LASE GmbH - Moderne Lasermessgeräte & hochentwickelte Softwareapplikationen // State-of-the-art laser sensors & sophisticated software applications

Another start-up of LaseRCD for rail wagon unloaders at Vale in Sao Luis, Brazil

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(LASE GmbH) (Wesel, 11.08.2018)

LASE finished another follow-up order for 3D laser measurement systems for rail wagon unloaders at Vale in Sao Luis, Brazil

The application LaseRCD (Rail Car Dumper) has been installed in the Ponta de Madeira Port in Sao Luis (state of Maranhao, Brazil), where Vale has located his port terminal for the shipping of mining materials. Here our 3D laser measurement systems allow a reliable detection of foreign objects on the wagons before and a further emptiness control after the unloading process. According to previous successful projects in Sao Luis with this application before, three further LaseRCD systems have been commissioned for ThyssenKrupp Brazil and end customer Vale at O-type rotary tandem dumpers there again.

Before the iron ore arrives in Sao Luis, it is transported by train out of the world’s biggest open pit iron ore mine at Vale’s S11D in the Carajas region, which needs to cover a distance of 892 km. One train (totally 35 trains are in simultaneous circulation) even has a length of 3.3 km, which consists of 330(!) wagons. In the port terminal of Sao Luis so called O-type rotary tandem dumpers are used, in which two cars/wagons can be unloaded at once without uncoupling through rotating couplings. For the unloading process VALE required a measurement system, which is able both to determine unexpected objects on top of the material in a wagon and to undertake an emptiness control after the unloading process.

Object detection and emptiness control

At the begin of the processing in the dumping stations (tandem type) in Sao Luis, two wagons filled with bulk material drive into the station and are checked for objects like humans, animals, branches etc. on top of the material. In case of a positive check the wagons will be tipped over for unloading and return to their initial position. Normally the wagons should be empty, but it is possible that humid material can remain inside the wagon. In this case the remaining material is detected and is removed manually by the service staff before another dumping process.

3D laser scanner technology for accurate wagon control

For this solution at tandem dumpers LASE uses two 3D laser scanners, which are mounted centrally above each wagon as well as the software application LaseRCD, that collects the scanner data and does all needed calculations.When the wagons are positioned inside the dumper and being fixed by clamps, the laser scanners measure the surface of the material by 3D scan planes and detect it for unexpected objects. If nothing is detected the application signals the prior PLC to tip over the wagons. Afterwards the emptied wagons roll back to their initial position and the further emptiness control is triggered, where the inner surface of the wagon is scanned and a 3D scan profile image is created. This one is compared with an internally stored image (zero scan) of an totally empty wagon. In case of any difference by remaining material inside the wagon, the application generates a signal (three levels of non-emptiness signals) and sends volume data of the remaining material to the PLC. In order to protect the laser scanners against dust and rain, they are mounted into stainless steel hoods, which clean the scanner windows by an included air pressure unit. All systems have been implemented in collaboration with our Brazilian distribution partner C+ Tecnologia.

In order to see one of the 3D laser measurement systems for Rail Car Dumpers in operation, just have a look at the video on our YouTube channel: https://www.youtube.com/watch?v=Tkj06OfJI7s

Further information about the application for an efficient handling of rotary car dumping systems can be found on the product page here...

 

Image on top: Wagons in line waiting before dumping process in O-type rotary tandem dumper / © LASE

Project completion for laser volume measurement systems on conveyor belts and yard stacking machines at Vale’s S11D in Brazil

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(LASE GmbH) (Wesel, 09.04.2018)

LASE has finished a further project for volume measurement of stockpiles at Vale’s S11D Complex in North Brazil. In this huge plant iron ore is measured on different storage and regulation yards by 2D and 3D laser scanners, which deliver exact data about the volume, height and position for the management of seven stockpiles. Totally four 3D- and nine 2D laser scanners have been equipped on seven stacker and reclaimer machines resp. material yards.

