Using the Elios 3 Drone to Monitor Stockpiles at a Cement Plant
The Elios 3 has revolutionized stockpile monitoring at a cement plant by reducing risks, saving time, and improving data accuracy. Here's how it works.
Key Benefits at a Glance
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Safety By using the Elios 3 drone, workers no longer need to climb on top of stockpiles with GNSS equipment, significantly reducing the risk of falls or material collapse. This makes the process much safer for everyone involved. |
Speed With just 7–8 flights, the Elios 3 can survey up to 30 different stockpiles in under two hours, making it an incredibly efficient solution for large areas. |
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Scalable These monthly surveys now cover stockpiles ranging from several hundred to over 10,000 cubic meters, showing the flexibility and adaptability of the Elios 3. |
Accuracy The LiDAR technology on the Elios 3 captures detailed point clouds, enabling precise volume calculations in CloudCompare. These measurements are accurate to within a centimeter, far more reliable than manual estimations. |
Effective stockpile management is crucial for the smooth operation of any industrial facility. Inaccurate measurements can lead to production halts, increased costs, and operational delays. However, traditional methods often come with their own set of challenges:
- Manual measurements require workers to climb onto stockpiles, which is both dangerous and time-consuming.
- Each site has unique requirements, making a one-size-fits-all approach difficult.
- Surveys must be quick and efficient to avoid disrupting ongoing operations.
A Safer and Smarter Approach to Stockpile Measurement
InspecDrone, a German-based drone service provider founded in 2018 by Simon and Susanne Kumm, specializes in providing safe and accurate data through aerial solutions. Their clients include cement plants, metal processing facilities, power generation sites, and more. By using drones, they help improve safety, reduce downtime, and provide critical insights that support better decision-making.
Drones allow for safe and remote inspection of stockpiles
One of their clients operates a cement plant where regular stockpile measurements are essential. Previously, they relied on visual estimates and manual GPS surveys, but these were not always reliable. They wanted a more accurate and consistent method of tracking inventory.
The goal was threefold: improve material tracking, eliminate the need for risky manual inspections, and ensure accurate, repeatable measurements. After evaluating several options, InspecDrone chose the Elios 3 for its precision and ability to operate in both indoor and outdoor environments.
How the Elios 3 Helps Monitor Cement Stockpiles
During the initial visit, the team assessed the site, which included both open stockpiles and those stored inside bunkers. The Elios 3’s compact design and collision tolerance made it ideal for flying in tight spaces without worrying about damage. This allowed them to collect all necessary data without requiring workers to walk on top of the piles.
The Elios 3 collects precise data from hard-to-reach areas
After completing the flights, the data was processed in CloudCompare. Despite the complex layout of the storage area, the team was able to generate accurate volume measurements. The results were then shared with the client, who found the data highly useful for planning future orders and managing inventory effectively.
Ongoing Drone Surveys for Consistent Results
Following the success of the first survey, the cement plant requested regular inspections. With the Elios 3, InspecDrone now conducts monthly surveys covering 30 stockpiles and bunkers, some as large as 10,000 cubic meters. Each survey takes only 7–8 flights, significantly reducing the time and effort required compared to traditional methods.
LiDAR point clouds show the exact dimensions of stockpiles
Beyond just measuring volumes, the Elios 3 also helps identify "dead stock"—material that is not being used. This information is crucial for optimizing storage space and planning future operations. The drone’s ability to capture detailed models of the site ensures that managers have a clear picture of what’s available and what needs to be replenished.
Expanding the Use of Drones for Industrial Inspections
The Elios 3’s combination of LiDAR technology and durable design makes it an excellent tool for a wide range of industrial applications. In addition to stockpile monitoring, InspecDrone is now using it to inspect the interiors of silos and other structures, further enhancing safety and efficiency.
As the technology continues to evolve, the potential for new workflows and applications grows. The Elios 3 is proving to be more than just a tool—it’s a game-changer for industries that rely on accurate and timely data. With its growing capabilities, the future looks promising for drone-based solutions in industrial settings.
The most accurate surveys with the Elios 3 are completed using its specialized surveying payload, ensuring that every measurement is precise, reliable, and valuable for decision-making.
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