Revolutionary advancements using acoustical-based technology features multiple-point measurement and employs 3D mapping software that graphically depicts the topography of the bin to deliver volume accuracy that surpasses the performance of single-point measurement devices.
What kind of volume accuracy can you expect?
3D technology has been proven to deliver up to .5% to 3% volume accuracy when mounted in the proper location and used in a bin that is less than 45’ in diameter. For bins wider than 45’ or silos wider than they are tall, volume accuracy will begin to diminish, but will still be more accurate than any single-point device. The reason for less accuracy in wider bins is the device sends acoustical pulses within a 70° beam angle. If the entire material surface is not covered, accuracy may be less, or you might need more than one 3D device in the bin to cover the entire material surface. Mounting the device in a less than optimal location will impact accuracy, as will obstructions in the bin that might interfere with the signal.
How does 3D technology measure up?
Typically, a single-point device such as a weight and cable-based sensors or guided radar mounted 1/6 in from the outer diameter in a center-fill, center-discharge bin will provide 5% to 7% accuracy. When mounted properly, the location can account for the angle of repose in the case material is “cone up” or “cone down”. A single measurement point can be highly accurate – some devices such as radar or ultrasonic claim less than 1” – but that applies only for that one point in the silo.
How does 3D technology work?
A scanning device sends low-frequency acoustical pulses and receives echoes of the pulses from multiple points within the bin. Unlike most devices that are measuring one point and determining a single distance, 3D technology takes measurements from multiple points within the bin and uses these points to determine not just the level, but also calculate the volume of material in the bin. The low-frequency pulses used in 3D technology are proven to work in dusty environments – even flour and cement – where other technologies have failed.
What is 3D mapping?
Say there is an up or down cone, multiple filling or emptying points, the material is prone to sidewall buildup, or the material is a powder that is prone to bridging. This can result in a very uneven material topography where there are points in the bin that are lower or higher than the majority of the bin contents. If just one measurement is taken at a random point, it may not be truly representative of the volume of material remaining in the bin. 3D technology solves this problem by taking multiple measurements and providing the user minimum and maximum distances as well as an average distance, that is weighted and calculated based on actual measurement points. These measurement points are converted into a graphical representation of the bin contents that shows high and low points and detects sidewall buildup.
How is 3D optimized for my silos?
The optimal mounting location for the scanning device is determined using a program that takes the bin dimensions and outputs a drawing that shows the mounting location that will provide the best accuracy. The scanning device is then mounted on the top of the bin using a mounting plate that ensures the device is completely level. The patented acoustics-based technology sends out pulses that measure bin contents at multiple points inside the bin within a 70° beam angle. This data is sent to a personal computer loaded with 3D software that generates detailed log reports that allow the user to easily monitor inventories remotely from the comfort of an office.
What are the benefits of more accuracy?
Plants are demanding better accuracy whether they are looking to track the inventory of high-value plastic resins in a few small silos or the amount of corn in a million-bushel bin. For many operations, a few percentage points of accuracy can account for thousands of inventory dollars. Plant and purchasing personnel are looking to increase inventory turns, reduce carrying costs, and optimize purchasing cycles and delivery logistics. 3D accuracy can help explain variances by detecting variations in bin topography including sidewall buildup, while also helping plant managers optimally schedule maintenance and reduce downtime.
There is no level measurement device that will provide 100% volume accuracy, so it’s important to understand just how much accuracy is needed for your operation and to weigh the expense of gaining more accuracy versus the value to your operation. Getting the best results takes knowing the exact specifications of your silos, applying strapping tables to account for changes in bulk density throughout the silo, the patience to fine tune the technology to your silo parameters, and perhaps most important – to set realistic expectations. If you seek better accuracy, 3D technology delivers volume accuracy that surpasses any single-point level measurement device.
Processing operations that struggle with the challenges of inventory management and timely replenishment of all types of solids and powders can monitor silo levels on their smartphone, tablet, or desktop with complete solutions from BinMaster. A complete suite of continuous ...