After finishing the first project with a volume measurement system for 15 conveyor belts at S11D in the Brazilian municipality Canaã dos Carajas (Federal State of Para), LASE has equipped 2D and 3D laser measurement systems as well as a specific yard management software (LaseBVH - Bulk Volume Heap) for seven storage and regulation yards in the world’s biggest mining facility. Due to the project success and in order to fulfill the increasing demand on the automation of stacker or reclaimer machines for material handling, 2D- and 3D laser measurement technology has been chosen as key solution again.

In the regulation yard each of the three machines is equipped with three 2D laser scanners, which measure the stockpile in a vertical scan plane parallel to the machine boom. While the stacker machine is moving on the railway along the yard as well as during the stacking process, the laser scanners scan the stockpile permanently. With the knowledge of the exact machine position by using DGPS systems, a 3D image profile of each stockpile with incl. height and volume data is generated. These data are displayed in a specific manager software where all stockpiles are divided into zones.

In the other yard for storage operations four reclaimer machines are provided with each one 3D laser scanner, which are mounted at the highest point of the machine. By collecting all 3D measurement data and the exact position (DGPS) of the machine, a 3D image of the surrounding stockpiles is created here as well. The LaseBVH application software also contains special filter algorithms to extract machine construction parts (e.g. boom, struts) out of the scan data and shows the real volume and profile information accurately.

All data from the GPS system, laser scanners and the machines are collected by a specific LASE Control Unit (LCU) and are forwarded to the central control station by an Ethernet connection. This system architecture allows a permanent digital monitoring of all machines for a frictionless operation. Because of its robust design the application LaseBVH allows reliable operations even at rough outdoor conditions like in this iron ore facility at Vale’s S11D.

Find out more on our product website…

 

Image on top: View over a mining yard at S11D Complex / © LASE

Further truck volume measurement system for Central Ring Road construction in Moscow

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(LASE GmbH) (Wesel, 20.11.2017)

For the road works of a further huge central ring motorway around Moscow (Russia), the laser-based measurement system LaseTVM is in use at several different stations along the construction site. The task is to measure the accurate volume of trucks, which deliver bulk materials like sand or crushed stones. The customer, a huge Russian road construction company, is having a reliable control system against weight manipulations and overpayment now.

The application LaseTVM is installed at three different checkpoints on a road construction sitewhich covers a distance of 105 around the city region of Moscow. While the construction phase lots of bulk material like sand or crushed stones need to be used for the base course of the asphalt, which are purchased by the construction company. For the accurate account of the used bulk material a highly exact volume measurement system for the dump trucks was demanded for this task. By applying the laser-based application LaseTVM - Truck Volume Measurement the customer is now able to get precise volumes of the delivered materials.

At each stationary checkpoint next to the motorway one LaseTVM system is installed. A 3D laser scanner from the LASE 3000D-C2-11x Series is mounted on a metal framed truck gate. The laser measurement data are processed to the specific LaseTVM software and visualized to the operator. Two further IP-cameras are installed at the gate’s front and back side in order to recognize the license plates. An additional video camera on top of the gate monitors the trucks, with showing the loading area and the type of material to the operator. A cover hood protects the 3D laser scanner and the cameras from weather influences and an additional lightning device allows camera recognition also by night.

The standard operating procedure starts with the entry of a loaded truck approaching the gate with slow speed of approx. 5 km/h, where the license ID and a topview image of each incoming truck is recorded. Then the truck has to reach a central position under the gate where the laser scanner starts the 3D measurement process. At the same time the operator can check against the loaded material type within the delivery documents and the camera images. After an average scan time of 10 seconds the initial measurement procedure is finished and the truck can drive to the storage yard for being unloaded.

