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Breaking Boundaries: Innovating Cement Silo Load Monitoring for Enhanced Efficiency

“Sanlien's innovative instrumentation solution has revolutionized Yatung Ready-Mixed Concrete Corp.'s operations, ensuring precise inventory management and excellence in concrete production."

The Yatung Ready-Mixed Concrete Corp. Project Team

Introduction

Background:

Yatung Ready-Mixed Concrete Corp. emerged as a significant player in the ready-mixed concrete industry within Taiwan. Originally established as a business division under Asia Cement Corporation, Yatung Ready-Mixed Concrete Corp. took shape in August 1999 in response to the burgeoning demand for ready-mixed concrete services. Since its inception, the company has exhibited sustained growth, continually enlarging its operational footprint and service capabilities across the region.

Challenge: 

Yatung Ready-Mixed Concrete Corp. encountered a significant challenge stemming from its traditional method of measuring cement inventory within the silos. The reliance on the conventional approach of the traditional hanging rope method posed several limitations and drawbacks. This method, characterized by its manual and labor-intensive nature, lacked precision and real-time monitoring capabilities. As a result, Yatung faced difficulties in accurately assessing the quantity of cement remaining in the silos, leading to inefficiencies in inventory management and potential disruptions in production processes. The inherent shortcomings of the traditional measurement method underscored the pressing need for a modernized and technologically advanced solution to address the evolving demands of the ready-mixed concrete industry.

Industiral Cement Silo Load Monitoring_Sanlien

Solution:

To address the challenges posed by the traditional hanging rope method, Sanlien Technology proposed a state-of-the-art solution utilizing automated load monitoring technology.

In the Automated Load Monitoring Method introduced by Sanlien Technology, the key principle lies in the strain experienced by the silo supports (base columns) as they bear the weight of the stored raw materials. According to structural mechanics, this strain can be quantified by measuring the displacement or deformation of the supports, which directly correlates with the applied load.

The formula for calculating the load is as follows:

Load = Strain × Young’s Modulus of Steel × Cross-Sectional Area of the Supports

 

Image depicting industrial cement silo load monitoring using strain gauge measurement technology

By measuring the strain using VW spot weldable strain gauges and recording it with VWdot4 vibrating wire data loggers, Sanlien’s solution enables precise determination of the weight of the materials stored in the silos. This real-time data is then transmitted to Yatung Ready-Mixed Concrete Corp. through the dot cloud platform, providing them with accurate and up-to-date information for efficient inventory management and production planning.

This integration of advanced instrumentation not only enhances the accuracy of load monitoring but also streamlines the operational processes of Yatung Ready-Mixed Concrete Corp., ensuring optimal performance and productivity in their concrete production activities.

Image showing a VW Spot Weldable Strain Gauge equipped with a datalogger for precise loading monitoring

Challenge:

During the monitoring process, a significant challenge arose due to the phenomenon of thermal expansion and contraction affecting the strain measurements in the silos. As temperatures fluctuated, the silos underwent thermal expansion or contraction, leading to additional strain readings unrelated to the actual load. This phenomenon introduced inaccuracies in the load monitoring system, potentially compromising the precision of inventory management and production planning.

Solution:

In response to the challenge posed by thermal expansion and contraction, a meticulous approach was adopted to incorporate temperature correction into the load monitoring system. The solution involved the implementation of a temperature expansion coefficient correction methodology to adjust the strain measurements accordingly.

Using regression analysis techniques, the relationship between temperature fluctuations and strain readings was established over a period of 2-3 months. This analysis enabled the derivation of an accurate expansion coefficient representing the thermal response of the silos. Subsequently, the corrected weight of the materials stored in the silos was calculated, ensuring accurate inventory management despite environmental influences.

Conclusion and Looking Forward:

In summary, the adoption of Sanlien Technology’s automated load monitoring solution has transformed Yatung Ready-Mixed Concrete Corp.’s operations. By replacing outdated methods with advanced instrumentation and real-time data monitoring, the company has achieved precise inventory management and streamlined production processes. Overcoming challenges such as thermal expansion, this solution has positioned Yatung Ready-Mixed Concrete Corp. as a leader in technological innovation within the industry. Moving forward, these advancements promise continued efficiency, sustainability, and competitiveness in the concrete sector.

Industrial cement storage silo with load monitoring equipment connected to Dot Cloud for real-time data analysis.