Case Study: Real-Time Material Profiling on Conveyors using Ultrasonic Sensors

In bulk material processing environments, accurately determining the volume and distribution of materials on conveyor belts in critical for efficient operations. Manual inspections are not only a safety concern, but also prone to human error. Traditional contact-based sensors suffer from wear and require regular maintenance, while non-contact sensors often lack the speed needed to capture real-time changes in material flow.

Solution

To address these challenges and improve process control, a mining customer implemented a real-time material profiling system using ABM’s fast-response ultrasonic level sensors. Designed for harsh, dusty industrial environments the sensors feature an innovative self-cleaning ultrasonic transducer to ensure consistent readings and maintenance-free operation.

The sensors are mounted above conveyor belts, operating at a rate of 20 echoes per second and outputting high temporal resolution data for real-time material profiling. The data is fed into the control system to enable accurate volume estimation, early detection of uneven loading or spillage and automated regulation of upstream feed rates.

Results

The high-frequency, real-time data provided by the ultrasonic sensor offered immediate improvements in process control and efficiency:

• Improved material volume accuracy, enabling better production planning
• Faster response to loading inconsistencies, reducing downtime and material waste
• Enhanced automation through integration with control logic and feedback systems
• Increased workplace safety by minimizing the need for manual inspections near moving equipment

Conclusion

This ultrasonic-based profiling system offers a non-contact, high-resolution solution for monitoring bulk materials on conveyor belts. By leveraging ABM’s fast-response sensors and intelligent data processing, the client achieved improved process control, better material handling efficiency, and enhanced operational safety.