Afterwards the truck needs to return to the measurement gate for a final emptiness control. The 3D laser scanner measures the empty load area of the truck and forwards the scan data to the LaseTVM software, which calculates the volume out of the difference from both measurement data (full vs. empty). Thus the truck ID and a topview image are recorded again and stored in the data base. For a comprehensive and transparent data handling the customer is able to monitor all delivered material volumes by specific filter options within the software. By using this system the customer is protected against possible manipulations of the delivered material. The volumetric measurement method was a conscious decision by the customer. Due to experiences from previous projects with truck weighing systems it could be revealed that weight was manipulated by water addition. Because of the variety of trucks only a visual inspection of the material is not sufficient. The LaseTVM measurement system allows the customer having a reliable, tamper-proof and documented control of the delivered material, which provides them and their suppliers a debitable settlement basis.

More information about the application LaseTVM can be found on the product page here...

 

Image on top: Truck approaches measuring frame with 3D laser scanner for load volume measurement / © LASE

LASE provides truck volume measurement system for M11 motorway project in Russia

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(LASE GmbH) (Wesel, 20.05.2017)

In order to measure the exact loading volume of dump trucks LASE implemented the application LaseTVM on a road construction site for the customer EuroTransStroy in St. Petersburg, Russia. The laser-based measurement system determines the exact volume of purchased bulk materials like sand and crushed stones with highest accuracy to prevent load differences. Furthermore the recognition of the license plates and the load area for a fully comprehensive and transparent data handling are another features within this implementation.

EuroTransStroy is one of the biggest road construction companies in Russia and is involved in the road extension of the motorway M11 Moscow-Saint Petersburg, which should be finished until the beginning of the 2018 FIFA World Cup. The total length of this alternative connection for the easing of traffic is about 684 km and here the last 38 km will be prepared. While the construction phase lots of bulk material like sand or crushed stones need to be used for the base course of the asphalt, which are purchased by EuroTransStroy. For the accurate account of the used bulk material a highly exact volume measurement system for the dump trucks was demanded for this task. By applying the laser-based application LaseTVM - Truck Volume Measurement the customer is now able to get precise volumes of the delivered materials.

The system is installed at a stationary checkpoint next to the motorway where a 3D laser scanner from the LASE 3000D-C2-11x Series is mounted on a metal framed truck gate. The laser measurement data are processed to the specific LaseTVM software and visualized to the operator. Two further IP-cameras are installed at the gate’s front and back side in order to recognize the license plates. An additional video camera on top of the gate monitors the trucks, with showing the loading area and the type of material to the operator. A cover hood protects the 3D laser scanner and the cameras from weather influences and an additional lightning device allows camera recognition also by night.

The standard operating procedure starts with the entry of a loaded truck approaching the gate with slow speed of approx. 5 km/h, where the license ID and a topview image of each incoming truck is recorded. Then the truck has to reach a central position under the gate where the laser scanner starts the 3D measurement process. At the same time the operator can check against the loaded material type within the delivery documents and the camera images. After an average scan time of 10 seconds the initial measurement procedure is finished and the truck can drive to the storage yard for being unloaded.
Afterwards the truck needs to return to the measurement gate for a final emptiness control. The 3D laser scanner measures the empty load area of the truck and forwards the scan data to the LaseTVM software, which calculates the volume out of the difference from both measurement data (full vs. empty). Thus the truck ID and a topview image are recorded again and stored in the data base.

For a comprehensive and transparent data handling the customer company EuroTransStroy is able to monitor all delivered material volumes by specific filter options within the software. By using this system the customer is protected against possible manipulations of the delivered material. The volumetric measurement method was a conscious decision by the customer. Due to experiences from previous projects with truck weighing systems it could be revealed that weight was manipulated by water addition. Because of the variety of trucks only a visual inspection of the material is not sufficient. The LaseTVM measurement system allows EuroTransStroy having a reliable, tamper-proof and documented control of the delivered material, which provides them and their suppliers a debitable settlement basis.

More information about the application LaseTVM can be found on the product page here...

