Using the Elios 3 Drone to Monitor Stockpiles at a Cement Plant
The Elios 3 has revolutionized the way stockpile surveys are conducted, significantly reducing risks and inspection time while improving data accuracy. Here's how it works.
Key Benefits in a Nutshell
|
Safety By using a drone, there’s no need for personnel to climb onto stockpiles with a GNSS rover, eliminating the risk of falls or material collapse. This makes the process much safer for workers. |
Speed The Elios 3 allows for the monitoring of up to 30 stockpiles in just 7–8 flights, completing all data collection in under two hours for large areas. This is far more efficient than traditional methods. |
|
Scalable These stockpile surveys with the Elios 3 are now conducted on a monthly basis, covering piles ranging from a few hundred to over 10,000 cubic meters in size. |
Accuracy With the Elios 3’s LiDAR scans, point clouds and volume calculations can be done in CloudCompare. The measurements are accurate to within a centimeter, far surpassing manual estimations. |
Effective stockpile management is crucial for operational efficiency in industrial plants. Inaccurate measurements can lead to production halts, costly downtime, and logistical headaches. However, measuring these stockpiles traditionally comes with its own set of challenges:
- It can be dangerous for workers to physically access stockpiles with GNSS equipment, risking falls or unstable materials.
- Each site has unique requirements—some need one-time measurements, others regular monitoring, making a standardized approach difficult.
- Efficiency is key; any survey must not interfere with ongoing operations or delay critical tasks.
How Drones Are Transforming Stockpile Monitoring
InspecDrone, a German-based drone service provider founded in 2018 by Simon and Susanne Kumm, specializes in providing safe and precise aerial solutions for industries like cement, metal processing, power generation, and waste-to-energy. Their mission is to enhance safety, reduce costs, and deliver reliable data through drone technology.
A drone can safely inspect stockpiles from a distance
One of their clients operates a cement plant with numerous stockpiles that require frequent measurement. Previously, they relied on visual estimates and manual GNSS surveys, which were both imprecise and risky. They wanted a more reliable solution.
The main objectives were:
- Track stored materials accurately to better plan deliveries and quantities.
- Eliminate the need for workers to walk on top of stockpiles with GPS devices, reducing safety risks.
- Obtain precise and measurable data for consistent reporting.
InspecDrone evaluated several drones and chose the Elios 3 for its high-precision LiDAR and ability to operate in both indoor and outdoor environments, including confined spaces like storage bunkers.
How the Elios 3 Helps Monitor Cement Stockpiles
During the initial visit, InspecDrone assessed the site, which included both indoor and outdoor stockpiles. The Elios 3’s collision-tolerant design allowed it to safely navigate tight spaces without concern for potential damage. This eliminated the need for workers to be on top of the piles, enhancing safety and efficiency.
Accurate volume measurement with the Elios 3
After flying the drone around the stockpiles, the team processed the data in CloudCompare. Due to the unique layout of the storage area, careful post-processing was required to ensure accurate volume calculations. Once completed, the results were shared with the client, who was highly satisfied with the precision and reliability of the data.
Regular Surveys for Ongoing Stockpile Management
Following the success of the first survey, the cement plant requested regular inspections. The Elios 3 proved to be an invaluable tool, allowing InspecDrone to cover 30 stockpiles and bunkers in just 7–8 flights each month. The data provided helped managers plan refills and monitor current stock levels effectively.
LiDAR point clouds provide detailed stockpile models
Additionally, the accurate 3D models created by the Elios 3 allow the plant to identify unused material (dead stock) and calculate available space. This helps optimize storage and prevent overstocking or shortages.
Expanding Drone Applications for Industrial Inspections
The combination of LiDAR and the Elios 3’s robust design has made it a game-changer for stockpile monitoring. It offers greater accuracy than manual methods and ensures safer operations. InspecDrone is now expanding its services to include interior inspections of cement silos, further increasing efficiency and reducing downtime.
The Elios 3 continues to prove its value in industrial settings, offering precise, reliable, and safe solutions for complex environments. As its capabilities evolve, so too will the workflows it enables, opening up new possibilities for real-time data collection and decision-making.
For the most accurate and detailed surveys, the Elios 3’s surveying payload is essential, ensuring that every measurement is as precise as possible.
Carbon Steel Coil,Hot Rolled Steel Plate,Carbon Steel Plate Coil,A36 Carbon Steel Coil
Shandong Great Steel Co.,Ltd , https://www.great-steel.com