid levels. Level sensors use different techniques such as ultrasonic waves, capacitive detection, and float mechanisms to determine the level of materials.
Types of Level Sensors
Ultrasonic Level Sensors
Non Contact Ultrasonic Level Sensor
Ultrasonic level sensors are used to measure the distance to a surface by emitting ultrasonic pulses and then measuring the time it takes for the echo to return. They are commonly used for level measurement in tanks, silos, and containers. Many modern ultrasonic level sensors also feature digital communications options such as RS-485, Modbus, or even Ethernet, allowing for more complex integration into industrial monitoring systems and providing capabilities for remote diagnostics and configuration.
Applications of Ultrasonic Level Sensors
- Non-contact measurement in harsh environments where traditional sensors might fail due to contamination or chemical interaction.
- Measuring the level of contents in fuel tanks, especially in large storage facilities.
- Vehicle detection in parking systems and toll booths.
Capacitive Level Sensors
NPN Non-Flush Type Capacitive Proximity Sensor
When a material comes into contact with the sensor, it changes the dielectric constant between the plates of the capacitive sensor, changing the dielectric constant. This change in capacitance is detected and converted into an output signal. Capacitive level sensors are used to measure the level of liquids, solids, or powders in a container or vessel by detecting changes in capacitance affected by the presence or absence of the material being measured.
Applications of Capacitive Level Sensors
- Measuring levels of viscous liquids such as oils and syrups in food processing plants.
- Wastewater treatment facilities for monitoring sludge levels.
- High-precision level control in semiconductor manufacturing processes.
Float Level Sensors
P31 float level sensor
A float level sensor is a type of level sensor that uses a floating element to detect the level of liquid. The float moves a mechanical switch, such as a reed switch or micro-switch, and upon reaching a certain level, it activates or deactivates the switch, sending a signal.
Applications of Float Level Sensors
- Agricultural irrigation systems to control water distribution based on storage levels.
- Oil level measurement in crankcases and oil-filled transformers in the power industry.
- Marine applications, including bilge water level detection in boats and ships.
Advantages of Level Sensors
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Versatile Application
Level sensors, such as capacitive or ultrasonic sensors, can be tailored to detect a wide range of substances, from liquids to granular solids. For example, capacitive sensors can detect levels in materials with dielectric constants as low as 1.1 (e.g., dry grains) to over 80 (e.g., water). -
Non-Invasive Measurement
Ultrasonic level sensors can measure liquid levels without direct contact by emitting sound waves that reflect off the surface of the liquid. These sensors can accurately measure levels in tanks up to 10 meters deep, making them ideal for applications where contamination or sensor wear is a concern. -
Continuous Monitoring
Radar level sensors provide continuous, real-time monitoring with high accuracy (±2 mm) and can operate in harsh environments, including high-pressure or high-temperature conditions. They can measure levels in large industrial tanks up to 70 meters tall, using microwave signals that penetrate vapors and are unaffected by foam or dust.
Disadvantages of Level Sensors
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Cost Constraints
Advanced level sensors, such as guided wave radar or laser level sensors, can be expensive, depending on the accuracy and range required. These sensors are typically used in critical applications like chemical processing or oil and gas storage. -
Environmental Sensitivity
Ultrasonic level sensors may suffer from inaccuracies in environments with temperature fluctuations, high humidity, or pressure variations. For example, temperature changes can affect the speed of sound, leading to errors in level measurement. -
Calibration and Maintenance
Some level sensors, such as capacitive sensors, may require regular calibration to maintain accuracy, especially in environments with varying dielectric properties of the material being measured. Additionally, sensors exposed to viscous or dirty media may need periodic cleaning to prevent buildup that could interfere with readings.
Flow Sensors
Flow Sensor-VA500 Flow Sensor
Flow sensors measure the rate and volume of fluid flow and convert this information into an electrical signal. They are essential for managing and controlling fluid dynamics in various applications. Flow sensors operate based on different principles such as mechanical, thermal, electromagnetic, or optical methods.
Types of Flow Sensors
Differential Pressure Flow Sensors
JEP-300 Flange Mounted Differential Pressure Sensors
Differential pressure flow sensors work based on Bernoulli's principle. Differential pressure flow sensors are instruments designed to measure the flow rate of liquids, gasses, or steam by sensing the pressure drop across a constriction in the flow path.
