Loading rail cars and trains faster and better

indurad iLoadout is a highly reliable system with over 20 successful installations, primarily in iron ore and coal loadouts across Germany, Brazil, Canada, South Africa, and Australia. Its main purpose is to optimize and automate bulk loading processes.

 

Using robust radar technology, the system identifies railcars and provides real-time measurements of their position before, during, and after the loading process. It efficiently monitors and controls the flow of material into the railcars, offering precise volume and profile measurements for each railcar during loading. Additionally, iLoadout delivers essential information such as feed, density, and fill level details, ensuring comprehensive data for accurate and efficient loading operations. 

 

Customers report increased tonnage per railcar with dramatically reduced loading variance.

1

> 2% more ore per railcar (1t)

less railcars needed for the same amount shipped

2

avg. 75% reduction of manual overload removal

continuous loadout with fewer interruptions

3

avg. 33% reduction in loading time

more trains per day - less cost

IMPROVEMENT THAT SPEAKS FOR ITSELF

RAISING THE SETPOINT TOWARDS THE RAILCAR LIMIT

VERSATILE, UPGRADABLE AND CUSTOMIZEABLE SYSTEM

indurad radar data is used in a variety of ways to provide customers with best-in-class automation. The following table shows some of the measurement results that form the basis of the customized solution that Indurad provides to its customers.

RADAR SENSORS ARE THE KEY

iLoadout uses several different indurad radar sensors to measure all important data for controlling the loadout process.

This information is the basis for all other automation packages offered by indurad.

PE CELL REPLACEMENT

better results with less hardware

Traditional car positioning relies on PE cells, which face challenges in the mining environment and necessitate regular maintenance. Sunlight and dust adversely affect the accuracy of these cells.

 

Furthermore, during maintenance, the cells are often relocated or taken out, further diminishing the system’s effectiveness. To address these issues, indurad offers a solution using fixed  iLDR sensors for car positioning and gap detection. These sensors remain unaffected by the environment, making them maintenance-free and reliable. 

 

High precision with less hardware

combined with speed measurement, virtually any PE cell signal at any position is possible

Easy Retrofit and Intregration

Easy to mount and integrate into existing PLC system

Stand alone PE-Cell replacement

Train speed measurement

RAILCAR SPEED MEASUREMENT

contactless speed measurement

more accurate, cheaper than speed cameras

indurad offers a specialized version of the  iDVR (Doppler Velocity Radar) that measures train speed with the utmost precision on the spot. This capability is crucial during the loading process as the train speed varies from railcar to railcar. These small yet significant factors play a key role in achieving superior loading automation, ensuring efficient and accurate loading operations.

 

Ultra-high resolution from low to high speed

detects small speed changes in real time

No maintenance required

operates under dusty, wet and dirty conditions

2D Railcar scan

2D radar sensors scanning railcars

before, during and after loadout

indurad’s 2D radar sensors are used to measure the surface profile. For example

  • Detection of hang up + residual material before loading
  • Railcar type and load capacity detection based on geometry 
  • Chute control – measurement of material flow before and after the chute
  • Measurement of railcars leaving the loading area

These measurements are used for several software features to automate the loading facility.

Real-time 2D measurement

solid radar 2D radar surface scans independent of environmental conditions

In-Go, Out-Go Volume & Profile

provides online volumetric scanning of railcar and material.

2D railcar scanner

iLOADOUT ANIMATION VIDEO

iLoadout is a radar-based control solution for train loadout (TLO) It enables process optimization, automation, and inventory control while reducing costs, spillage, and material variation.

iLoadout consists of several hardware sensors and solution modules. It integrates seamlessly with most PLC and SCADA systems. Most of Indurad’s installations have been brownfield or retrofit solutions.

The train loadout system is used for iron ore, coal, cement, rain and potash loading.

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