PrecisionFill
Automated Bulk Material Filling
Load faster, fill more evenly, and reduce dependence on operator skill.
Radar-guided material placement that measures the surface as it builds, finds the available space, and steers the fill automatically — in the dust and darkness where optical sensors fail completely.
Grain carts & truck loading · Coal, ore and aggregate
Adapts to different materials, receiving containers and equipment
At a glance
The short version.
PrecisionFill is a radar-guided automated filling system for bulk material. Zadar imaging radar measures the material surface in real time, finds the available space in the container and automatically steers the equipment's loading controls toward a target fill profile.
- Measures
- Material surface, flow and fill level in real time
- Controls
- Fill location, through the equipment's loading controls
- Fill strategy
- Toward a defined profile, with predictive slow-down and stop
- Works in
- Heavy dust, dirt and darkness
- Materials
- Grain, coal, ore and aggregates
- Equipment
- Grain carts, truck loading and bulk handling systems
- Integration
- Configured per application with OEMs and integrators
How it works
Intelligently fill containers with bulk material in real time.
PrecisionFill combines Zadar's imaging radar technology with radar-based flow and fill level measurement algorithms to monitor the material surface, identify available space, and adjust fill location automatically toward the desired fill profile.
As material accumulates, the system updates its measurements and automatically guides the equipment's loading controls. Radar provides surface information in dusty, dirty, and dark environments where cameras and optical sensors fail completely.
See the sensors behind itBenefits
Load material faster and reduce loss, without experienced operators.
Reduce Operator Workload
Automate the spout-pointing process that otherwise requires high operator attention and skill.
Shorten Loading Times
Reduce manual interruptions and load at maximum flow rates without error.
Improve Fill Evenness
Direct material toward available space and eliminate uneven surfaces.
Use Available Capacity Completely
Fill toward a defined profile while reducing the risk of spillage and overfilling.
Reduce Loss
A predictive filling algorithm slows and stops filling, keeping filled material inside target zones.
Reliable in Poor Conditions
Radar technology works even in highly dusty or visually obscured environments.
See it work
Radar that reads a surface.
Zadar imaging radar detecting and identifying surfaces in real time, the same kind of measurement PrecisionFill uses to see a material surface through dust.
Surface detection with Zadar imaging radar. More on Zadar's YouTube channel.
Radar vs. camera vs. LiDAR
Why automated filling should run on radar.
The moment material starts flowing, the air fills with dust. Here is how the sensing technologies compare when you need to see a material surface you cannot see by eye.
| Condition | Zadar 4D imaging radar | Camera | LiDAR |
|---|---|---|---|
| Darkness | Unaffected. Radar sends its own signal and needs no ambient light. | Needs light or infrared illumination. | Unaffected. Uses its own laser. |
| Dust, smoke and fog | Sees through airborne particles. | Degraded or blinded. | Light scatters off particles; degraded. |
| Rain and snow | Minimal effect. | Degraded by droplets on the lens and in the air. | Degraded by returns from droplets and flakes. |
| Glare and direct sun | Unaffected. | Can be blinded. | Can add noise in strong sunlight. |
| Dirt on the sensor | Tolerant. Works behind a radome. | A dirty lens blocks the view. | A dirty window blocks the view. |
| Speed of objects | Measured directly for every point (Doppler). | Estimated across frames. | Usually estimated across frames. |
| Privacy | No identifiable images. | Captures faces and plates. | No identifiable images. |
| Resolution | Lower than LiDAR; Zadar imaging radar narrows the gap with sub-degree angular resolution. | Highest detail in good conditions. | High. |
Radar is not a replacement for every sensor. Many deployments pair it with cameras: radar keeps working when the camera cannot, and the camera adds visual detail when conditions allow.
FAQ
Questions buyers ask.
What is PrecisionFill?
PrecisionFill is a radar-guided automated filling system for bulk material. Zadar imaging radar measures the material surface in real time, identifies available space and automatically guides the equipment's loading controls toward a target fill profile.
How does radar-guided filling work?
PrecisionFill combines Zadar imaging radar with radar-based flow and fill level measurement algorithms. It monitors the material surface, finds the available space and adjusts the fill location toward the desired profile. As material accumulates, the system updates its measurements and keeps guiding the loading controls.
Which materials and equipment does PrecisionFill support?
PrecisionFill can be adapted to grain carts and truck loading as well as coal, ore and aggregate handling. Zadar configures the surface measurement, filling strategy and machine connection for each material, container and machine.
Why use radar instead of cameras or laser sensors?
Filling generates heavy dust, and loading often happens in dirty or dark conditions. Radar keeps measuring the material surface where cameras and optical sensors fail completely.
Does PrecisionFill prevent spillage and overfilling?
PrecisionFill fills toward a defined profile, and its predictive filling algorithm slows and stops the flow to keep material within the target zones, which reduces the risk of spillage and overfilling.
Can PrecisionFill be integrated into our existing equipment?
Yes. Zadar works with equipment manufacturers and integrators on a customized basis to connect PrecisionFill to machine controls. Contact our team to scope your application.
Get started
Bring automated filling to your system.
From grain carts and truck loading to coal, ore, and aggregate handling, PrecisionFill's sensing and control approach can be adapted to different materials, receiving containers, and equipment.
Zadar works with equipment manufacturers and integrators to configure the surface measurement, filling strategy, and connection to machine controls for each application on a customized basis.