Level Sensor Selection in the Age of IoT
As industries move data from sensors to cloud-based databases, better decisions on inventory use, ordering, and accounting are paying benefits.
BinMaster technology falls into the Internet of Things (IoT) world with products that streamline remote monitoring of bulk products like grain, plastic pellets, and aggregates stored in bins, silos, and other storage vessels.
IoT Inventory Sensors and Software
From a business standpoint, inventory management serves a great purpose for inventory balancing, planning, and control. It’s important to have the right amount of inventory to avoid lost orders and money tied up in safety stock.
Selecting smart sensors is critical for success.
Provides insights for data-driven decisions; increase efficiency and drive down costs
Shortens lead times for production
Reduces carrying costs and last-minute purchases
Reduces waste on bulk inventory that could spoil
Feeds accurate inventory data to Enterprise Resource Planning (ERP) systems
Streamlines transportation and timely ordering
SmartBob® Weight and Cable Sensor
Pros
Not affected by dust, material buildup on the sensor, or other adverse process conditions
Can be used in extremely light, signal-absorbing materials
Measures bins up to 150 feet tall
Not affected by material characteristics such as low dielectric constant or angle of repose
Very simple setup and installation; remote sensor requires no calibration
High-temperature models available up to 500°F
Consistent, repeatable, and accurate measurements
Compatible with Binventory® and BinCloud® apps
A variety of digital and analog outputs are available
Cable replacement, wireless communications, and hazardous location approvals available
Cons
On-demand system; does not provide an instantaneous response to change in the material level
Seasonal maintenance may be required to clean out a mechanical cavity in very dusty conditions, if air-purge is not used
Not recommended in high-pressure bins
Minimal contact with stored material
Guided Wave Radar
Pros
Continuous level measurement in light OR heavy bulk solids: powders, granules, bulk solids, and liquids
Measures ranges up to 100 feet with accuracy within 0.08”
4-20 mA and Modbus RTU communications
Performs reliably in high dust or condensation
Suitable for vessels of almost any shape or diameter, including narrow tanks
Virtually maintenance free
Hazardous location approvals
BinDisc simple setup and configuration
Compatible with Binventory software
Cable replacement and wireless communications available
Cons
Sensing probe is in constant contact with the material
Material must have a minimum dielectric constant above 1.3 lb./ft.³
Large or bulky materials like rocks may damage the probe or be difficult to sense
3DLevelScanner
Pros
Continuous level measurement up to 200 ft.
Non-intrusive, non-contact design
Measures uneven powder or solid material surfaces; detects cone up, cone down, or sidewall buildup
Provides minimum, maximum, and average distances
Calculates highly accurate bin volume due to multi-point mapping of the material surface
Self-cleaning system with minimal maintenance requirements
Can serve high-temperature applications up to 365°F
Provides automatic compensation in temperature changes
Analog and digital communication options
Leading-edge 3D MultiVision PC software available for multiple vessel monitoring and 3D bin visualization
Approved for hazardous locations
Not affected by material characteristics or low dielectric constants
RL model compatible with Binventory software
Cons
Acoustic device; elevated background noise can have an effect on its performance
Setup requires care in mounting the sensor in the proper location to best map the vessel
Time required to process multiple pulse echoes limits the sample rate
Not recommended for liquid applications
Corrugation on small vessels can cause false echoes
Not recommended for materials with a bulk density under 11 lb./ft.³
NCR-86 Non-Contact Radar
Pros
Powerful 80 GHz radar with substantial 393 ft. measuring range
4° beam angle for better precision and targeting
Same sensor technology used by self-driving cars
Strong signal performs well in dust
Fast reaction/update time tracks filling or emptying activity
Versatile for use in solids, liquids, and slurries
Signal is not affected by corrugation
Loop-power capability
Compatible with Binventory and BinCloud softwares
4-20 mA and Modbus RTU communications
Cons
Single point measurement will not take material topography into account
Minimum dielectric constant of material must be above 1.3 lb./ft.³
Need more assistance selecting a cloud-compatible level sensor? Contact the BinMaster team today.