Radar Level Meters in Railway Grain Handling and Bulk Material Transport
In modern grain logistics and storage systems, railway freight stations are crucial hubs in the supply chain. Grain unloading from trains, bulk material transport, and storage loading all require extremely high accuracy and reliability in level measurement. Any abnormality in level control can lead to overfilling, equipment idling, or production delays, directly affecting storage efficiency and grain safety.
Shenzhen Jiwei Automations Ltd. (hereinafter “Jiwei”) leverages its advanced measurement and control technology to offer the PRO series radar level meters, delivering high-precision, reliable, and continuous level monitoring even under complex conditions. This article presents the application and performance of Jiwei radar level meters in train unloading, bulk material transport, and storage operations, using Caijia Railway Freight Station, Lishu County, Jilin Province as a case study.
1. Railway Grain Handling Process and Level Measurement Requirements
Caijia Railway Freight Station, located in Caijia Town, Lishu County, Jilin Province, about 500 meters from National Highway 102, is a key grain handling hub in the region. It features dedicated tracks and advanced grain conveying equipment. The main operational process includes train arrival, grain unloading, bulk material transport, storage stacking, and loading for dispatch. The operations can be divided into:
Train Unloading
Upon arrival, trains unload grain into storage or temporary silos via bucket elevators and belt conveyors. The unloading capacity reaches 500–600 tons per hour. Grain flow characteristics vary widely in density, flowability, and moisture content, requiring high-speed, accurate, and interference-resistant level measurement devices.
In-warehouse Transport and Stacking
Grain from the bottom of the silos is transferred via double air-cushion belt conveyors, bucket elevators, and scraper conveyors to temporary storage or top feeders for stacking. Dust, airflow disturbances, and local pile formation are common, demanding anti-adhesion and interference-resistant level devices capable of operating in dusty and particle-prone environments.
Storage Loading
After stacking, grain is loaded into trucks using automatic bulk loaders or weighing scales. Continuous level monitoring is required to prevent overfilling or emptying, ensuring loading efficiency and measurement accuracy.
Critical level measurement points include bucket elevators, scraper conveyors, double air-cushion belt conveyor inlets, storage silos, and loading points.
2. Jiwei PRO Series Radar Level Meter Solution
The Jiwei PRO series radar level meters provide high-precision, stable, and interference-resistant measurement solutions for railway grain handling and bulk material transport. Designed for harsh environments, these meters deliver continuous, high-accuracy level monitoring with rapid response to material changes. Even under high dust, high humidity, or particle vibration conditions, they maintain stable and precise readings. Proprietary algorithms with software copyright further enhance signal processing and measurement reliability.
High-Precision Continuous Level Monitoring
Equipped with 80GHz FMCW continuous-wave radar, narrow beam angle, and zero blind zone, the meters accurately measure granular grain surfaces or low dielectric constant materials such as corn, wheat, and soybeans, providing fast response and continuous monitoring.
Non-contact Measurement Design
Non-contact measurement avoids interference from dust, piling, and particle vibration, reducing wear and extending service life.
Strong Interference Resistance
During unloading and bucket elevator operations, dust, airflow, and particle vibrations occur. The built-in intelligent echo algorithm identifies false echoes and tracks the true material surface to ensure stable, reliable readings.
Durable and Corrosion-Resistant
The fully sealed radar antenna made of PTFE/PPS is resistant to high temperature, abrasion, and corrosion, suitable for dusty and humid environments, ensuring long-term stable operation without frequent maintenance.
Multiple Installation Options and Communication Interfaces
Supports flange, threaded, and bracket installation for various silo structures. Provides 4–20mA and Modbus interfaces, enabling PLC or DCS integration for automatic replenishment, loading control, and remote monitoring.
3. Case Study — Caijia Railway Freight Station (Lishu County, Jilin Province)
The station handles train unloading, bucket elevators, scraper conveyors, top feeders, and automatic truck loading. Specific applications include:
Bucket Elevator Level Monitoring
Radar level meters monitor silos and bucket elevator levels in real time, preventing overfill or empty running.
Scraper Conveyor Level Control
Monitors material levels from the silo bottom to temporary storage or loading points. Integrated with PLC, it enables automatic control, reducing manual intervention and improving system safety.
Continuous Storage Silo Level Monitoring
Meters installed at the silo top provide continuous monitoring of grain pile height. Even under high dust, uneven flow, and tall piles, the radar level meters deliver precise readings, supporting automated distribution and truck loading.
Automated Truck Loading
Radar meters provide continuous feedback for automatic loaders, controlling discharge speed and stopping points to ensure accurate loading while minimizing wasted grain at the silo bottom.
4. Application Results and Customer Feedback
Stable Operation
PRO series radar level meters operate continuously for over six months under high dust, high humidity, and temperature variations without false alarms or signal drift.
Increased Productivity
Automated coordination of bucket elevators, conveyors, and loaders achieves unattended operation, increasing unloading efficiency by 15–20% and reducing labor costs.
Equipment Safety Assurance
Real-time monitoring prevents bucket elevator overloading or idle running, scraper conveyor blockages, and silo overfill incidents.
Reduced Maintenance Costs
Non-contact design and intelligent echo algorithm reduce wear and maintenance, enabling long-term stable operation and lowering inspection frequency.
Support for Smart Management
4–20mA and Modbus outputs allow integration with smart warehouse or industrial control systems, enabling remote monitoring and data visualization for digital management upgrades.
5. Conclusion
At Caijia Railway Freight Station, Jiwei PRO series radar level meters have demonstrated high reliability, precision, and intelligent control in complex dusty, bulk material transport, and storage environments. They provide continuous, stable level data for bucket elevators, scraper conveyors, and storage operations, supporting robust automation.
Jiwei radar level meters replace high-end imported products, achieving leading domestic performance, reducing manual intervention through smart integration, and improving grain handling efficiency and safety. As railway grain logistics moves toward automation and digitalization, Jiwei PRO series radar level meters will continue to provide reliable, durable, and intelligent measurement solutions for the industry.