3D Level Measurement for Bins, Tanks & Silos

Reduced accuracy in wider bins is attributed to the fact that the device emits acoustic pulses within a 70° beam angle. Therefore, accuracy will be reduced if the entire surface of the material is not covered. Alternatively, more than one 3D device will be required in the bin to cover the whole material surface.

Other factors that may affect accuracy include placing the device in an inappropriate location, extreme noise during the filling process, and obstructions in the bin that may interfere with the acoustic signal.

Drawbacks of Single-Point Measurement

A single-point device will usually provide 5% to 7% accuracy when placed 1/6” from the external diameter in a center-fill, center-discharge bin. Guided radar-type devices or weight-and-cable-based sensors offer this level of precision. Ultrasonic or radar devices claim down to 1”—however, this applies only to that single point in the silo. Additionally, these technologies may not be as precise when dust exists in the bin.

Principle Operation of 3D Technology

The BinMaster 3DLevelScanner transmits low-frequency acoustical pulses, then receives echoes of the pulses from numerous points in the bin. 3D technology takes measurements from numerous points and utilizes them to calculate the level and volume of material in the bin—unlike most devices that measure one point and calculate a single distance.

3D technology works in dusty conditions and can even be used on cement and flour. It is a self-cleaning device that requires very minimal maintenance.

3D Mapping

When there are numerous filling or emptying points or a cone within a bin, bulk material will build up on sidewalls. If the material is a powder, it will be prone to bridging. This can promote irregular material topography where points in the bin are either higher or lower compared to the majority of the bin contents.

Taking a single measurement at a random point will not accurately represent the volume of material. 3D technology defeats this challenge by taking measurements of multiple points in order to provide minimum, average, and maximum distances.

3D Technology in Silos

The optimal mounting location of a 3DLevelScanner is ascertained with a program that takes the size of the bin and creates a drawing. This drawing depicts the mounting location that will offer excellent precision. 

The scanning device is then positioned on top of the bin with a mounting plate that ensures the device is completely level.

Benefits of Improved Accuracy

Whether facilities are looking to monitor the inventory of plastic resins in small silos or the quantity of corn in a bushel bin, high-accuracy inventory has become a standard. 

In most operations, inaccurate inventory becomes costly. Plant personnel are searching for ways to boost turnaround, cut carrying expenditures, and optimize procuring cycles and delivery logistics. 3D accuracy aids in explaining the differences by tracking changes in buildup and bin topography, simultaneously helping plant managers schedule maintenance and minimize downtime.

No level measurement device can provide 100% volume accuracy. Hence, it`s essential to understand how much precision is required for a particular operation, then calculate the cost of achieving better accuracy against the value of the operation. For optimum results, it is necessary to know the exact specifications of the silos, apply strapping tables to account for variations in bulk density, and have the perseverance to perfect the technology in order to suit specific silo parameters. 

For plants seeking improved accuracy, 3D technology provides an ideal solution as it offers volume accuracy that is better than other single-point level measurement devices.