Bunker fill level management

Automation for optimized material handling

The bunker fill level management system enables the accurate detection of the bunker level, allowing operators in the central control room to make informed decisions to improve material handling.

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Our offering

The bunker model

  • Minimal deviation from real value
  • Section view of each bunker
  • Maintains even level within each field
  • Coal quality management support
  • Bunker wall is constant and bucket chain (inclination, horizontal position) is a variable parameter
  • Algorithm to estimate the amount of lignite out of reach of the bucket chain

Power supply and electrification

Major mechanical and electrical installations impact the efficiency of a mine. Our engineers ensure that the right technologies and products are used to offer maximum energy savings. Based on decades of experience, we select the correct cable dimensions, and plan the layout for seemless commissioning. Our goal is to reduce your energy consumption, savings that will continue over the life of your plant.


Machines operate in tough conditions, and require instrumentation solutions that are certified to international standards. ABB’s field-proven sensor technology meets those standards and is specifically designed to perform in harsh environments. Our highly accurate sensor technology provides exact measurement values, consistently delivering the right data to the operational system.

Data communication via wireless LAN

  • Sensor values transmitted via Profibus and Parallel I/O. Ethernet data transmission from the reclaimers to the dump house via wireless LAN.
  • OPC data communication to the industrial PC with the bunker model inside the dump house
  • Stable communication link even when a second access point (repeater) is used
  • Data routing via Ethernet connection into the SQL database server of the central control station

Motors and drive systems

A bucket chain excavator is a complex machine with many movable parts, including a boom that has to slew and raise, crawlers to move the excavator forward, and a bucket wheel that turns. All of these movements require motors and drives. Our experts ensure that both of these products are sized correctly to provide the power and control required for the application.

Fire warning, intercom and lighting concepts

With increasing emphasis on safety and environmental issues, large equipment needs more than just automation. That’s why ABB is offering energy efficient light concepts, as well as fire warning and firefighting systems, which can include all equipment (video, radio and speaker systems) on the machine.

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