It takes just five basic components to design an inventory system for managing solids, powders, or liquids stored in bins, tanks, silos, and other storage vessels.
1. Select the Right Sensor Type for Your Materials and Processing Environment
Continuous level sensors collect measurements consistently or at timed intervals. Real-time data is ideal for fast-paced processing environments, in vessels where frequent filling or emptying occurs, or anywhere that workers need enhanced visibility into bins and silos.
Common technologies include:
- Non-Contact Radar
- 3D Level Scanners
- SmartBob
- Guided Wave Radar
- Ultrasonic
- Laser
2. Connect and Network Sensors to a Control System or Software.
Sensors must be able to communicate via a wired or wireless communication network. Wireless systems reduce the cost and complexity of installation using over-the-air communications.
- Daisy chain: A wiring scheme that allows multiple sensors to be wired together in a sequence to reduce the amount of wiring needed.
- Gateways: Sensors send level data to a gateway that uses LoRa (long-range) communications to transmit data to a website application or software.
- Wireless Systems: Wireless radios, bridges, and repeaters are used to span long distances without the use of expensive wiring.
3. Determine How You Want to Access Inventory Data
Consider the type of device you want to use—phone, tablet, or PC? How many locations or number of sites and vessels will be monitored? Will employees be working at the plant or remotely?
- Directly into a PLC or HMI
- BinView® or FeedView®: Logging into website application
- Binventory™: Installing software on a local network
- Facilitate Vendor Managed Inventory
4. Provide Real-Time, Convenient Inventory Access for Plant Personnel
Save people time to make them more productive. Inventory data at plants is often stored at a centralized location, such as a control room. Make real-time data easily accessible via a walk-up or drive-up push-button console.
- Digital Panel Meters: Compatible with all types of sensor outputs, including 4-20 mA or Modbus RTU. Large, ultrabright displays are readable in smoke, fog, or bright sunlight.
- Control Consoles: Monitor up to 120 vessels on a single console. Display options for height of the product, headroom, percentage full, and weight.
5) Use Point-Level Sensors to Alert to High and Low Levels
Eliminate material outages and prevent overfills using sensors that alert when vessels are almost empty or full. Get uninterrupted processing, improved margins, and increased outputs.
Affordable sensors include:
- Rotary
- Vibrating Rod
- Capacitance Probe
- Tilt Switch
- Diaphragm Switch
