Rail car loading automation solution
Mining and port operations rely on an effective and highly productive rail loadout system. Currently, high variability in human control and unreliable optical sensors result in a high standard deviation in the rail car payload.
Overloaded railcars may cause penalty fees, entail track cleaning and increase the risk of derailment. Underloaded railcars decrease throughput and increase costs per tonne.
iLoadout PackageProfile Measurement
iDRR sensor based solution to measure the profile of the material from front to rear in the wagons. indurad´s robust radar technology allows for the placement of sensors in close proximity to the loading chutes or gates. This allows for immediate profiling and quick loading parameter adjustments.
iLoadout PackageRail Car Speed
iDVR sensor based speed measurement for the rail stock. Indurad´s radar based speed measurement is more reliable, more accurate and has less latency than optical, mechanical or track switch systems.
iLoadout PackageRail Car Gap
The accurate localization of gaps between rail cars is essential for TLO automation. An array of high-precision iLDR sensors in various positions allows for reliable gap detection.
iLoadout PackageRail Car Type
To identify different wagon types an iLDR sensor is located on the ingo gate. This sensor maps the side profile of each car. Using pattern recognition, this feature determines the wagon type and allows for loading parameter adjustment. This radar based feature is more reliable than RFID-based car type identification systems.
iLoadout PackageOptical Character Recognition
indurad OCR cameras record all numerical or alphabetical ID information on rail cars. All data is stored in a solution data base for post-process analysis.
iLoadout PackageResidual Material Check
Compressed or wet material tends to get stuck in corners and on the bottom of wagons. With an iSDR sensor it is possible to detect, locate and measure any quantity of residual material.
iLoadout PackageCar Height and Spring Distortion
Typically two pairs of iLDR sensors are located on the ingo and outgo of the TLO to measure the initial and final height of rail cars. This allows for chute height adjustments for optimal loading and calculating spring distortion under load.
iLoadout PackageTerminating Volume Calculation
Several radar sensors on the outgo gate measure the loading profile. In combination with the train speed, this enables calculation of load volume and volume distribution.
iLoadout PackageAngle of Repose Calculation
Several radar sensors on the outgo gate measure the load surface profile. Front and rear material angles of repose are calculated to allow for optimizing chute or gate opening and closing timing.
iLoadout PackageFront and Rear Freeboard Measurement
Several radar sensors on the outgo gate measure the loading profile. Based on car type and loading profile, the front and rear material freeboard (horizontal distance of material to wagon edge) is calculated. This allows for optimizing material load distribution and increasing loaded volume.
iLoadout PackageSide Freeboard Measurement
Several radar sensors on the outgo gate measure the loading profile. Based on car type and loading profile, the front and rear material freeboard (horizontal distance of material to wagon edge) is calculated. This allows for optimizing material placement and increasing loaded volume.
iLoadout PackageOre Car Visualization
3D renderings of loaded ore cars on panel PC or for SCADA integration. This feature allows for a detailed loading performance analysis.
iLoadout PackageDensity Calculation
An indurad iBelt combined with an existing belt scale allows for live density calculation of TLO material infeed. This feature assists with predictive parameter adjustments.
iLoadout PackageSilo Volume
This feature allows for balancing infeed volume (feeder or reclaiming speed) and output volume (train speed) to prevent overfilling of bin or running out of material.
iLoadout PackageOpen Door Detection
The iLoadout bottom dump open door detection feature is based on the high precision iLDR technology. This feature prevents spillage and downtime.
iLoadout PackageCollision Avoidance & Chute Level Adjust
iLDR based locomotive detection and wagon height measurement feature to prevent collisions of railstock with loading chutes or gates.
How does it work?
Solution Layout: The iLoadout™ Solution is based on a reliable multi-sensor concept comprising
- indurad DopplerVelocityRadar iDVR™ for rail car speed measurement
- indurad DualRangeRadar iDRR™ for material profiling
- indurad LinearDynamicRadar iLDR™ for gap detection
All data is merged into a complex, sector-based model for volumetric control. The sensors are vertically mounted within the rail loading station near the chutes or clam gates on the incoming and outgoing side, as well as horizontally beside the tracks.
For reclaim tunnel type loadout systems, indurad additionally installs an
- indurad DualRangeRadar iDRR™ for stacking control
This allows for zone-based volumetric stockpile control even under challenging conditions with steep craters and rat holes beyond the natural angle of repose.
Why is it an improvement?
Common Technologies: Current technologies in train loadout systems comprise light barriers with reflector bars for gap detection, large track scale systems and multiple cameras. The situation is characterized by a large number of manual control interactions.
- Load higher number of rail cars per hour
- Less spillage in reclaim tunnels and in loadout stations
- Measurements not affected by dust and fog
- Contact-free ore car speed control at extreme low velocities
- No manual cleaning of sensors required
- Optional packages like iStacker™ for stacker buffer systems and iApron™ for surge bin buffers