Overview: Drivers, Challenges, and Core Role of LiDAR in Bulk Material Automation

Automation in bulk material handling (e.g., ports, mines, power plants) is a key driver for improving operational efficiency, enhancing safety, and reducing costs. The pursuit of economic benefits, increasingly strict safety regulations, and the need for 24/7 stable operations collectively propel the industry toward automation and intelligence. However, bulk material handling environments are extremely harsh, presenting severe challenges: pervasive dust, wet or even water mist/steam conditions, intense equipment vibrations, extreme temperatures, complex heavy machinery coordination, and dynamic operational scenarios all impose stringent requirements on the sensing capabilities of automation systems.

Against this backdrop, LiDAR (Light Detection and Ranging) technology has emerged as one of the core sensing technologies for bulk material handling automation, leveraging its ability to provide precise, high-density 3D spatial perception data. LiDAR offers critical environmental geometric information for automation systems, enabling core functions such as obstacle detection, equipment positioning, environmental mapping, and material volume calculation—far beyond the capabilities of simple presence-detection sensors. Particularly, the advent of high-resolution 3D LiDAR has overcome the limitations of traditional sensing solutions (e.g., 2D LiDAR, radar, vision sensors), making high-precision, reliable automation in complex, dynamic, and harsh environments a reality. Automation is not just about replacing human labor; it aims to achieve operational precision, stability, and safety levels unattainable by manual operations, especially in environments posing potential risks to personnel. LiDAR赋予machines the ability to reliably "see" and understand their surroundings, forming the foundation for advanced automation goals.

Key Application Scenario: Large Equipment Collision Avoidance Systems

(Applicable to: Port Cranes RTG/RMG/STS, Stockyard Reclaimers, Ship Loaders/Unloaders, AGVs)

Application Requirements

In busy bulk material handling areas, large equipment such as cranes, stockyard reclaimers, ship loaders/unloaders, and automated guided vehicles (AGVs) operate simultaneously. Preventing collisions between these assets is critical. Additionally, the system must avoid collisions between key equipment components (e.g., crane booms, grapples) and fixed structures (e.g., ship hulls, silo walls) or stockpiles, while ensuring safe distances from on-site personnel or smaller vehicles. A precise and reliable collision avoidance system is fundamental to safeguarding personnel, reducing equipment damage, and maintaining operational continuity.

Typical Deployment and Architecture

Sensors are typically installed at critical positions on large equipment, such as the trolley/carriage mechanisms, booms, and portal legs of cranes; the cantilevers or fuselages of stockyard reclaimers; and the perimeters of AGVs’ chassis, providing 360° omnidirectional or directional detection coverage. Raw point cloud data or processed target information collected by the sensors is transmitted in real time to a programmable logic controller (PLC) or dedicated safety control unit. These control units issue commands to the equipment’s main control system based on pre-set safety logic and distance thresholds, triggering actions such as deceleration, stop, or alarms. Tight integration between sensors and equipment control systems is key to effective collision avoidance.

Traditional Solutions and Pain Points

- 2D LiDAR (e.g., SICK LMS/LRS series): Commonly used for planar obstacle detection. Limitations include detecting only objects within the sensor’s scanning plane, failing to identify aerial obstacles (e.g., booms), low-lying ground objects (e.g., misplaced tools), or irregularly shaped objects partially outside the plane. Multiple 2D LiDARs are often required for broader coverage, increasing wiring, integration, and maintenance complexity. Performance may degrade in adverse weather (rain, fog, dust).

- 2D LiDAR + Pan-Tilt Unit (PTU): Attempts to acquire 3D data via mechanical rotation/pitching of 2D LiDAR. This introduces additional moving parts (PTU), significantly reducing system reliability, increasing failure points, and maintenance needs. Slow mechanical scanning speeds struggle to meet real-time collision avoidance requirements for fast-moving equipment or dynamic environments. Calibration between LiDAR and PTU is complex and may drift over time, affecting measurement accuracy.

- Radar: Advantages include good penetration in harsh weather (rain, fog, dust). However, inherent angular and range resolution are typically lower than LiDAR, making it difficult to precisely identify object shapes, distinguish adjacent targets, or detect small obstacles. Signal interference may occur in dense multi-equipment environments.

- Ultrasonic Sensors: Limited detection range (typically for short-distance collision avoidance) and susceptible to environmental factors like wind and temperature changes.

