Enhancing Safety in Grain Processing with Radar Level Measurement— Application of Jiwei Radar Level Transmitters in Grain Bins and Silos
Background
In the grain processing industry, safe and efficient material handling is a critical foundation for continuous and stable operation. Whether in grain bins or tall silos, level information directly affects loading and unloading efficiency, inventory accuracy, and, more importantly, personnel safety and long-term equipment reliability.
In a grain processing project, Jiwei radar level transmitters were introduced to provide continuous and stable online level measurement in grain bins and silos. By integrating real-time level data into the control system, the solution supports filling control, inventory monitoring, and high-level alarms, significantly improving overall automation and operational safety.
Previous Level Measurement Methods
Before the installation of radar level transmitters, the site mainly relied on manual methods to determine material levels. Operators were required to regularly climb to the top of grain bins or silos and visually estimate the level or use simple measuring tools.
In some locations, mechanical level switches were also used for high-level alarms. However, in actual operation, these methods exposed several limitations:
- Frequent climbing for manual measurement posed clear safety risks
- Mechanical switches were easily affected by dust and material buildup, reducing reliability
- Maintenance and cleaning requirements were high, impacting production continuity
Under high-dust and frequent loading conditions typical of grain processing, these traditional methods could no longer meet modern requirements for safety and efficiency.
A More Suitable Solution: Jiwei Radar Level Transmitters
To improve site conditions, Jiwei radar level transmitters were selected for continuous level measurement in both grain bins and silos.
The radar level transmitter operates based on non-contact millimeter-wave radar technology. It emits high-frequency electromagnetic waves and calculates the distance to the material surface by analyzing the reflected echo, providing real-time and stable level data.
This measurement principle offers several key advantages:
- Non-contact measurement eliminates wear, material buildup, and adhesion, making it suitable for long-term continuous operation
- Measurement is independent of the material’s dielectric constant, ensuring stable performance across different grain types and moisture variations
- Reliable operation in high-dust environments, unaffected by dust generated during filling and emptying
In addition to these measurement advantages, Jiwei radar level transmitters provide comprehensive software and communication capabilities:
- Core measurement and signal processing software is independently developed and continuously optimized for bulk solid applications
- RS-485 output is supported, enabling direct integration into existing control systems
- The “Jiwei Smart Control®” WeChat mini program and mobile APP enable true Bluetooth direct connection, allowing parameter configuration and status monitoring without additional gateways
- One-click remote firmware upgrades ensure access to the latest algorithms and functions throughout the device lifecycle
- Jiwei engineers can assist with remote commissioning, optimizing parameters based on silo structure, material characteristics, and operating conditions to achieve the best possible measurement performance
By combining robust hardware with flexible and intelligent software, Jiwei radar level transmitters provide a long-term, reliable, and continuously optimized level measurement solution for grain bins and silos.
Cost-Effective and Flexible Radar Level Solutions
Jiwei radar level transmitters are available in multiple measuring ranges and installation options to match different silo heights, structures, and application requirements. They are suitable for both small and medium-sized flat-bottom grain bins as well as tall silos with large storage heights. Flexible configurations of measuring range, antenna design, and process connection enable standardized selection across different grain storage scenarios.
The compact and lightweight design allows direct installation on silo roofs using flanges, threaded connections, or existing mounting openings. No additional support structures or silo modifications are required, reducing installation complexity and cost. Even existing silos that have been in service for many years can be easily retrofitted.
For commissioning and operation, the radar transmitters support remote parameter configuration and online adjustment. Using the Jiwei Smart Control® app or mini program via Bluetooth, operators can complete basic setup, range configuration, and signal verification from ground level, minimizing the need for repeated climbing.
This approach simplifies commissioning, shortens the time from installation to operation, and allows convenient parameter optimization as operating conditions change, ensuring long-term stable measurement performance.
Installation and Commissioning
During project implementation, Jiwei radar level transmitters were installed on the tops of grain bins and silos, measuring vertically toward the material surface. This installation method concentrates radar energy on the main material accumulation area and minimizes signal interference caused by installation angle deviations.
With a narrow beam angle design, the radar measurement zone is well defined, effectively avoiding interference echoes from silo walls, reinforcements, tie rods, and inlet structures. During filling and discharge, even with rapid material movement, heavy dust generation, and fluctuating material surfaces, the radar transmitters consistently identify the true material level without signal instability.
Commissioning required only basic parameter configuration such as measuring range and output settings. No complex echo learning or repeated calibration was necessary, allowing operators to quickly put the instruments into service and significantly reducing project implementation time.
Stable Performance in Actual Operation
In long-term operation, Jiwei radar level transmitters demonstrated strong adaptability and stable performance:
- During filling and emptying, even with rapid level changes, output signals remained continuous and stable without noticeable fluctuation
- Under high-dust conditions, especially during material transfer and loading, the radar measurement did not lose signal or generate false readings
- After several months of operation, grain dust accumulated on the antenna surface; however, measurement results remained stable and unaffected
This performance is enabled by Jiwei’s intelligent signal processing software, which effectively distinguishes true material echoes from dust and buildup-related reflections, automatically suppressing invalid signals to maintain reliable long-term measurement.
The stable level data is integrated into the control system for filling control, inventory monitoring, and high-level alarms, significantly reducing manual inspection and intervention while enhancing safety and operational efficiency.
Conclusion
In the grain processing industry, level measurement is not merely an instrumentation choice but a key factor influencing safety, efficiency, and automation. Long-term measurement stability and reliability directly determine the effectiveness of filling control, inventory management, and safety systems.
With robust hardware design, mature signal processing algorithms, and strong adaptability to on-site conditions, Jiwei radar level transmitters provide a safe, low-maintenance, and long-term stable level measurement solution for grain bins and silos, supporting the continued automation upgrade of grain processing facilities.