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BinMaster: 3D Level Sensors can solve the toughest Food Storage Challenges
Lincoln (NE), United States – For almost a decade, 3DLevelScanners have been providing highly accurate level and volume measurement in challenging materials contained in bins, tanks, and silos.
Measuring and mapping the material surface, these sensor sends pulses in a 70° beam angle, taking multiple level measurements and accounting for uneven surface topography when calculating volume.
Each sensor comes with 3DVision software that reports the lowest and highest points detected and the average level based upon a weighted average of all measurements in the bin. For the MV and the MVL models, a colorful graphical representation indicates where high and low spots exist in the silo. 3D scanners keep pushing the boundaries – and addressing the concerns of increasingly complex food operations. This article shares a few of the newest innovations.
View multiple Silos on a single Screen
MultiVision software for inventory visibility across an organization
Inventory management affects multiple departments across a food processing organization. Plant personnel need adequate inventory for production, purchasing needs to know what to order and when, and finance needs accurate valuation for financial statements.
To provide corporate-wide visibility, the optional 3D MultiVision software enables users to view data for multiple bins in a single window. And since it is Windows-based, it can be configured for 24/7 access via an organization’s Local Area Network (LAN).
MultiVision software can be used with all versions of the non-contact, dust penetrating 3DLevelScanner including the RL, S, M, MV and MVL models. By clicking on a single bin, users can zoom in on detailed information for the bin including minimum, maximum, and average levels. For the MV and MVL models, they can also see the 3D visualization of bin contents. The software allows multiple users at multiple locations to view bin level and volume data on a permissions basis.
Upon selecting a single tank, the user can get specific details about minimum, maximum, and average volume and view the 3D visual.3D MultiVision software makes it easy to share real-time bin data across the entire organization (or with vendors using VMI) to improve purchasing, logistics, operational decisions, and financial management.
With user-friendly setup and intuitive operation, each user can customize their screen to view all bins or a group of bins and color-code bins by material type. Users can set high and low-level alerts to be notified when bins reach critical levels. Because the software is installed on the LAN, there are no third-party applications or data access fees.
Teflon-Coated Sensor for Clingy Materials
Reduces maintenance in powders and sticky granules
For materials that want to cling to the sensor, a Teflon-coated transducer can be a great option. The Teflon coating resists buildup of dust, ensuring the scanner performs optimally in challenging materials such as powders or solids that generate excessive dust when the bin is filling or active. This special finish also extends the maintenance cycle by significantly reducing the need to clean the device after prolonged periods of use.
Some common applications for the Teflon-coated transducer include meals, sugar, starches, brans, and other similar materials that are prone to cling to surfaces.
It is especially appropriate for food processors in industries such as baking, pasta, and candy where non-contact technology is a requirement for food safety. Grain millers will also find measuring ground soybeans, wheat, rice, or corn less troublesome when using the Teflon-coated model of the 3DLevelScanner.
Detect and Alert to Center of Gravity Danger
Prevent silo collapse or damage using 3DLevelScanners
Many powdered and solid substances used in food processing tend to clump, pile unevenly, and flow unpredictably from storage vessels. Not only does this make monitoring the volume of material inside the vessel challenging; uneven disbursement of material can also take its toll on the storage vessel itself.
Over time, the walls of steel or concrete silos have been known to wear or fail causing cracking, denting, buckling, and bending. In the most severe cases, it can lead to catastrophic silo collapse. This has been seen in grain bins worldwide, where the walls of large storage vessels give way to the weight of grain that has built up on one side of the bin over time.
For plant operations that want to detect uneven loading of silos that contributes to structural wear or failures, there is now a software option that uses 3DLevelScanners to identify the location of the center of gravity, display it graphically, and alert when the center of gravity falls outside of a predefined area.