Applications of Differential Pressure Flow Sensors
- Monitoring and controlling flow rates in HVAC systems to ensure proper air circulation and energy efficiency.
- Oil and gas industries for measuring the flow of hydrocarbons in pipelines and wells.
- Automotive testing to measure the flow of air and fluids in engine and cooling systems.
Turbine Flow Sensors
4-20ma 4inch Digital Flowmeter
Turbine flow sensors are devices used to measure the flow rate of liquids, typically water, chemicals, or fuels, by utilizing the rotational motion of a turbine placed in the fluid stream.
Applications of Turbine Flow Sensors
- Energy management in power plants for measuring steam or water flow.
- Chemical processing plants for precise dosing and control of liquid chemical flows.
- Marine applications, including monitoring fuel and water flow on ships and boats.
Thermal Mass Flow Sensors
Digital Thermal Mass Flow Controllers
Thermal mass flow sensors are devices used to measure the flow rate of gasses, based on the heat transfer principle.
Applications of Thermal Mass Flow Sensors
- Aerospace applications, for testing and controlling cabin air flow and fuel systems.
- Chemical processing, to monitor and control the flow of gasses in reactions.
- Semiconductor manufacturing, for precise control of gas flow in deposition and etching processes.
Advantages of Flow Sensors
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Accurate Measurement
High-end flow sensors, such as Coriolis or ultrasonic sensors, can achieve accuracy levels of ±0.1% to ±0.5% of the measured value, making them vital for precise applications like chemical dosing or fuel monitoring. -
Real-Time Monitoring
Flow sensors like turbine or electromagnetic types provide real-time flow data with response times as quick as a few milliseconds, allowing for immediate adjustments in processes like cooling systems or water treatment. -
Wide Range of Applications
Flow sensors can measure a variety of media, including liquids, gasses, and even slurries. For example, ultrasonic flow sensors can handle pipe sizes ranging from 0.5 cm to several meters in diameter, making them suitable for everything from small medical devices to large industrial pipelines.
Disadvantages of Flow Sensors
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Cost Constraints
Advanced flow sensors, such as Coriolis flow meters, can be expensive, depending on the size and application, particularly in high-precision industrial processes. -
Sensitivity to Contaminants
Sensors like turbine flow meters can be disrupted by particles, bubbles, or deposits in the fluid, leading to potential measurement errors or even mechanical failure. This is especially problematic in dirty or unfiltered fluids. -
Maintenance Requirements
Mechanical flow sensors, such as paddle wheel or turbine types, often require regular maintenance to prevent wear and tear from moving parts, which can degrade accuracy over time. Additionally, these sensors may need periodic recalibration to maintain their performance, particularly in critical applications like medical dosing or chemical processing.
Accelerometers
Accelerometers- Piezoelectric accelerometer
Accelerometers are sensors used to measure acceleration forces, including static forces like gravity and dynamic forces resulting from motion or vibration. Accelerometers detect changes in acceleration by measuring the displacement of a mass inside the sensor due to acceleration forces. They are utilized in microelectromechanical systems (MEMS) technology, where a small mass (proof mass) is suspended in a microstructure and moves in response to acceleration.
Types of Accelerometers
Capacitive Accelerometers
MEMS Capacitive Triaxial Accelerometer
Capacitive accelerometers measure changes in capacitance due to acceleration forces. As the accelerometer moves, the distance between the capacitive plates changes, and this altering capacitance is detected and converted into an electrical signal.
Applications of Capacitive Accelerometers
- Consumer electronics, for orientation detection in smartphones, tablets, and gaming devices.
- Automotive systems, for airbag deployment sensors and vehicle stability control.
- Structural health monitoring, to assess the integrity of buildings and bridges.
Piezoelectric Accelerometers
Piezoelectric acceleration sensor
Piezoelectric accelerometers are sensors that measure acceleration by converting mechanical motion into an electrical signal using the piezoelectric effect. The piezoelectric effect is the ability of certain materials to generate an electric charge in response to applied mechanical stress. Piezoelectric accelerometers are known for their high sensitivity, making them capable of detecting very small changes in acceleration.
