Smart radar-based level monitoring and control for crushers and conveyor belts

Micropilot FMR20B radar sensor provides reliable, non‑contact 80 GHz level measurement on conveyor belts and at crusher inlets, even under extreme dust, vibration and dynamic material flow conditions. Combined with FlexView FMA90 control unit, measured values are visualized in real time and continuously monitored against predefined limits. Configurable alarm functions enable early detection of overloads and blockages, supporting reliable operation and protecting conveyor belts and crushers.

With Micropilot FMR20B radar sensor and FlexView FMA90 control unit, operators gain full transparency over conveyor belt and crusher processes in real time. The combination of focused 80 GHz radar technology, intuitive visualization and intelligent limit‑based control enables early intervention before overloads or blockages occur. This reduces manual intervention, avoids unplanned shutdowns and safeguards valuable equipment. The result is higher plant availability, optimized throughput and long‑term operational reliability in demanding bulk material handling applications.

Material handling processes involving conveyor belts and crushers are exposed to particularly demanding operating conditions. At crusher inlets, large rocks cause impact loads and strong vibration, while heavy dust loads place additional stress on measurement technology. Limited installation space further complicates reliable measurements at these measurement points. On conveyor belts, bulk material height and belt load can fluctuate rapidly due to changing feed rates and varying materials. In outdoor installations, additional influences such as dust, wind or rain further increase process complexity. If overloads or blockages are detected too late, materials can back up and cause belt damage or crusher overloads. To avoid such unsafe operating conditions, operators require reliable monitoring and control of conveyor belts and crushers.

A simple start to smarter control is achieved by combining reliable radar level measurement with intelligent visualization and control. Micropilot FMR20B delivers continuous, non‑contact level measurement at crusher inlets and on conveyor belts. Thanks to focused 80 GHz radar technology, measurements remain stable and precise even under conditions of heavy dust, strong vibration, impact loads and fast‑changing material surfaces. The radar level sensor operates independently of grain size and material distribution, providing reliable measurements under these harsh material handling conditions.

The measured values are transmitted to FlexView FMA90, which serves as the central visualization and control unit. FlexView FMA90 enhances your sensors and brings every insight into clear view by displaying real-time level values and trend curves on the intuitive 3.5-inch color touchscreen or via remote access. In addition to visualization, FlexView FMA90 provides smart, limit-based control. Radar level measurement values are continuously evaluated against predefined thresholds. When critical limits are reached, integrated switching outputs automatically generate alarms, interlocks or control actions. Conveyor belt speed can be reduced or stopped to prevent crusher overloads or conveyor belt damage, stabilizing the overall material flow and protecting downstream equipment. Guided setup sequences, as well as automatic sensor detection and configuration via HART, significantly reduce commissioning effort. The solution supports intuitive operation and parameter adjustment, even in difficult installation environments.