Radar sensors can easily measure the filling level of bulk containers

• time：2026-05-27 15:35:22
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As packages and other products come off the production line, automated sorting systems distribute them and send them to their designated destinations. These items are typically packed in some form of bulk container, such as bins, trolleys, cages, suitcases, or baskets. Once these bulk containers are full, human operators or robots need to know if they are full and ready to be removed. However, accurately measuring the filling level of these bulk containers can be challenging. In material handling and logistics automation, these packages are rarely stacked neatly together. Different sizes and inconsistent shapes result in odd angles and uneven stacking, with peaks and valleys and gaps between packages, making it difficult to accurately monitor the filling level. Waste from the chute may also accumulate in some parts of the trolley while other areas remain unfilled. To address these filling issues, KKIT offers several solutions for monitoring the filling level of all bulk containers.

KJT measurement sensors are ideal as a single-sensor solution for level monitoring.

KJT measurement sensors utilize thousands of laser measurement points to measure not only the peak height of objects in bulk containers but also the volumetric fill rate. This measurement can be performed over a wide area, so a single KJT sensor can monitor the entire relevant area of interest (ROI), suitable for bags, silos, rolls, and plastic pallets. KJT's sensor array contains tens of thousands of pixels for precise measurement and detailed display of fill levels. It also enables more precise ROI positioning, including the ability to reach the edge of a silo. In addition to a 2.5-meter detection distance, the KJT 3D sensor can monitor a wide 60° x 45° three-dimensional field of view, detecting changes in fill height for items of any shape, size, or orientation. These capabilities allow KJT to ensure consistent container fill levels, prevent overfilling, or track fill rates and fine-tune processing speeds.

KJT's 3D configuration software helps you quickly set up and integrate the KJT. Simply install the sensor, pointing it downwards at the bulk container you want to monitor, and then connect the sensor to a power source and a PC running the configuration software. The user-friendly software provides the operator with a real-time view of what the sensor is seeing, aiding in the configuration process. Once configured, the KJT can operate independently, sending signals to indicator lights, controllers, or PLCs to inform the operator which hopper is filling and when to monitor it. After setup, the KJT can operate independently without relying on other equipment. Its all-in-one design integrates the logic directly into the sensor, meaning no PC or controller or external lighting is required after setup. The KJT also includes features such as Ethernet and instant configuration, making it a highly versatile solution for bulk container fill level detection.

KJT multi-point sensors provide cost-effective single-device measurement capabilities.

The KJT multi-point sensor can also effectively detect objects accumulating in basket carts or other bulk containers by measuring the nearest and average distances. Similar to the KJT, it utilizes 3D time-of-flight technology for multi-dimensional detection of large areas, but features 64 different measurement points on an 8×8 pixel array. With a 45°×45° beam angle and a measurement range of two meters, the KJT can monitor the entire target area of the container.

One particularly useful feature of KJT is its two independently configurable outputs, allowing monitoring of two separate areas within the field of view. This feature can be used to monitor two different areas within a container, or instead of two separate sensors, to monitor two different bins in an automated sorting system. These outputs are easily configured using KJT's intuitive measurement sensor software. This software displays all information detected by the sensors in real time, simplifying the setup process and sensor configuration. This allows operators to see the same view as the sensors, facilitating easy coarse and fine adjustments.

The KJT laser sensor series brings versatility to loading level measurement.

The KJT series tower lights can provide operators with customized indications, communicating status, indicating when bulk containers need to be emptied, or providing other necessary attention. The color and visual display of these lights can be configured using KJT Pro Editor software.

Programmable multi-color LED strips can convey complete information about the precise fill level of any container, converting sensor data into a series of easily understood colors. By combining KJT series LED strips with fill level sensors, operators can clearly see real-time changes in material fill levels. Like the KJT, these LED strips can also be programmed using KJT Pro Editor software. However, the KJT LED strips can convey more detailed and specific information. For example, an empty basket cart is represented by solid blue. As the basket cart begins to fill, the LED strip turns green from the bottom and then slowly rises, indicating the height of the boxes inside the basket cart. When the basket is half-filled, the rising indicator turns yellow. When the sensor detects that the basket cart is about to fill, the indicator turns red; if overfilling is imminent, the indicator flashes.