A 3DLevelScanner is mounted on the roof of the silo in an optimal location to view the material surface in the silo. Level measurements are used to determine the X, Y, and Z coordinates of the center of gravity based upon the material topography. The coordinates are processed in 3DMultiVision software via a proprietary RS-485 communication protocol. Users define the alert parameters and accepted area into which the center of gravity must fall. A 3D visual will indicate where the center of gravity is located and show if the current center of gravity falls in the acceptable area.
In this first example (see image below), it is evident from the 3D graphic that material is disbursed evenly and the cone is up.
The average, minimum, and maximum levels are displayed along with the volume and mass. Also, volume as a percentage full and the maximum volume are displayed in the software. The acceptable zone for the center of gravity is indicated in green and the Center of Gravity of 0.05 along the bottom of the readings falls clearly in the acceptable zone.
Operations can use this unique solution to help reduce structural stress when loading or emptying a silo. It is a valuable preventive maintenance tool that can alert to the need for inspection or cleaning. Use over time can prolong silo integrity and create a safer environment by alerting to potential structural stress caused by uneven loading.
The second example (see image below) indicates an alert status, displaying the vessel in red on the screen. The 3D visual indicates that as the vessel has been emptied, material has built up on one side of the vessel.
The center of gravity has fallen outside of the set parameters and is displayed in red as -1.03. A red Center of Gravity Alert is displayed at the top of the screen. Plant operations or maintenance can be alerted to aerate or clean the vessel before damage occurs.
Measure Volumes in a Wedge- or Pie-shaped Silo
Accurate inventory for ingredients in segmented silos
Food processing operations routinely handle many ingredients, some of which can be stored in segmented silos. Tracking inventory by volume in these irregularly-shaped spaces can be tricky, especially for powders or granules that want to build up along the interior walls or the outer silo perimeter. Plant operations or purchasing personnel burdened with managing inventory in pie- shaped segments of silos now have a solution that provides very accurate volume data. The 3DLevelScanner measures and models the topography of material contained in these unusual pie-shaped wedges.
This newest release of 3DVision software update then applies the measured distances to a 3D model of vessel dimensions and converts it to a highly accurate volume measurement.
Other measurement sensors, such as non-contact radar, guided wave radar, or weight-and-cable style sensors measure only a single distance in these formidably-shaped segments. The location of the filling or emptying points or lack of material flow may cause uneven piling of material, which could cause inventory estimates based upon a single measurement to be inaccurate. By comparison, the 3DLevelScanner maps the material surface accounting for variations or buildup then factors in the radius and height of the segment being measured, making the volume accuracy very precise.
Using a system that provides accurate data about the amount and dollar value of material on hand can help reduce safety stocks, increase inventory turns, and pay for itself by freeing up cash that could be tied up in inventory.
This can be especially true for high-dollar ingredients being used in many contemporary food products. Additionally, buildup on the outer perimeter of the silo segment or along on the interior walls of each segment can be detected, accounted for in inventory, and addressed by maintenance if needed. The same 3DLevel Scanner can be used for either segmented or round silos, making it a versatile choice over its long sensor life.
Level Monitoring in Flat Storage Warehouses
Breakthrough technology measures level per section
With grain production worldwide reaching record levels, there is a shortage of grain storage as valuable commodities await further processing. An intermediate step to protect grain is the use of large covered storage buildings where grain is piled us- ing overhead conveyors or vehicles. However, due to irregular piling, it is extremely difficult to estimate the amount of grain in these temporary warehouses.
Several 3DLevelScanners are strategically mounted on the roof with each scanner measuring multiple points in a 70-degree beam angle.
Another revolutionary advancement not offered with any other inventory management system is a new software option that can measure the level of materials piled under structures. Multiple sensors measure and map levels across the material surface, while MultiVision software separates the piled material into virtual sections. Minimum, maximum, and average levels per section are reported for up to 99 unique sections. The data is aggregated to output a visual showing the topography of the entire storage building.
