Innovative Sensing Solutions for Dusty, Long-Distance Industrial Challenges

When it comes to challenging sensing applications, industrial environments like outdoor sawdust bins can push technology to its limits. At Ramco Innovations, we thrive on solving these complex scenarios, and our Kansas City office recently delivered a standout solution with the expertise of Doug Lybarger.

The Challenge

Sensing the level of sawdust in a 60-foot bin posed several challenges:

Dusty Environment: The high concentration of dust reduced visibility and created harsh conditions for standard sensors.

Outdoor Exposure: The sensor needed to withstand outdoor elements, including fluctuating temperatures and moisture.

Long Sensing Distance: Measuring accurately across 60 feet required a solution that could perform consistently over long distances.


The Solution

Doug designed a system combining Banner Engineering’s T30R-1515-KIQ Radar Sensor with the WLS27 Pro Series Programmable LED Strip Light, delivering reliable sensing and clear indication. 

  1. Banner T30R-1515-KIQ Radar Sensor: 

  1. This rugged radar sensor excels in harsh, dusty environments and long-range applications. 

  1. With a sensing range of up to 15 meters (49 feet), it was ideal for gauging sawdust levels. 

  1. The 4-20 mA analog output and IO-Link capabilities enabled seamless integration with the system for real-time monitoring and control. 

  1. WLS27 Pro-Series Programmable LED Strip Light: 

  1. Designed for industrial use, this LED strip light offered both indication and illumination in one package. 

  1. Using Banner’s Pro Editor software, Doug programmed the light to visually indicate the bin’s sawdust level with high-visibility animations and color changes. 

  1. Its sealed, chemical-resistant housing ensured durability in the outdoor environment, while its smooth glow provided clear status updates even at a distance. 

The Outcome:

This innovative pairing provided the customer with:

Reliable Performance: The T30R Radar Sensor delivered accurate readings, unaffected by dust or outdoor conditions.

Enhanced Visibility: The WLS27 Pro-Series LED light offered easy-to-read bin-level indication, reducing operator guesswork.

Streamlined Operations: The system simplified monitoring and improved efficiency by combining sensing and indication in a durable, low-maintenance solution.

Why It Matters:

This project showcases the versatility and power of Banner’s sensors and LED lights in addressing real-world industrial challenges. By combining advanced technology with expert application engineering, Ramco Innovations continues to deliver solutions that improve safety, efficiency, and process reliability for our customers.