Applications of Piezoelectric Accelerometers
- Consumer electronics, to enhance stability and functionality in cameras and other sensitive devices.
- Energy sector, particularly in wind turbines, for vibration analysis and condition monitoring.
- Military and defense, for testing and monitoring the performance and structural integrity of military equipment.
Advantages of Accelerometers
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High Sensitivity
Accelerometers can detect minute changes in motion, with sensitivity levels down to micro-g levels (e.g., ±0.001g). This makes them crucial in applications where detecting early signs of wear and tear can prevent costly breakdowns. -
Wide Application Range
They are used in a variety of fields, from consumer electronics (e.g., smartphones and wearables) to industrial equipment, automotive systems, and aerospace. -
Compact Size
Modern accelerometers are small and lightweight, often measuring just a few millimeters on each side (e.g., 2x2 mm), allowing them to be easily integrated into portable devices and complex machinery without adding significant bulk.
Disadvantages of Accelerometers
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Susceptibility to Noise
Accelerometers can be sensitive to external noise and vibrations. They pick up external vibrations or electromagnetic interference, which may introduce noise into the data, hence requiring additional filtering and signal processing to ensure accurate readings. -
Limited Range
While accelerometers are great for detecting small movements, they may struggle with accurately measuring high acceleration forces, often requiring a trade-off between sensitivity and range. For instance, in aerospace applications where forces can exceed 100g, specialized high-range accelerometers are required. -
Power Consumption
Some high-performance accelerometers, particularly those with multi-axis (e.g., 3-axis or 6-axis) capabilities, can have higher power demands. This is a concern in battery-operated devices like drones or wearable sensors, where power efficiency is critical for extending operational time.
Gas and Chemical Sensors
Gas and Chemical Sensor
Gas and chemical sensors detect the presence and concentration of gasses or chemicals in the environment and convert this information into an electrical signal. When the target gas comes into contact with the electrode of the sensor, it undergoes a redox reaction (either oxidation or reduction). This reaction generates a current proportional to the gas concentration and this current is used to determine the gas level.
Types of Gas and Chemical Sensors
Electrochemical Sensors
Electrochemical Gas sensors
Electrochemical sensors are devices that measure the concentration of specific gasses by using an electrochemical reaction. The chemical redox reaction generates or consumes electrons, creating a current proportional to the gas concentration.
Applications of Electrochemical Sensors
- Environmental monitoring for detecting and measuring pollutants like CO, NOx, and O2 in the air.
- Medical diagnostics for analyzing blood gasses and electrolytes such as pH, CO2, and oxygen in clinical settings.
- Automotive applications for measuring exhaust gas compositions to control emissions and improve engine efficiency.
Metal Oxide Sensors
Metal Oxide Gas Sensors
Metal oxide sensors, also known as metal-oxide-semiconductor (MOS) sensors, are widely used for detecting gasses and volatile organic compounds (VOCs). These sensors operate based on changes in the electrical resistance of a metal oxide material when it interacts with target gasses.
Applications of Metal Oxide Sensors
- Enhancing air quality control in HVAC systems in building management systems.
- Smart city integration for city-wide air quality monitoring.
- Detecting gas leaks and enhancing safety in consumer electronics like smart home devices.
Optical Gas Sensors
MIPEX NDIR Optical Gas Sensors
Optical gas and chemical sensors use light to detect the presence and concentration of gasses and chemicals. These sensors leverage principles such as absorption, fluorescence, and scattering of light to provide highly sensitive and selective measurements.
Applications of Optical Gas Sensors
- Industrial process control for monitoring gas concentrations in chemical and manufacturing processes for safety and efficiency.
- Detecting hydrocarbon levels in offshore and onshore facilities to prevent leaks and ensure safety.
- Early detection of smoke and toxic gasses released in fires.