In this screen image, the topography of material is displayed and used to detect level per section.This first-of-its-kind solution is used to estimate inventory and improve production efficiency. Identifying high and low sections allows for automating process control and managing the filling or extraction of materials. In proven installations, up to 20 3DLevelScanners have been mounted in the upper structure of the warehouse roof. The building is virtually divided into sections as small as 1.
5 by 1.5 meters with 3D sensors continuously measuring changes across the surface and providing unique visual and data reporting of inventory in the massive structure. This cutting-edge technology is ideal for corn or other grains stored in covered warehouses. In 2009, 3D scanner technology started a revolution in precise inventory management. Their evolution continues to address the unique needs of industry as the worlds of sensor hardware and software intersect with new solutions.
About the Author
Jenny Christensen, MBA is the vice president of marketing for Garner Industries, home and manufacturer of BinMaster Level Controls.
About BinMaster
BinMaster is an ISO 9001:2015 certified US manufacturer of point and continuous level indicators and inventory management systems used for monitoring the level of bulk solids or liquids in bins, tanks, silos, and hoppers.
More information on BinMaster
Google Search – Web
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BinMaster on the Portal
BinMaster Videos on bulk-online
BinMaster Licenses Emerson 3D Solids Scanner and Software
About Us
BinMaster / Garner Industries is located in Lincoln, Nebraska, USA.
Operations that struggle with the challenges of inventory management and timely replenishment of all types of powders, bulk materials or liquids can monitor bin levels on their smartphone, tablet or desktop computer with complete solutions from BinMaster. A complete set of continuous level sensors, point level indicators, inventory management and inventory monitoring devices and software simplify material management while protecting people from the risks associated with silo climbing.
Lincoln Nebraska, USA manufactures sensors and software used to control levels in bins, tanks, bins, chutes and bins. Continuous level measurement options include cable-based SmartBob, Guided Wave Radar, Laser, and 80 GHz non-contact radar, all of which are compatible with Binventory™ software. Battery operated wireless laser level transmitters are compatible with the BinView® or FeedView® web application for remote monitoring.
The unique 3DLevelScanner measures and displays material for accurate volume determination and is the only sensor to create a 3D image of the contents of a silo.
BinMaster is the exclusive global supplier of this unique technology and has been putting these sensors into service in silos containing powders and solids for over a decade.
Point level indicators provide automatic level notification using rotors, diaphragm switches, capacitive probes, tilt switches and vibrating rod level sensors. Dust detection devices warn of leakage and unsafe particulate levels. Flow detection sensors prevent cross-contamination and help meet FSMA requirements for human and animal feed. Aeration Devices Keep powders and solids fluid so that they do not pack into hoppers, along hopper walls, or into a vessel cone.
Robust, custom systems can be designed for a single site or networked for every silo, tank and silo in a multinational operation. Add Pile Inventory Inventory Reports using images from iPhone or drone to your SaaS dashboard. Monitor your livestock feed inventory from your phone, tablet or PC using the FeedView® web app.
BinMaster is an American manufacturer certified to ISO 9001 quality management systems - requirements.
For more information about BinMaster, visit www.binmaster.com.
What we do in a nutshell
BinMaster provides precise inventory management for processing plants where materials are stored in bins, tanks and silos.
Where we supply
UK, Ireland, Africa, Asia, Australia, South America, North America
Industries we supply
Chemicals, Power & Electricity, Food & Beverage, Glass Ceramics, Cement, Metals & Minerals , OEM, Paper & Pulp, Pharmaceutical Cosmetics, Toiletries, Plastics & Rubber, Recycling, Tobacco, Water & Wastewater
Something interesting you might not know about us:
BinMaster is a subsidiary of Garner Industries and has fully integrated CNC machining capabilities.
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Monitor inventory in tanks and bins with BinCloud
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Hopper Level and Bearings - What Grain Mills Need to Know
3D Scanners Take Silo Volume Measurement to the Next Level
Highlights
Listen to this Article
State-of-the-Art Non-Contact Silo Solids Volume Measurement Technology
There are many solids detection devices on the market today powders in silos. Many devices will only alert when material reaches a certain high or low level in the bin.
