Solids / Bulk Handling

Radar-based bulk volume, material speed, misalignment measurement

• Volume flow (m³, yd³, ft³)  99.9% precision material measurement
• Material speed (m/s, fps, yd/s) precise material speed measurement
• Bulk & belt position – center of gravity, freeboard, belt misalignment

VOLUME FLOW MEASUREMENT – high speed 2D radar scan

A 2D radar sensor is mounted above the conveyor and scans a cross section of the passing material. In combination with a fixed speed value of the passing material, a PLC or drive input signal or – best in combination with our speed radar – a volume measurement is provided. In addition, height information and material distribution information can be obtained from this measurement.
*Surface contour for volume measurement – exact measurement due to full surface coverage
*Spillage & overload detection – enables safe operation and supports blending functionalities

MATERIAL SPEED MEASUREMENT – radar based contactless speed measurement

Based on an indurad Doppler Velocity Radar, the system is able to measure the speed of the material passing underneath. This is the true material velocity value, which is the exact basis for high precision volume scanning. The bulk velocity measurement can also be used independently, for example to optimize belt speeds or to detect material slippage.
*High precision speed measurement – 99% speed accuracy – much better than other measurement systems
*No maintenance – no-contact measurement without the need for re-calibration

BELT MISALIGNMENT – measuring belt alignment in the rollers

Belt misalignment causes significant damage to the belt and reduces belt life. A belt that does not run well in the rollers consumes more power from the drives. The risk of spillage is increased. iBelt Misalignment measures the position of the belt at a specific point or along the entire conveyor and is the basis for intervention and optimization.
*Belt protection – first step to reduce wear on conveyor belts
*Energy reduction – reducing energy waste by misalignment

FREEBOARD MEASUREMENT – belt misalignment and material position

Based on the belt misalignment sensor, the system detects the freeboard on the belt to the left and right of the material. This information allows control and understanding of the material position on the belt, providing the basis for more efficient control of transfer points and material flow.
*Transfer point position optimization – see asap if material dispatch on belt is not centered
*Belt wear & safety – detect unhealthy material position that increases wear and spillage

ADVANCED DATA – based on cross-section and speed measurement

This set of specific software algorithms is the result of years of development. The advanced data package provides information on material distribution, center of gravity and height distributions for each instant and for historical data. This allows for a better understanding of bulk processes and belt usage, while optimizing control. The system uses self-learning algorithms and AI concepts.
*Optimizing belt utilization and flow control – learning, understanding and improving mine-wide belt usage
*Increase safety & reduce wear – reduce spillage, avoid mistakes in blending processes and predictive maintenance

Installs in one Shift

Indurads iBelt is an off the shelf product which is delivered in two packages: one with the sensors and cables, the other with the compact cabinet. Installation and commissioning is easy and can usually be done within one shift. This makes the solution easy and cost-effective to deploy. Unlike other systems, such as belt scales, no recalibration is required. Unlike other optical systems (such as lasers or lidars), the system works regardless of environmental conditions, such as dense fog, dust, rain or snow.

iStockpile is truly the best solution on the market for accurate and live 3D inventory control of all types of stockpiles, adding value to a wide range of bulk material handling processes. From simple 3D material profile scanning to advanced features such as dead bulk detection, reclaim feeder control, unique material quality control and more, iStockpile is a simple and reliable step-by-step implementation solution.

• Increase productivity up to 10% ingo and outgo automation, no manual surveying
• Increase capacity up to 15% understand & eliminate/reduce dead bulk zones
• Increase safety slope angles, rat holeing, remote control, worker exposure
• Deliver up to spec optimize blending processes to the point

SCAN STRATEGIES

Stockpile measurement can be performed using two methods, which can also be used in combination. Stockpiles managed with tripper cars, A-frame reclaimers, or similar handling equipment are outfitted with a position sensor and a 2D radar sensor. As this equipment moves, a 3D image of the stockpile is created or updated. Alternatively, for situations requiring a permanent scan or where no stockpile handling equipment is present, fixed 3D radars are installed above the bulk material to provide accurate measurements.

A-FRAME RECLAIMER – 3D, cutting assistance, collision avoidance

The solution utilizes an iLDR-H linear measurement radar to measure the linear position of the A-frame reclaimer accurately. Additionally, 2D radar sensors installed on the portal measure the stockpile in 3D, enabling collision avoidance and providing cutting assistance during the process. When stacking material, the solution ensures the creation of a homogeneous pile, optimizing the distribution and arrangement of materials for improved efficiency and uniformity.
*Improved reclaiming rate – continuous reclaiming, avoiding avalanches
*Inventory information – and automatic blending functionalities

sulfur stockpile FIFO automation

TRIPPER CAR – volumetric measurement and linear position

By combining 2D radar sensors with 1D linear measurement devices, the system generates a precise 3D surface representation of the entire stockpile. Leveraging this data, the system can automatically control the movement of trippers to ensure the creation of homogeneous piles.
*Tripper car automation – utilizing stockpile in the best way
*3D online inventory information – exact representation of the stockpile in real time

2D radar sensors mounted on a tripper car

FIXED SENSOR INSTALL – 3D inventory information at all times

Regardless of the position of the tripper car, this option provides accurate inventory information at all times. Sensors can be installed inside the building – for example, under walkways or on other structures. All sensors are connected via Ethernet to a central processing unit, which then makes the information available company-wide.
*Increase operating time – monitor material behavior & reduce unscheduled downtime
*Increase Productivity – maintain optimal inventory levels

3D MODEL – advanced 3D inventory information

iStockpile offers a comprehensive 3D representation of the stockpile derived from radar data. This valuable information can be seamlessly integrated and shared with PLC and SCADA systems. Moreover, the user-friendly Human-Machine Interface (HMI) provides a fully rotatable 3D image of the stockpile. Users can define specific areas, such as draw points and material qualities, and obtain essential data like volumes, maximum and minimum fill levels, and more, for these designated areas. This intuitive interface empowers users with precise insights and control over stockpile management and facilitates effective decision-making.
*3D stockpile picture & volume information – webGL based easy accessible + SCADA + PLC
*Customizable zones – material specific area definition, draw point automation

3D model visualization in web browser and in SCADA system

 

DIFFERENT OPTIONS FOR YOUR STOCKPILE (This video has no sound)

UNPRECEDENTED RESULTS IN DUSTY CONDITIONS

Whether your application is material volume on a belt conveyor, or stockpile inventory management, contact one of our offices, or use the form found in the link below.  We will be happy to discuss a solution for your application

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