- Vision Sensors (Cameras): Provide rich scene information under good lighting but degrade sharply in low-light, nighttime, strong light/glare, dust, rain, or fog. Cameras cannot directly measure distances precisely, relying on complex algorithms for depth estimation with uncertain reliability.

- 1550nm LiDAR: Promoted for longer detection range and higher eye-safety power thresholds. Core pain points: 1) High cost due to InGaAs detectors and special lasers, far exceeding 865/905nm silicon-based LiDAR; 2) Higher water vapor absorption than 865/905nm, leading to severe performance degradation in fog, high humidity, or steam; 3) May require higher drive power; 4) Potential anti-interference issues in some designs.

- TripleIn VMS/PS/RT: An existing solution provider using PS series 2D scanners with RT360 rotating platforms (essentially a sophisticated 2D+PTU scheme). While PS sensors offer long detection range (up to 350m), the system inherits inherent limitations of 2D+PTU in scanning speed, mechanical reliability, and complexity, potentially inferior to native 3D rotating LiDAR. Details of KEM patented technology are unclear.

Performance Requirements

Collision avoidance systems demand strict sensor specifications:

- Sufficient detection range (tens to hundreds of meters, depending on equipment size and speed) for adequate reaction time;

- Wide field of view (FoV) for comprehensive monitoring;

- High data update rate (frame rate) to capture dynamic changes;

- Sufficient resolution and accuracy to identify obstacle dimensions and positions;

- Extremely high reliability (MTTF) for continuous safety protection;

- Strong adaptability to harsh environments (high IP protection, wide temperature range, shock/vibration resistance) and anti-interference capabilities.

Ouster 3D Digital LiDAR Replacement Benefits

- Omnidirectional 3D Coverage: Single or few Ouster 3D LiDARs provide high-density 3D point clouds, effectively covering complex geometries and eliminating vertical blind spots of 2D LiDAR. For example, OS0 (90° VFoV), OS1 (45° VFoV), and especially OSDome (180° VFoV) detect both ground and aerial obstacles, significantly outperforming multiple 2D sensors or 2D+PTU setups. OSDome is ideal for eliminating close-range upper and lower blind spots.

- Ultra-High Reliability: Ouster employs a single-chip semiconductor digital architecture, including proprietary ASIC chips, integrated SPAD/VCSEL arrays, and slip-ring-free data/power transmission, fundamentally eliminating failure sources of traditional mechanical scanning LiDAR (e.g., slip rings, discrete optoelectronic components, high-speed moving parts, low-redundancy designs). REV7 OS0 and OS1 models claim MTTF exceeding 250,000 hours, far surpassing traditional mechanical scanners (literature cites 1,000–3,000 hours) and PTU systems, drastically reducing maintenance needs and safety risks/downtime costs from sensor failures.

- Superior Environmental Robustness: Ouster LiDAR is designed for harsh conditions, with IP68/IP69K protection (dust/waterproof, resistant to high-pressure washing), wide operating temperature range (-40°C to +60°C), and high shock (e.g., 100G) and vibration (e.g., 1000Hz) resistance. The 865nm wavelength absorbs less water vapor than 1550nm; combined with large optical aperture design and advanced digital signal processing, it excels in rain, fog, dust, and high humidity/steam. The REV7 platform enhances detection of dark objects like tires, reaching up to 400m.

- Superior Performance Metrics: Up to 128-line vertical resolution and 5.2 million points/sec output rate capture fine obstacles and complex scene details. 10 or 20 Hz high frame rate meets real-time detection in dynamic environments. REV7 doubles detection range (e.g., OS1 detects 10% reflectivity targets at 90m, OS2 at 200m) and improves accuracy. REV7’s zero-blind-zone feature (OS0 SR/OS1/OSDome) is critical for close-range collision avoidance.

- Simplified Integration & Reduced Total Cost of Ownership (TCO): Replacing multiple 2D sensors, PTUs, cameras, etc., with Ouster 3D LiDAR simplifies system design, reducing BOM costs, wiring complexity, power requirements, and installation/debugging time. Inherent high reliability lowers lifecycle maintenance costs and downtime losses. While individual 3D LiDAR may cost more than basic 2D sensors, the overall TCO advantage is significant due to reduced complexity and improved reliability, especially in high-reliability automation applications. Ouster’s pricing strategy aims to make high-performance digital LiDAR a viable upgrade from 2D solutions.

