This report will provide details based on the article "Establishing a level measurement system in licensed warehousing facilities," published in Official Gazette No. 32999 by the Licensed Warehousing Department of the General Directorate of Internal Trade of the Ministry of Commerce.
General topics are as follows.
1. What is a radar level sensor? What is its operating principle?
A radar level sensor is an effective device used in industrial applications to measure the level of substances such as liquids, solids, or powders. It's based on the principle of sending high-frequency electromagnetic waves to the surface of an object and obtaining level information via the returned signals. Radar level sensors can be divided into two categories: the basic series, which we can call price-performance products, and the professional series. The basic series sensors are capable of measuring up to 30 meters. The professional series can measure up to 120 meters.
2. Reading and recording silo levels in licensed warehouses using reporting programs.
Reporting programs are programs that record all movements in automation systems and provide retroactive monitoring. All movements and operations performed in the automation system are automatically transferred to the program as raw data via an SQL database. The incoming raw data is processed within the program, entered into the relevant data registers, and recorded in the computer environment. This recorded data is presented to the user in the interface display system. Radar level information is also stored here as volume and mass. All movements can also be viewed retroactively by filtering.
3. Radar level sensor selection
The main criteria for radar level sensor selection are as follows.
We have tried and tested both the professional and basic series. First of all, I would like to point out that radar level sensors do not provide mass or volume information. It only provides distance (height) information. When comparing radar level sensors, providing stable and highly sensitive data in dusty environments means the sensor is performing its job. Volume and mass calculations are entirely a matter of industry experience and engineering.
Trialr was conducted on three brands: Endress+hauser, Siemens, and Vega. Trials began in July 2020 and have continued intermittently until today.
In professional series trials for these three brands, all three brands successfully achieved high-precision and accuracy measurements. A one-year trial was conducted with these sensors. However, due to the high investment costs at the time, the project was put on hold.
Trials on the Basic series began three months ago and are still ongoing. Siemens and Endress+hauser are being tested here. (Since Vega produces the basic series and Siemens produces the Siemens series, Siemens was also considered Vega. Vega officials provided this information themselves.) In the tests conducted, both Siemens and Endress+hauser made measurements with sufficient precision and accuracy. However, slight fluctuations and movement in the silo were detected even when there was no operation. For this reason, we preferred Endress+hauser. Because if we had chosen Siemens (Vega), we would probably have had to choose the Professional series. This translates to twice the extra cost per sensor.
In the figures above, you can see the graphs of two consecutive weeks. A transfer is being made from silo 22 to silo 20. As can be seen from the graph, the Siemens silo gives fluctuating signals when the silo is empty and during periods of movement, while the Endress+hauser silo shows no fluctuations.
Result: When selecting a radar level sensor, the sensor's frequency range, measurement sensitivity, and ability to suppress noise and echo signals (we see in the graphs how much this feature affects measurement quality due to Endress+Hauser's availability) are two very important factors. Other details are not directly significant factors in measurement quality but can be considered as improving factors.
4. The Importance of Integrating Radar Level Sensors with Automation Systems
Integrating radar level sensors with automation systems is crucial for product safety in the facility, comparing them with data from the scale (input software), ensuring input and output controls, and ensuring accurate capacity calculations.
As I mentioned before, the information obtained from the radar is only level information. To calculate tonnage, the average hectoliter (silo-based if possible, otherwise ISIN-based) is automatically extracted from the scale. This value alone is not sufficient for capacity calculations. Tonnage information is obtained by combining various information, such as the product's compression coefficient, silo level, whether the silo is filling or emptying, and the facility's geographic location. Additionally, detections must be made based on the automation system's movements. For example, downward movement should be detected during unloading, and upward movement during filling. The minimum and maximum speeds of this movement should be determined over time, and radar activity should be monitored when the facility is not moving. All such possibilities are evaluated to assess the facility's current situation and prevent potential theft or errors. As previously mentioned, these processes require industry experience and engineering expertise. This investment will not achieve its intended purpose if the radar is read by a separate system and not compared with the data from the automation and scales.
5. Reporting and automation software must be integrated with software such as lidos located at licensed warehouse entrances.
All software in the field must be integrated with each other. Data exchange within the system prevents theft, sending the wrong product to silos, and performing erroneous operations.
It also allows for the verification of reliable and accurate information by checking each software separately. The infrastructure for data transfer to the central recording and control system planned by the Ministry of Commerce will then be prepared.
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