Volumen³ measuring system on a mobile crusher

VOLUMEN³

The key difference

A belt scale measures through mechanical load on the conveyor belt. Volumen³ measures the volume of the material on the belt without contact. This reduces installation effort, wear, readjustment and operating errors — especially on mobile plants.

Direct comparison

Criterion Traditional belt scale Volumen³
Measuring principle Mechanical weight measurement via rollers, load cells or belt load. Contactless optical volume measurement of the material flow on the conveyor belt.
Installation Often complex. Frequently, a roller section has to be removed from the discharge conveyor or modified. Simple installation above the conveyor belt, usually near the drive drum or above a suitable roller station.
Intervention in the machine Mechanical intervention in the belt construction is required. The discharge conveyor construction remains unchanged. No roller station section has to be removed.
Mobile plants Sensitive to relocation, inclination, movement or non-horizontal setup. Developed for mobile crushing, screening and shredding plants. Angle changes after moving the machine do not require complex recalibration.
Readjustment Often required after moving the machine. Time-consuming in practice. No regular readjustment is required after installation. Only a short adjustment is needed when a new conveyor belt is fitted.
Wear Mechanical components can wear or become contaminated. Contactless sensor technology. No sensor wear caused by material contact.
Dust, rain, snow, light Depending on the system, it can be susceptible to dirt, moisture or difficult ambient conditions. Designed for harsh environments, high humidity, rain, snow, dust and strong light conditions.
Material density Very light or varying material densities can cause measurement issues. Also suitable for low material densities, for example when shredding wood or lightweight materials.
Belt widths Often matched to one specific machine or belt width. One measuring system can be used for different belt widths, up to 1600 mm.
Operation Operation and calibration can require explanation. Clear menu guidance, simple entry of customer, material and operator, plus automatic taring.
Documentation Depends on the system and integration. Daily counter, additional counters, job counter and printouts at adjustable intervals for customers and internal cost allocation.
Flexibility Usually permanently tied to one machine. One evaluation and measuring unit can be used on several prepared machines. Changeover takes only a few minutes.

The main advantages of Volumen³

Contactless and wear-free

The sensor technology measures without mechanical contact with the material. This prevents wear-related measurement errors at the sensor.

Developed for mobile plants

Volumen³ is particularly useful for mobile crushers, shredders and screening plants because relocation and discharge angles are taken into account in practical operation.

One system for multiple machines

If several machines are prepared, the measuring unit can be used wherever it is currently needed.

No complex belt modification

There is no need to remove an entire roller section from the discharge conveyor. The machine remains structurally unchanged.

Fast automatic taring

After switching on the system, taring is selected on the measuring system. The process runs automatically and takes about one minute.

Documentation for customers

Printouts per hour, per day or at freely selectable intervals provide clear proof for customers and internal accounting.

0.1 mm
Measurement resolution
up to 1600 mm
Suitable for wide conveyor belts
approx. 5 min.
Changeover to a prepared machine
approx. 1 min.
Automatic taring

One measuring system for multiple machines

Many operators do not own just one machine, but several mobile machines. For example, machine 1 may be a mobile crusher and machine 2 a mobile shredder. Volumen³ can be prepared so that the measuring system can be used on both machines.

For this purpose, both machines are equipped with the required mounting and connection components. The actual evaluation and measuring unit is only plugged in where it is currently needed.

Preparation per machine

  • 1x frame for the measuring unit
  • 1x mounting plate for the evaluation unit
  • 1x battery connection for the evaluation unit
  • 1x speed sensor for the drive drum
  • 1x cable connection between measuring unit and evaluation unit

Changeover during operation

If the measuring system is needed on the shredder, the evaluation and measuring unit are moved, the connection cable is connected and the speed sensor is plugged in. In practice, this takes only a few minutes.

The measuring system is then switched on and automatic taring is started. After about one minute, the system is ready for measurement.

Installation on the crushing, screening or shredding plant

The frame is mounted on the respective conveyor belt. It is important that the measuring unit is positioned so that the laser hits the belt at a point where the belt cannot lift. In most cases, this is the area around the center of the drive drum axis.

The mounting height is typically around 50 cm. The exact position depends on the machine type, the belt geometry and the available installation space.

  1. Install the speed sensor.
  2. Mount the frame for the measuring unit.
  3. Mount the frame for the evaluation unit.
  4. Connect the measuring unit and the evaluation unit with the connection cable.
  5. Connect the evaluation unit to the power supply.
  6. Connect the measuring system so that it switches on together with the crushing plant.

Workflow during contract crushing

Volumen³ is designed so that the operator has as little additional work as possible in daily operation. The system has one daily counter and two additional counters. One of these counters can be used, for example, as a total counter and the other as a job counter.

  1. The crushing plant is started at the customer’s site. At the same time, the measuring system also starts.
  2. The job counter is set to 0.
  3. Customer, material and operator are entered.
  4. The printer creates standard hourly printouts of the produced quantity.
  5. At the end of the day, the system adds up the hourly values to calculate daily production.
  6. The customer can sign the daily printout or the total printout at the end of the job.

The standard printout is generated hourly. Other intervals can also be set if required, for example minute-by-minute or only once at the end of the day.

Why Volumen³ is especially convincing on mobile plants

Problems with traditional belt scales

  • complex mechanical installation
  • possible need to transport the machine to the workshop
  • removal or modification of a roller section
  • readjustment after moving the machine
  • problems with non-horizontal setup
  • susceptible to dust, dirt and weather conditions
  • measurement deviations due to changes in belt position or inclination
  • operation often requires explanation

Advantages of Volumen³

  • contactless optical measurement
  • no intervention in the conveyor belt construction
  • can be used on several prepared machines
  • developed for harsh environments and mobile plants
  • independent of angle changes in typical operation
  • suitable for concrete, asphalt, wood, compost, household waste and powdery materials
  • simple menu guidance and short operator training
  • printouts and data for customers, accounting and performance documentation

Technical and practical properties

Robust system

The system is designed for dust, moisture, cold, heat and tough operation on mobile plants.

Temperature range

The operating range extends from -25 °C to +60 °C. A heater is provided for winter operation.

IP65 protection class

Dustproof and watertight design for tough use on the conveyor belt.

No belt speed limitation

There are no restrictions regarding belt speed.

Lightweight measuring unit

The measuring unit is compact and can be easily mounted or relocated.

Interfaces available

Interfaces such as Profibus, CANBUS, GPRS or other options are available for connection to downstream processes.

Conclusion: Volumen³ does more than replace a belt scale — it simplifies the entire measuring process.

For operators of mobile crushing, screening and shredding plants, Volumen³ is particularly interesting when several machines are available, machines are moved regularly and reliable production data is required for customers, accounting and internal evaluation. Contactless measurement, simple installation, flexible use on different belt widths and clear documentation make Volumen³ a practical alternative to a traditional belt scale.