 

Image on top: 3D laser scanner from LASE 3000D-C2-11x Series mounted under protection hood / © LASE

LASE delivers to Vale’s world’s biggest mining project at S11D Complex in Brazil

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(LASE GmbH) (Wesel, 21.03.2017)

LASE has provided the delivery of 15 LaseBVC conveyor belt measuring systems to history’s biggest iron ore mining project by Vale in the S11D Complex in North Brazil. In this huge plant the material volume, which is being transported on conveyors needs to be determined by specific measurement applications from LASE.

In the Brazilian municipality Canaã dos Carajas (Federal State of Para) the mining company Vale has opened the world’s largest mining project in history in last December. After starting with the commercial operation in January, LASE has already begun with the rollout of the application LaseBVC (Bulk Volume Conveyor) and delivered 14 volume measurement system for conveyors in the so called  S11D Eliezer Batista Complex. Together with our longstanding Brazilian partner company C+ Tecnologia the laser-based bulk material measurement systems will be commissioned for end customer Vale properly. This prestigious project sets a new standard in the mining industry where advanced technology meets high productivity.

In order to measure the height of iron ore on conveyors as well as its volume, one laser scanner is mounted above each conveyor belt. The scan direction of the laser systems runs across the transfer direction of the conveyed material and generates 2D profiles. These are compared to so called zero-profiles, which have been stored during the initial commission of a conveyor belt. By knowing the individual difference and the belt speed, the exact volume can be determined consequently. Additionally, if the bulk density is known, the mass flow can be calculated, too.

By the use of high-resolution laser scanners with a scan ratio of up to 100 scans per second the material can be recorded even at high transportation speeds. Special algorithms within the LaseBVC software application for the adjustment and calibration ensure high measurement accuracy. The system can be operated intuitively due to an user-oriented dialogue control and configuration wizards for a simple commissioning. For integration in production plants these common interfaces are already integrated: Ethernet TCP/IP, Profibus DP, Analog 0...20 mA and Serial RS 422. Because of its robust design the application LaseBVC allows a reliable operation even at raw environmental conditions.

Find out more on our product website…

 

Image on top: Overview of the mining area at S11D Complex / © LASE

Successful implementation of heap profile and volume measurement system at ADANI

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Further two reclaimers have been equipped with 3D laser measurement system at ADANI ports in Mundra, India

 

Image: View from the stacker/ reclaimer machine onto the storage area / © LASE

21.07.2016 // Further two reclaimers have been equipped with 3D laser measurement system at ADANI ports in Mundra, India. The system also includes a specific manager application, where a segmentation of multiple piles is shown as well as volume and weight information. A high reusability for further projects was concluded.

The system for heap volume measurement determines information like e.g. volume, 3D profile, peaks by using 3D laser scanners from the LASE 3000D-S-13x Series, which are installed on top of a stacker/reclaimer machine. In total two machines have been equipped with laser scanners at Adani, whereof three piles can be measured simultaneously. The laser data information from both machines are shown within a manager application. Here all different heaps/piles are displayed clearly and a segmentation of the material is possible, too. Due to fulfil specific customer needs, weight measurement data will be also recognized within the manager application.

Depending on the heap-size, one (or more) 3D-laser scanner is installed on a machine for the realisation. This scanner is „looking“ above from the machine on the heap and scans the heap profile. In connection with the current stacker position a 3-dimensional image of the whole heap profile can be developed and compared to a „0-profile“within the application software, which has been taken during the calibration. Out of the obtained data the LASE CEWS application software calculates the profile and the volume of the heap precisely. The current filling level of each single field is transferred to the process control system, which recognises the removal/supply of material automatically.

Increasing numbers of customers need to automate their stackers and reclaimers within the raw material stockyards. In order to drive the machines automatically, it is necessary to know the profile of the piles on both sides of each machine. For this purpose 3D laser measurement technology is the most suitable technology.

