iCrusher serves as a highly dependable solution for blockage detection and fill level control in all types of industrial crushers. indurad sensor technology‘s remarkable reliability and availability make iCrusher the ideal foundation for enhancing the overall crushing process. This technology has been extensively demonstrated to enhance the performance of crushers across various brands, models and mineral types.
iCrusher serves as a highly dependable solution for blockage detection and fill level control in all types of industrial crushers. indurad sensor technology‘s remarkable reliability and availability make iCrusher the ideal foundation for enhancing the overall crushing process. This technology has been extensively demonstrated to enhance the performance of crushers across various brands, models and mineral types.
Early detection of blockages using four advanced algorithms ensures rapid response, reducing unplanned stops and maintaining throughput.
Real-time truck detection and “Just-in-Time” dumping reduce queue times and spillage, improving haulage efficiency.
Precise material flow and volume monitoring maintain optimal fill levels, maximizing crusher utilization and energy efficiency.
Detect blockages and monitor material profiles
Control feed rate to keep crushers running smoothly
Trend analysis of dump pocket volume and feed rate
Manage wear and damage to the crusher & the apron feeder
primary crusher operations are enhanced in the following key locations
iCrusherPRIMARY leverages a robust network of maintenance-free radar sensors and auxiliary components, designed for harsh mining environments.
High-speed 2D radar sensors monitor fill levels across four dump pocket quadrants and detect truck presence/dumping events up to 60m. Reliable in dust, fog, and extreme conditions.
3D radar with 60° tilt capability scans the material surface for volume measurement and blockage detection, ensuring precise process control.
High-power indoor unit processes data from multiple radar sensors, integrating seamlessly with PLC and SCADA systems via Modbus TCP/IP, PROFIBUS, or PROFINET.
Wi-Fi and 4G-GSM access point enables commissioned and remote support, ensuring secure, rapid system diagnostics and updates.
Full HD Ethernet camera with day/night functionality and digital pan/tilt/zoom, providing visual confirmation in low-light or harsh conditions.
iCrusherPRIMARY’s software modules process radar data to deliver actionable insights, accessible via the iWEB interface or PLC/SCADA integration.
Generates a 2D material contour and calculates absolute (m²) and relative (%) fill levels across four crusher quadrants. Filters irrelevant data for accurate profiling.
- Real-time fill level monitoring in four quadrants
- Polygon and ball filters for precise data processing
- Configurable container shape for accurate measurements
Creates a real-time 3D height map of the dump pocket, calculating material volume (m³) and tracking flow across four zones for process optimization.
- Volume output via fieldbus
- Visualizes material surface in iWEB
- Supports blockage detection and flow control
iCrusherPRIMARY’s software modules process radar data to deliver actionable insights, accessible via the iWEB interface or PLC/SCADA integration.
Based on indurad’s 2D radar sensors, truck presence, position, and the dump event are detected. This information is used for automatic crusher control.
allows automation and safety interlock
basis for automation and blockage analysis logic
The solution monitors the material in the dump pocket to provide the automation system with high-speed level measurements and detects unusual changes in the 3D surface profile and material volume flow in the different segments to provide highly reliable and early blockage detection. This allows the crusher automation to protect from dumping onto a blocked crusher and increases crusher availability by ensuring blockages are resolved promptly.
measures volume flow through the crusher
measures material behaviour and crushing speed
1D ore pass monitoring, 2D vault feeder control, 3D buildup scan
Avoid low levels to extend the apron feeder life by >5%
Maximize live buffer with 3D in Vaults and 1D in ore pass
A 1D iLDR-H radar sensor under a primary crusher measures the level of a 200 meter long ore pass in an iron ore mine in Norway. The system shows the continuous changes in the level, allowing the customer to control the crushing and conveying.
In addition, the information on ore pass volume and changes in the ore pass allows informed decisions to be made to ensure that the ore pass is not worn or blocked.
Conveyor belt flow & belt misalignment, condition monitoring & wear
Gyratory | Jaw | Crusher Vault
Tertiary
Tertiary | Cone Crusher
Apron & plate feeder 2D level and material volume
Screendeck performance and material yield measurement
Chute blockage detection and material flow monitoring
Level measurement, blockage detection and material flow monitoring
3D silo volume measurement + rathole detection monitoring
3D dome volume measurement, material tracking and feeder control
3D stockpile scanning, quality model and automation
3D stockpile scanning, quality model and automation
3D stockpile scanning, quality model and automation
Train loadout productivity increase by automation
Waggon unloader automation and material tracking
Stacker Automation, incl. 3D pile monitoring & material tracking
Material quality control and tracking, blending automation
Reclaimer automation and collision avoidance
Level9 collision avoidance for underground vehicles & personnel
Level9 collision avoidance for underground vehicles & personnel
IPCC automation and heavy machine positioning solutions
IPCC automation and heavy machine positioning solutions
Shiploader collision avoidance, 3D hatch scan and full automation
Horizontal and vertical boom CAS, 3D hatch scan and automation
Vessel detection and ship guidance system for berthing operations
Monthly payments, subscription services
Project based implementation as capital expenditure
Diverse management team driving customer success.
Cross-industry partner network for sales and service - always close to the customer.
company success story and recent developments transforming mining.
Join the Indurad family and develop your career in an exciting environment.
Learn about new developments and the shows and conferences we attend.
The core DNA of indurad. Learn more about the publicly funded RnD.
Hexagon Mining provides solutions for safer, more productive mining operations.
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