Product Overview

Because solid materials in silos tend to form angles of repose, resulting in significant variations in material surface elevation, and often adhere to the silo walls, traditional single-point radar level transmitters—regardless of their installation location—cannot accurately reflect the true internal configuration of the silo. Therefore, 3D detection has become an inevitable trend and necessity for the development of certain industries in the industrial sector. This product can accurately detect the 3D information of solid materials. Based on terahertz frequency-modulated continuous-wave radar, a rotating and tilting mechanism drives the radar sensor to perform a 360° high-resolution scan of the material surface. By integrating image processing, big data analysis, AI, machine learning, 3D point cloud conversion and modeling, cloud storage, and computing technologies, it can operate automatically and continuously 24 hours a day, It rapidly measures and accurately captures real-time 3D information of the material surface,

generates 3D visualizations, and calculates relevant parameters such as material level, volume, and weight. The 3D scanning radar addresses critical challenges in material inventory and level detection, enabling intelligent and digitized material management, visualized production data and transparent production processes, as well as unmanned and automated on-site operations. This elevates management capabilities, decision-making capabilities, and safety protection capabilities to a new level.

3D Point Cloud Visualization of the Tank Farm

Industry Applications

3D scanning radar uses a narrow beam with strong penetration capabilities, making it well-suited for complex operating environments. It is unaffected by harsh conditions such as high temperatures, high dust levels, corrosion, steam, rain, and fog, and offers excellent value for money. It is widely used for measuring solid materials in various storage locations, such as silos, shipping containers, and bulk solid storage facilities. Industries where it is applied include: grain, chemicals, steel, energy, cement, food, power plants, plastics manufacturing, metal processing, glass manufacturing, and lumber processing

Advantages and Features

3D Imaging and Visualization

A 3D scanning radar scans the surface of the material and the side walls of the silo. After processing by algorithms deployed on a cloud server, precise 3D data is obtained and used to create a 3D model. This allows the actual shape of the material surface and silo side walls to be accurately and intuitively reproduced on the human-machine interface, generating a visual 3D image.

This method employs multidimensional super-resolution reconstruction technology for terahertz radar signals and offers high computational accuracy.

The processing algorithm deployed on cloud servers incorporates machine learning to establish a mapping relationship between radar echo data and material pile configurations based on convolutional neural networks, significantly improving the resolution of the three-dimensional surface morphology of the material. Additionally, the 3D modeling process employs advanced algorithms—including precise fitting, noise removal, and material segmentation—to enhance computational accuracy.

Intelligent inventory management systems replace manual inspections or physical counts, reducing costs and improving efficiency

Using 3D data, we can obtain relevant information such as material levels, volume, and mass. This prevents material spills while providing real-time, accurate data on material intake, sales, and inventory, ensuring the accuracy of financial costs and profits. By configuring measurement intervals based on actual needs, the system automatically performs inventory counts and measurements, enhancing production tracking capabilities and operational efficiency. This enables real-time and convenient inventory monitoring, maximizes the potential of material management, and optimizes delivery and procurement plans. This prevents stockouts from disrupting production continuity and delivery schedules, while also avoiding excessive material procurement that ties up corporate capital.

Real-time monitoring to enhance safety

By automatically calculating based on real-time 3D data of the material, this system replaces manual measurement, improving both measurement speed and accuracy while eliminating human errors and false alarms. It enables the timely detection or prevention of abnormal material depletion or disappearance. The system performs real-time measurements of the material surface and silo sidewalls, displays real-time 3D visualizations, and provides real-time insights into the distribution of material within the silo and any material buildup on the sidewalls, thereby enabling real-time dynamic monitoring of the material surface and silo sidewalls. This prevents structural damage or even collapse of the silo caused by material collapse or uneven distribution, helping to promptly identify potential faults,

address them in advance, and prevent losses; it also prevents misjudgments of inventory levels caused by material accumulation or buildup on the silo walls, and provides a reference for timely silo cleaning. With 24/7 automated detection requiring no manual intervention, this system effectively addresses key challenges such as demanding operational requirements, high labor intensity, low process efficiency, and limited digital capabilities. It enhances the organization and management of material production, eliminates concerns about harsh measurement environments, safeguards operator health, and eliminates safety hazards.

Unrestricted by operating conditions, automatic stitching and registration enable precise measurement of large-scale storage devices

3D scanning radar is equipped with a powerful software system. For measurement needs covering extremely large areas—such as extra-large silos, dome-shaped silos, and large open-top silos—3D scanning radar is the optimal solution. Installing two or more 3D scanning radars ensures complete coverage of the required measurement area within the silo. The image stitching and registration algorithm deployed on cloud servers stitches and registers the 3D data acquired by each 3D scanning radar to form a comprehensive 3D map of the entire measurement area within the silo. This ultimately presents a unified 3D visualization of the entire measurement area. The 3D scanning radar can intelligently mask irrelevant areas to enable smart management. The antenna housing features an innovative dust-proof and sealed design that prevents dust accumulation. The high-temperature wave-penetrating material reduces radar wave attenuation, ensuring data accuracy. As shown in the example below, multiple 3D scanning radars can be connected simultaneously to the control bus. Data is transmitted to the software system via the control bus, allowing users to monitor and measure multiple silos simultaneously through the visualization software. Combining remote cloud processing technology with Bluetooth wireless transmission, the host device (desktop computer, laptop, digital production management LCD display, etc.) can display 3D visualization images, material levels, volume, mass, and other relevant parameters obtained from the cloud server on its interface, and also perform debugging and control of the 3D scanning radar.

The software system is customizable, flexible, and highly compatible

The software system features a robust architecture, excellent compatibility, and strong scalability. Through automated scripts, it performs a comprehensive range of functions, from 3D point cloud data acquisition, trimming and segmentation, transformation and processing, measurement, and calculation, to database management, reporting, and web-based visualization. By integrating data with relevant modules, such as ERP systems, the solution achieves management objectives related to “quantity, quality, procurement, consumption, and inventory.” It provides real-time access to precise data on material 3D information, inventory levels, and usage, and presents results in diverse formats (such as 3D visualizations and data reports). This enables end-to-end closed-loop management of benefit analysis, procurement, and inventory, thereby promoting quality improvement and efficiency gains for the enterprise. Through real-time and accurate 3D visualization, the system provides surveying models and spatial coordinates in real time, thereby guiding related process operations. For example, in the metallurgical production process of a blast furnace, 3D visualization images reveal the distribution and coordinate values of materials throughout the furnace. This enables adjustments to the charging process to form an optimal charge bed shape, ultimately improving blast furnace operating conditions. By integrating operational control strategies with automated material handling control programs, the system enables round-the-clock automated, unmanned operations. This standardizes, intelligently manages, and automates material yard handling processes, reducing labor costs and enhancing safety.

Remote cloud processing technology enables monitoring and control across multiple devices and locations

During the scanning process, measurement data can be transmitted to a cloud server, allowing users to collect real-time data from containers of any size across different locations. Additionally, the cloud server provides storage capacity for historical data recording and retrieval. Processing algorithms deployed on the cloud server integrate and process measurement data in real time, generating 3D visualizations and producing data reports. The use of cloud processing technology enables real-time monitoring of data across multiple terminals and locations, as well as real-time remote control of 3D scanning radars from multiple terminals and locations.

echnical Specifications