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These point level devices, such as rotary, are very affordable and reliable.
They will prevent the silo from overflowing, but do not provide an accurate inventory. Rather, they simply warn of an impending overflow so you can stop the process, which can create a cleaning nightmare.
Continuous sensors, such as non-contact radar, guided wave radar, and devices with a lifting cable or plumb line, measure the material level at only one point in the silo.
Many hard materials tend to accumulate unevenly and create uneven topography. As a result, one measurement point may not represent how much material is available, depending on the measurement location. This is the result of an inaccurate inventory volume.
How 3D scanners measure
The measuring range starts 19 inches below the process connection thread (upper dead zone). Unlike any other technology, 3DLevelScanner takes measurements at multiple points in the bunker. These points detect the uneven topography of the material to determine the volume of material in the bin.
The measurement points are not simply averaged to calculate the volume of the bin. Instead, the advanced algorithm assigns a "weight" to each point to determine the true volume of material in the bin.
Solids and powders are materials that are difficult to handle. Many are dirty and dusty, making some types of sensors useless or unreliable in harsh environments. Some are heavy and uneven, which can cause damage to guided wave radars or load cells and cables.
Materials that accumulate randomly and are difficult to flow make it difficult to determine what is actually left in the silo. This is why sometimes there is not enough level data from one measurement point to calculate reserves.
Today's 3D scanning technology is a game changer when it comes to inventory accuracy. These sensors continuously measure and display the surface of the material, providing real-time inventory monitoring. The technology is non-contact, so there is no risk of damaging the sensor with heavy material.
Acoustic-based technology penetrates dust so it works reliably in dirty, dusty silos. In addition, 3D technology is much more accurate than any single-point measuring device, as it takes into account the irregularities on the surface of the material.
Multi-point measurement really matters
The advanced acoustic technology used in 3DLevelScanners, also called 3D Solids Scanners, is very different from other types of level sensors. As the name suggests, these devices scan the surface of the material to take multiple measurements, taking into account high and low points in the silo.
The surface scan also detects conditions such as cone up or cone down, and buildup that may be present along the side of the vessel. Data from multiple measurement points is processed using advanced firmware and algorithms, and combined with silo parameters loaded into the software, a highly accurate volume estimate is provided. Additional data is also provided, such as the highest, lowest, and average level of the material.
Reliable in heavy dust
One of the biggest problems in silos is excessive dust, which can make some types of sensors inaccurate or unreliable until the dust settles.
Operating at very low frequencies, the 3D scanner is not bothered by dust and can work stably and reliably regardless of vessel conditions.
This technology has been proven in many different difficult materials including flour and many food products, as well as in the energy and mining industries to measure materials such as fly ash, ores, alumina powder, carbon black, limestone, manganese, dolomite, bentonite , silica granules, talc. powder and all types of sand, including crushed stone or quartz sand.
Great safety measure
When inventory is fully automated, there is no need to climb the silos to take measurements. This not only saves time, but also eliminates the risk of falls and related injuries, as well as the hassle of insurance and paperwork associated with accidents.
Mills today comply with strict safety regulations regarding lifting and entering silos and risk heavy fines if violations are found. Installing an automated inventory system allows you to manage material flows from a computer in the safety of the office.
CONS
- Excessive background noise can affect acoustic performance.
- Installation requires care to mount the sensor in the correct location and display tank dimensions accurately.
- Time required to process multiple echoes limits sample rate
- Corrugations in the walls of small vessels can cause false echoes
- Not recommended for materials with bulk density less than 11 lb/cu. feet by absorbing acoustic pulse
A busy plant requires real-time inventory to ensure operational and financial efficiency. This helps improve inventory turnover to make room for deliveries entering silos and preparing loads for trucks or trains bound for customers.
