3D Technology for Reliable, Accurate Inventory Monitoring in Corn Silos. Presented by: Mike Mossage 3D Product Manager

Transcription

1 3D Technology for Reliable, Accurate Inventory Monitoring in Corn Silos Presented by: Mike Mossage 3D Product Manager 1

2 3D Scanner Basics Scanner mounts on top of bin Measures & maps surface Sends data via RS-485 or 4-20 ma Software records data and 3D map of contents & calculates level, volume and mass 2

3 Anatomy of a 3DLevelScanner Display Head Neck Transducers Closed Three Independent Transducers Open 3

4 3D Safety & Reliability No need to go on-site, outdoors or climb ladders to measure bins manually Non-contact measurement means no risk of contamination Bin levels from here? Low frequency technology penetrates dust Continuous, multiple-point measurement Uses three independent channels to transmit and receive, which ensures accuracy Built-in temperature sensor ensures reliable data in fluctuating temperatures Or here? Works in challenging environments! 4

5 Penetrates Dust and Requires Minimal Maintenance Self-cleaning with minimal routine maintenance required Sensor resists buildup of dust inside of transducer Works where other technologies are unreliable or have failed Scanner Sensors inside stay clean in dusty environments. Flour mill installation 5

6 3D Differences from Conventional Level Measurement Sensors Reliable in dusty environments Accounts for uneven material surfaces Detects sidewall buildup Provides visualization of material surface Milling Improves inventory accuracy Estimates material volume Appropriate for very large bins Ethanol Photos of actual installed locations! 6

7 Radar Sensor Shortfalls Only a few models (with high GHz) perform reliably in dusty environments Measures level only at a single point in large vessel, does not take into account uneven topography Provides level only at one measurement point, but not volume No visual of material in the silo to detect high and low spots Costly, time-consuming maintenance or air purge needed for cleaning Can only view level of one vessel at a time must view each sensor separately Grain Photos of actual installed locations! 7

8 Selecting the Right 3D Scanner Model S M MV MVL Bin Height Up to 200 Up to 200 Up to 200 Up to 200 Bin Diameter Up to 14 Up to 45 Up to 45 Unlimited. Number of units determined per application. Beam Angle for each scanner 3D Visual No No Yes Yes Output Data Average distance Estimated volume plus minimum, maximum, and average distance 3D visual, estimated volume plus minimum, maximum, and average distance 3D visual, estimated volume plus minimum, maximum, and average distance Best Application Tall, narrow bins with little or no corrugation Wide bins, taller than they are wide Wider bins, taller than they are wide Very wide bins All models can be used in silos with a larger diameter than specified, but with decreased accuracies as the beam angle will not span the entire surface of the material. 8

9 Multiple Point Measurement Means Better Accuracy Eliminates guesswork and inaccurate readings Maps uneven topography that randomly forms inside bins Accounts for cone up, cone down, or material buildup along bin sides Detects irregular surfaces caused by multiple fill and empty sites Calculates absolute surface level values, volume and mass inside a bin Operations can buy and sell commodities at the right time Customer s Taped Distance: 47.7 ft. 3D Average Distance: ft. 3D Minimum Distance: ft. 3D Maximum Distance: ft. 3D VOLUME: 47.34% 9

10 Food Processing Challenges Better accuracy and stability Primary interest is headroom distance Desired 3D visualization Material prone to rat-holing and buildup The old equipment wasn t working properly Irregular topography when emptying. Solution MV scanners installed on all 21 tanks 3DMultivision software monitors all tanks Benefits More precise headroom Mapping and visualization for material prone to buildup and rat-holing Ability to monitor multiple bins with one solution Scanners are installed on 21 silos. 10

11 Improve Inventory Accuracy for Two or more scanners installed in a single vessel Multiple scanners continuously measure and map material surface Covers greater surface area for more measurement points for greater accuracy Software combines data from multiple scanners to provide a single 3D visual Useful in large grain bins such as 105, 130 or million bushel bins Very Large Silos Photos of actual installed locations! 11

12 Grain Storage Challenges Large 105 diameter bin Contains dusty corn Concerned with employee safety Solution MVL model with 3D visualization 3DMultiVision software Benefits Improved volume accuracy More frequent, more reliable data Network viewing by multiple users Scanner #1 mounted near the center of the bin. No more climbing! Scanner #2 mounted halfway between the center and sidewall. 12

13 Site-Wide Inventory Management from a Single Screen View all bins at once no tedious one-ata-time opening of new window for each bin Set alerts for high or low status for each vessel One click access for a detailed bin view Suitable for a network of mixed scanner models Data is stored in a database and accessed on Local Area Network (LAN) Multiple users from multiple departments can access data base Customize views for just the tanks and data needed by each user Historical reports for managers, purchasing and financial use View all bins at once. Zoom in on a single bin. 13

14 Monitoring Corn & DDG Silos 14

15 Monitoring Corn & DDG Silos 15

16 Historical Reporting 16

17 Volume, Mass & 3D Visualization 17

18 Challenges Extremely dusty corn bins Large bins with uneven topography Needed greater accuracy Monitoring levels of multiple bins Ethanol Plant Solution MVL-2 systems on 75 diameter concrete silos and 105 diameter steel bins MV 3DLevelScanners on DDG concrete silos MultiVision software Scanners are installed on all four large silos. Benefits Works in dusty environment Tracks level during fill and empty Improved inventory accuracy Ability to monitor levels of all bins in real time Ethanol plants are among the heaviest users of 3D technology. 18

19 Optional Neck Extensions Enables scanner to clear obstructions that may interfere with acoustic signals Lowers transducers assembly below obstacles, through a thick roof, or on a raised socket Kits available in 2, 4, 6, and 10 lengths with either galvanized or stainless steel pipe Performance without signal degradation or special structural alterations or adapters 19

20 Grain Storage Challenges Large concrete silo with obstructions in top of bin Very wide, large silos Desired better accuracy in dust Solution Neck extension to clear structure MVL model with two scanners and 3D visualization Scanner mounted on large concrete silo. Benefits Improved volume accuracy using two scanners to cover surface Non-contact technology requires minimal maintenance Safer work environment for employees 20

21 Angled Mounting Adapters Scanners must be mounted in an optimal location to provide the greatest level of accuracy Use when installation in desired location isn t possible or must use existing hole Points transducers in desirable direction to improve coverage of the material surface Supports angles of either 10 or 20 Use only when mounting scanner in most desirable location is not possible Points scanner to improve surface coverage for better accuracy. 21

22 Teflon-Coated Sensors Resists buildup inside transducers in extremely dusty environments Ensures performance in powdered, granular or solid materials generating excessive dust when bin is filling or active Significantly extends the maintenance cycle by reducing need to clean device after prolonged periods of use Reduces need to climb tall silos enhancing safety and saving time 22

23 Soybean Meal Processing Transducers were becoming blocked and needed to be cleaned every week Since installing the Teflon-coated transducers, sensors have not been blocked Slick, self-cleaning surface requires minimal maintenance Before Teflon Transducers Similar applications Food processors in industries such as baking, pasta, and sugar When non-contact technology is a requirement Any material that is prone to clinging With Teflon Transducers 23

24 Lincoln, Nebraska, USA Mike Mossage 3D Product Manager