Image: LaseBVH software mask and manager application / © LASE

 

The system can be operated intuitively due to user-oriented dialogue control and configuration wizards for simple commissioning. The software analyses the raw data and divides the measured volume into a grid pattern. Then the current filling level of each single field is transferred to the process control system. By this information the process control system recognises the removal/supply of material automatically. Important state messages are logged and clearly displayed for additional documentation purposes. For integration in production plants all common interfaces are available, too.

The application has a high versatility and can be used for volume and profile measurements in several types of bulk material storages. This specific software derives from the product line CEWS Bulk Volume Module.

Find out more on our product site...

LASE receives sub-sequent order for further wagon tipplers in Brazil

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Commissioning of the application LaseRCD for further five dumping lines at this site (Image: Railcar Dumper with mounted 3D laser scanners / © LASE)

22.12.2014 // LASE receives sub-sequent order for further wagon tipplers in Sao Luis, Brazil

In collaboration with our Brazilian distribution partner C+ Tecnologia LASE has received further orders for the fully automated operation of so called wagon tipplers or rotary car dumping stations in Sao Luis, Brazil. Within this order LASE is going to install the proven application LaseRCD (Rotary Car Dumper) for further five dumping lines at this site. Thus the whole loading plant of world’s third biggest mining company VALE is already equipped with 3D measurement systems by LASE on all rail lines.

Iron ore which is mined in the up-country is transported by train to the lading ports at the coast for further shipments and where unloading processes are operated by rotary car dumping stations. In order to achieve the highest degree of automation in this process, not only the use of 3D laser scanners (LASE 3000D Series) but also a software implementation exercises the necessary control functions. Even at the entry of the wagon the LaseRCD-Application measures the wagon profile in order to detect objects or persons. After the following rotation an emptiness control is performed to examine possible remaining material. In case of remaining materials the wagon will be turned again or they can be removed manually. All those measurements are being controlled by the LaseRCD software application. Through synchronisation of the swiveling laser scanners and the rotating wagons as well as using protection housings with air-flushing against the pollution, the 3D laser measurement technology ensures a gapless and fully automated measurement with highest accuracy.

The whole process operation of the LaseRCD-Application can be found online on our product website

Further heap volume measurement system for coal power station at VIZAG

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Two new stacker/reclaimer machines equipped with 3D laser measurement systems by LASE (Image: © LASE)

17.12.2014 // Further heap volume measurement system for coal power station at VIZAG

The corporate group ADANI belongs to one of the biggest power producers in India. For the coal power plant VIZAG two new stacker/reclaimer machines each have been equipped with a 3D laser measurement system by LASE – furthermore ADANI relies on a gapless and continuous detection of heap profiles and heap volumes by the use of laser technology. The measurement system consists of a 3D laser scanner and one processing unit (LASE Control Unit/LCU) where the specific application software LaseBVH for heap profile and heap volume measurements is installed.

The scanner data are transferred to a Master-LCU in the main control station where an image of the whole storage area is summarized and visualized. The measurement system can be operated in two modes in which at Mode 1 a plain measurement drive over the whole storage area is performed. At Mode 2 a permanent scan process during the production will be undertaken. Thus a continuous heap profile and heap volume measurement as well as a permanent inventory are done.

Further applications for measuring yard profiles or yard volumes can be found in our online product overview

LASE 3000D Series

Published in Sensors

The high performance 3D laser scanners from the product range of the LASE 3000D Series are based on the components of a 2D laser scanner and a swiveling platform which is powered by a servo-drive. A high resolution encoder on the servo-drive measures the angle of rotation of the platform and by linkage of the 2D laser data with the Encoder data, high precision 3D profile measurements are produced.

For the terms of operation, the modular LASE CEWS Application software is beeing used. With this, lots of applications for a huge variety of industries can be solved by employing the LASE 3000D Series:

  • Measurement of length, width, height, level and location of objects or environments
  • Positioning of objects
  • Container recognition / measurement in the port
  • Support of crane open-loop controls by goods detection
  • Profile measurement
  • Object protection & building automation
  • Bulk measurement in terms of profile and volume in open cut minings or conveyor belts