- On-Chip Smart Processing, REV7: The REV7 platform introduces 3D Zone Monitoring, allowing users to define up to 128 3D detection zones (16 active simultaneously) within the sensor, which directly outputs obstacle presence status or trigger signals. This offloads the main controller and simplifies basic collision avoidance logic.

Integration Example Analysis

- Port Rubber-Tired Gantry Cranes (RTG): Narrow operating spaces increase collision risks with other RTGs, trucks, or yard obstacles. Traditional solutions use 2D LiDAR (e.g., SICK) on RTG portal legs or trolleys for planar collision avoidance, failing to detect areas under the spreader, outside lanes, or aerial obstacles, with degraded performance in port rain/fog. Recommend Ouster OS0 or OS1 REV7 sensors: wide vertical FoV (OS0 90°, OS1 45°) and 360° horizontal coverage for omnidirectional 3D detection, eliminating blind spots. High reliability (MTTF > 250k hrs) and IP68/69K protection suit harsh port environments; 865nm and digital processing enhance all-weather performance. Replacing multiple 2D sensors simplifies systems, improves safety, and achieves significant TCO optimization in real cases.

- Stockyard Reclaimer Cantilever Collision Avoidance: Reclaimers adjust cantilever height/position in real time to avoid stockpile/ground equipment collisions. Traditional solutions use long-range 2D LiDAR (e.g., SICK LRS3601) for profile scanning, capturing only single-plane data and struggling with complex 3D stockpile shapes—especially irregular/dynamic piles—posing collision risks. Recommend Ouster OS1 or OS2 REV7 at the cantilever tip: high-resolution 3D point clouds build real-time stockpile surface models, calculating safe distances precisely. OS2’s long range (200m @ 10%) suits large stockyards. Ouster LiDAR’s dust resistance is critical for mine/stockyard applications.

- Ship Loader/Unloader Collision System (SLAC): A case study by MRA Engineering and QCA Systems:

  - Machine: Ship loader/unloader.

  - Application: Prevent collisions between loader structures and ships of varying types/sizes.

  - Pain Points: Traditional cameras affected by lighting/weather; radar low accuracy; 2D/low-res 3D LiDAR narrow FoV, low resolution, slow scanning, failing real-time precise modeling.

  - Ouster Solution: Install multiple OS1-32 LiDARs on loaders for real-time 3D modeling of loader and hull.

  - Benefits: OS1’s high resolution and wide VFoV (45°) enable precise, blind-spot-free 3D mapping, calculating clearances between loader components and hulls,联动 (linking) with controls for automatic deceleration/avoidance. Validated in rain, snow, fog, and dust for all ship types. MRA notes that with proprietary filtering algorithms, Ouster LiDAR outperforms expectations in all environments, offering high precision and robustness as a significant upgrade to traditional solutions.

- Bulk Material Yard AGV Collision Avoidance: Unlike warehouse AGVs on flat floors, yard AGVs face rough terrain (uneven, gravel), more dust, and weather impacts. Simple 2D safety scanners (e.g., SICK TIM) detect planar obstacles but struggle with ground pits, low obstacles, or aerial objects. Recommend Ouster OS0 or OSDome REV7: 3D perception understands environments comprehensively, detecting complex obstacles and terrain changes. Wide vertical FoV (OS0 90°, OSDome 180°) is critical. High reliability and IP68/69K protection suit outdoor harshness. Combined with 3D Zone Monitoring, enables smarter, safer autonomous navigation and collision avoidance, even in human-machine collaborative zones.

- Bulk Material Gantry Cranes: LASE uses Ouster LiDAR in automated port solutions:

  - Machine: Port gantry cranes (case focuses on container cranes, applicable to bulk material gantries).

  - Application: Collision avoidance between cranes, and with vehicles/personnel/equipment; precise cargo positioning and safe lifting.

  - Pain Points: LASE’s legacy systems used 2D static/rotating scanners.

  - Ouster Solution: Replace 2D setups with 2–4 OS1 sensors in new/retrofit projects.

  - Benefits: Ouster’s high resolution and wide FoV achieve better coverage with fewer sensors, potentially reducing system costs. 3D data enables advanced automation, enhancing safety and efficiency. This case directly demonstrates TCO reduction and performance improvement by upgrading from 2D to Ouster 3D LiDAR, aligning with port automation trends.

Table 1: Comparison of Sensor Technology Solutions for Bulk Material Handling Automation