Advantages of Gas and Chemical Detection
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Early Detection
Gas sensors like electrochemical or metal oxide sensors can detect gasses at concentrations as low as parts per million (ppm). For example, carbon monoxide (CO) detectors are critical in homes and industries to detect CO at levels as low as 30 ppm, preventing potential poisoning and ensuring safety. -
Wide Application Range
Gas and chemical sensors are used in various industries. In automotive applications, oxygen sensors monitor the air-fuel mixture in engines to optimize combustion. In industrial settings, sensors detect harmful gasses like hydrogen sulfide (H₂S) in oil and gas facilities, protecting workers from toxic exposure. -
Real-Time Monitoring
Gas and chemical sensors offer continuous, real-time monitoring, which is crucial for maintaining safety in environments where gas leaks or chemical spills can occur suddenly. For example, the real-time monitoring of CH4 gas in natural gas pipelines.
Disadvantages of Gas and Chemical Detection
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Sensitivity to Interference
Gas sensors can be affected by environmental conditions. For instance, electrochemical sensors used in CO detectors can give false readings due to high humidity or temperature fluctuations. -
Maintenance and Calibration
Regular maintenance and calibration are required to ensure the sensors' accuracy and reliability, especially in harsh environments where sensor degradation can occur over time. -
Limited Lifespan
Many gas sensors, such as those using electrochemical technology, have a limited lifespan (typically 2-3 years). For example, CO sensors in residential detectors need to be replaced every 5-7 years to ensure they continue to function correctly, which can be a maintenance challenge in large-scale installations like industrial complexes or commercial buildings.
Electrical Sensors
Electrical Sensors - 101020027 Grove Electricity Sensor
Electrical sensors measure electrical properties such as voltage, current, and resistance and convert these measurements into electrical signals. They utilize methods like the Hall effect, shunt resistors, or current transformers to detect current flow and produce a proportional output signal.
Types of Electrical Sensors
Voltage Sensors
Single-phase AC Voltage Sensor Module
Voltage sensors detect the electrical potential difference between two points in a circuit. This can be done using various methods, including resistive voltage dividers, capacitive coupling, and inductive coupling.
Applications of Voltage Sensors
- Power system monitoring to track voltage levels in electrical grids to ensure stability and efficiency.
- Battery management systems in electric vehicles, portable electronics, and renewable energy storage systems.
- Telecommunications monitoring to ensure reliable voltage levels in communication equipment.
Current Sensors
ACS712-5A Current Sensor Module
Current sensors are devices designed to measure the flow of electric current in a conductor. They use shunt resistors to measure the voltage drop or employ the Hall effect, Rogowski coils, or current transformers to detect the magnetic field generated by the current flowing through a conductor.
Applications of Current Sensors
- Renewable energy systems to measure current in solar panels and wind turbines to optimize power output and system efficiency.
- Automotive systems to ensure proper operation of electrical components in vehicles, including hybrid and electric cars.
- Overcurrent protection to detect and respond to excessive current that could lead to equipment damage or fire hazards.
Resistance Sensors
Resistance Head Mounted High Temperature Sensors
Resistance sensors, also known as resistive sensors, measure changes in electrical resistance to detect physical quantities such as temperature, displacement, or pressure.
Applications of Resistance Sensors
- Temperature monitoring in industries such as consumer electronics, automotive, and HVAC systems.
- Chemical concentration analysis for environmental monitoring and process control.
- Presence detection in building management systems to detect occupancy.
Advantages of Electrical Sensors
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High Precision
Electrical sensors like Hall effect sensors can measure current with high accuracy, often within ±1% of the measured value. -
Wide Application Range
Electrical sensors are used across various industries, from smart grids to consumer electronics. -
Real-Time Monitoring
These sensors provide continuous data for immediate detection of overcurrent conditions or voltage instability.
Disadvantages of Electrical Sensors
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Susceptibility to Environmental Factors
Electrical sensors may be affected by electromagnetic interference, requiring shielding and filtering. -
Cost of High-Precision Sensors
Advanced sensors for critical applications, such as medical equipment, are expensive. -
Complexity in Installation
Installation in high-voltage environments requires careful planning for insulation and grounding.
Closing Notes:
Sensors are fundamental to the growth and effectiveness of IoT systems. Each sensor in a connected ecosystem plays a crucial role in enabling IoT systems and collecting the data to act upon. As sensor technology continues to advance, it will further enhance the capabilities of IoT, driving innovation across industries. The future potential of sensors in IoT is immense, promising smarter, safer, and more efficient applications that will transform our daily lives and environments.
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