3D scanners offer PC software that can be accessed from one location or across the entire enterprise. The MultiVision software allows you to monitor inventory in one or all bins and allows you to keep a historical inventory report on each vessel.
Self-cleaning sensor minimizes maintenance
The unique design and materials used to make the 3D scanners ensure that the surface will resist the accumulation of airborne dust particles on top of the silos.
In addition, the acoustic pulses emit a “chirping” sound that resonates and creates an almost imperceptible vibration that helps keep the inside of the scanner clean. This way the sensor stays clean and works without the need for an air purge at the top of the tank, which can be costly.
Proximity sensor will not be damaged
With an acoustic sensor, nothing comes into contact with the material, making it very reliable when working with heavy lumpy materials. There is no risk of equipment getting stuck in deep material or flaking off and damaging structure or equipment at the bottom of the silo.
No need to replace sensors or cables that wear out over time. Avoiding material contact helps ensure a long service life with minimal cost and preventive maintenance.
Level and volume models
3D scanners, like most other measurement devices, come in many different models and offer a wide range of options to adapt the device to the application.
In order to select the right model for your application, it is extremely important to communicate your expectations for the technology and how you plan to use the data you receive from the device. Many factories are geared towards a very high level of inventory accuracy.
The accuracy of a 3D scanner depends on several variables, starting with information about the size of the vessel, the presence of structure within it, and the material that is being measured. The installation location is also important because the scanner technology measures multiple points, so the device must have a clear view of the surface of the material.
The simplest and most affordable scanner model is called RL, which is short for Reliable Level. This model measures material with a narrow beam directly below the device, penetrating high levels of dust and working where other types of non-contact level sensors become unreliable or inaccurate.
This model is most often used when constant, highly reliable level measurement data is required.
This model is often used in applications that are less prone to excessive buildup and narrow or smaller bins.
Model M measures at a wider beam angle of 70°, making it suitable for larger diameter silos and silos with uneven material topography. It also generates additional data including minimum, maximum and average distance based on multiple measurements. Due to its ability to scan the material surface and take into account irregularities, it can provide a very high level of volume measurement accuracy in silos up to 45 feet in diameter.
At the top of the range is the MV, which does everything M does, plus adds a unique visualization feature. Using sophisticated algorithms and a lot of processing power, this model generates a 3D image that shows where the top and bottom points are in the bin, shows if the cone is up or down, and detects build-up on the sidewalls. This optional feature can be used to manage filling and emptying points and to determine if maintenance is required to remove deposits.
This model is often used in large silos where materials are stacked unevenly.
Other measures to improve accuracy Several 3D scanners are used to ensure volume accuracy in large diameter silos.
If the hopper is very wide or large, two or more scanners can be combined into a multi-scanner system. By adding a controller that synchronizes measurements from all scanners in a bin, the MVL model can provide very high volume measurement accuracy in very large diameter bins.
The number of scanners required to fit into a bin is determined by the size of the bin and the desired level of accuracy. MVL also generates a 3D rendering of the material surface based on measurements taken from all scanners.
Silos can be a tricky structure to measure and often have some surprises that need to be "fixed" a bit. For example, sometimes there is a structure at the top of the bin so the measuring device may try to measure the structure rather than the material.
Neck extensions have been designed for scanners that allow them to clear the structure and see beyond to get an accurate measurement of the material. Angle mounting flanges are designed to keep the unit level, while angle mounting adapters can be used when it is necessary to guide the unit into a problem bin.
Measure material stacked in domes
Not only for silos, today scanners are the only type of level sensors that can provide inventory information for domes. Because of their sheer size, multiple fill and empty points, and irregular piles of material, there was simply no way to automate inventory management for these vast storage applications.
The use of multiple scanners strategically positioned over the material to cover the entire surface is an innovative way to assess inventory in dome storage. Advanced software combines all measurements from multiple scanners and displays them in 3D for material volume estimation.
