Synergy Automatics · Industrial IoT
Bunker & Stockpile Level Monitoring
Measure stored coal or ore inventory and detect high-level, low-level and discharge problems.
What this connected-mine application does
Measure stored coal or ore inventory and detect high-level, low-level and discharge problems.
The practical objective is not simply to collect more data. It is to establish a trustworthy measurement chain, detect abnormal conditions, preserve the relevant operating context and route information to the team that can act on it.
- Continuous level and calculated volume
- High-high and low-low level switches
- Fill and discharge rate
- Feeder or gate status
- Temperature and gas where combustion risk exists
- Sensor echo quality or obstruction
| Primary field devices | Radar level transmitter; Point-level switch; Load cells where suitable; Gate and feeder position inputs; Temperature or gas sensors for risk areas |
|---|---|
| Data update pattern | Event-driven alarms with periodic telemetry. Critical events should be timestamped and transmitted immediately where the communications design permits. |
| Connectivity options | Industrial Ethernet, fibre, Wi-Fi, leaky-feeder, LoRaWAN or private LTE/5G as site conditions permit. |
| Alarm and analytics | Alarm on high-high, low-low, abnormal fill/discharge rate, blocked outlet, sensor fault or heating indicator. |
| Common integration | Common interfaces include dry contacts, 4–20 mA, Modbus RTU/TCP, OPC UA, EtherNet/IP, CAN/J1939, MQTT, SNMP or REST APIs where supported by the source equipment. |
| Data continuity | Timestamp at the edge, monitor signal quality and device health, and use store-and-forward buffering so short network outages do not create silent data gaps. |
| Environmental design | Use mine-suitable enclosures, protected cabling and glands, appropriate ingress/impact resistance, and certified equipment wherever the hazardous-area classification requires it. |
A five-layer implementation pattern
Measure
Approved sensors and machine interfaces capture the required physical or operating state.
Control locally
Existing PLCs, protection and safety systems retain their required local authority.
Acquire at edge
A rugged gateway timestamps, buffers, normalises and validates incoming data.
Transmit securely
Mine communications carry telemetry and alarms with health and quality monitoring.
Visualise and integrate
Dashboards, historians and APIs support response, maintenance and reporting.
Where the solution can be applied
- Underground bunker
- Surge bin and crusher feed
- Surface silo
- ROM or covered stockpile
Potential benefits
- Prevention of overfill and starvation
- Improved buffer and production planning
- Earlier indication of hang-up or rat-holing
- Remote inventory visibility
- Safer inspection of difficult vessels
Design details that determine success
- Select measurement technology for dust and irregular surfaces
- Validate vessel geometry and material angle of repose
- Provide independent high-high protection where required
- Avoid relying on a single level signal for personnel entry
Alarm on high-high, low-low, abnormal fill/discharge rate, blocked outlet, sensor fault or heating indicator. Dashboard alerts, remote notifications and analytics should complement—not replace—certified protection, local interlocks, emergency procedures, statutory inspections and competent decision-making.
Continue exploring the connected mine
Implementation questions
Can Bunker & Stockpile Level Monitoring connect to existing PLC, SCADA or mine systems?
Usually, yes. The preferred approach is to reuse approved source data and add isolated field instrumentation only where required. The final interface depends on available protocols, network segregation, data ownership and the source equipment vendor.
Does the IoT layer replace local protection or safety controls?
No. Protection relays, safety PLCs, emergency stops, gas trips, fire systems and other approved local functions remain the primary safety and control layer. IoT adds visibility, history, notifications and decision support.
What happens when underground communications are interrupted?
Critical local functions continue independently. A suitable edge gateway buffers timestamped data, raises a communications-health alarm and forwards retained records after the connection returns.
How are sensors and alarm levels selected?
Selection starts with the mine risk assessment, required decision, environmental classification, measuring range, response time, maintainability and applicable rules. Alarm and trip levels must be approved for the specific site and jurisdiction.
Discuss Bunker & Stockpile Level Monitoring
Discuss field instrumentation, edge connectivity, dashboards and integration with the Synergy Automatics team.
Engineering note: Instrument selection, hazardous-area certification, alarm limits, interlocks and network architecture must be validated against the mine risk assessment, applicable legislation, equipment approvals and site operating procedures.