When the fill level is correct, but the mass is not: gravimetric measurement with MicroCell
Everywhere bulk materials are stored, the following applies: The decisive factor is rarely the pure fill level – but rather the actual mass in the silo.
Nevertheless, measurements are often taken without contact, for example via radar, microwave, or ultrasound. These methods reliably determine the fill level. However, they say little about the actual weight of the contents.
And it is precisely from this that problems arise in everyday life.
Precise loading of trucks.
Why non-contact level measurement reaches its limits
Depending on the stored material, core flow can occur in the silo, with the material then moving only in the area of the outlet opening.
The result is bridge or chimney formation, leading to incorrect measurements. In extreme cases, this can lead to unnoticed emptying or overflowing of the silo.
Where mass is important, non-contact level measurement is often fraught with uncertainties.
The Alternative: Measure the Mass Directly
A simple, cost-optimized, and reliable solution is provided by gravimetric level measurement with MicroCells from REMBE® Kersting.
Instead of estimating the level, the mass is directly recorded: During filling and emptying, compressions, expansions, and shears occur in the silo structure. The MicroCells capture these deformations via integrated measuring strips and transmit them to the active measuring transducer ADAM, which calculates and displays the mass of the silo contents; via a (0)4–20 mA output signal and a robust stainless steel field housing also suitable for harsh environments.
Retrofit without downtime.
A common reservation about new measurement technology is the installation effort. Here, the system shows a particular strength.
The MicroCells are simply mounted externally on the supports of the silo, without emptying, rebuilding, or interrupting the operation of the silo.
The customer also handles the calibration themselves: The zero point is set during the next emptying, and a known mass is applied. From the change in tension in the material, the system determines the rest and then reliably measures the weight of the contents. The system operates maintenance-free and, thanks to temperature-compensated sensors, is operationally reliable.
More than fill level: precise loading
The same technique also helps where exact quantities are crucial – for example, when loading trucks.
If too little is loaded, additional trips and time loss occur. If too much is loaded, there is a risk of overloading and hazards, such as a safety risk for people in the truck's operating area. And multiple trips to the scale cost additional time.
The Microcell control can be integrated with the existing dosing control, allowing for automated loading alongside manual loading without any issues. Individually adapted, it is easy for the driver to operate without multiple re-weighings. This saves time, reduces errors, and increases process safety.
Conclusion: keeping an eye on the mass, without reconstruction
Where contactless level measurement does not deliver the desired results, gravimetric measurement with MicroCells is a simple and reliable alternative.
It can be retrofitted without downtime, operates maintenance-free, and provides exactly the information that matters: the actual mass.
Do you know how much is actually in your silos – or just what the fill level is?
Especially where core flow or bridging occurs, it is worth looking at the mass.
