AI-Soil Analyzer

Continuous aggregate
analyzer with Visual AI

Based on industrial artificial vision and AI, with sensors adapted to the control objective.

The challenge

mat-scan Pixelabs

01 Material variability

Constant variations in particle size, shape and composition. Changes in the index of flakes and fracture faces depending on the front, blasting and wear off the crusher.  Heterogeneous material typical of mobile plants on site.

02 Blind spot

Current control based on laboratory tests and spot sampling. Delayed results that are not representative of actual flow. Lack of visibility between production, quality, and process adjustment.

03 Impact on production and construction

Reprocessing, rejected stockpiles or corrective mixtures.Loss of plant performance and increased energy consumption. Reactive operation. Impact on deadlines, costs and compliance.

Advantages

Smart measurement, easy integration

Our advanced system, combined with AI-based analytics, allows us to characterize the aggregate in real time, providing detailed information for process control and optimization


Variables measured in real time

Particle Size

Continuous particle size analysis. Real-time size distribution by fraction.

Slab index

Automatic detection of elongated and flat particles.

Fracture faces

Estimation of the percentage of fractured faces.

Morphology and volume

Estimation of the morphology and volume


Direct integration

Real-time data

Data delivery via standard process signals (4–20 mA)

Easy integration

Native integration into existing DCS/SCADA systems

Non invasive

Displayed as just another sensor in the installation, with no changes to operations

Visualization

Display and use like any other
plant sensor

AI-Soil Analyzer

Continuous real-time aggregate monitoring system, installed directly on the main production belt in mobile or fixed plants. Based on industrial artificial vision and AI, with sensors adapted to the control objective.

    • Complete scanning of the aggregate produced, not based on spot sampling.
    • Elimination of the blind spot between production and quality control.
    • Particle size distribution
    • Fracture pattern and particle shape
    • Fracture surfaces and surface texture
    • RGB and 3D artificial vision for geometric and morphological analysis.
    • Visual AI algorithms trained for construction site and quarry environments.
    • Advance adjustment of crushers and screens.
    • Reduction in rework and out-of-specification material.
    • Improved performance and stability.

AI-SOIL ANALYZER

4 keys to optimize your operations

Optimize operations with continuous aggregate monitoring, enabling improved efficiency, reduced variability, and data-driven decision making.

Preventive control of the combustion process

– Continuous visibility of aggregate quality prior to storage or dispatch.
– Early detection of deviations in grain size, slabs and fracture faces.

Optimization of crushing and screening

– Advance adjustment of crushers and screens.
– Greater process stability in the face of variability in the front or material.
– Improved overall plant performance and energy consumption.

Preservation of critical equipment

– Reduction of overloads and unnecessary recirculation.
– Less wear and tear on crushers, screens, and conveyor belts.
– Early identification of suboptimal operating conditions.

Operational planning and logistics

– Real-time knowledge of actual quality produced, not estimated.
– Planning of stockpiles and destinations according to specifications.
– Fewer reprocesses, less rejected material and greater traceability.

Frequently Asked Questions

  • Pixelabs’ hardware is specifically designed for demanding industrial environments. AI algorithms are trained to filter out environmental visual interference, ensuring that the processed data corresponds exclusively to the fuel on the conveyor belt.

  • Our technology does not depend on a fixed color or shape, but rather on the chemical and physical signature of the material. When changes occur in the fuel mix, the system detects the variation. Thanks to the included support service, our team can remotely readjust the models to maintain accuracy levels without the need for further physical intervention.

  • No. The support structure design is non-intrusive and is installed ‘on top’ of the existing conveyor belt. Mechanical assembly and wiring tasks are coordinated to be carried out during routine maintenance windows or scheduled technical shutdowns, with an intervention time on the line of less than 6 hours.

  • Integration is native and straightforward. The system delivers variables (humidity, volume, and PCI) via 4-20mA current loops or standard protocols such as Modbus. This allows the plant system to receive the information as if it were any other process sensor.

  • No. The Pixelabs system acts as a real-time process control tool, analysing 100% of the fuel. Real-time measurement is highly accurate and correlates well with laboratory results, but it is not intended to replace detailed testing of small quantities of material using industry-standard analytical methods. Both systems provide positive feedback for improved plant performance.

  • The system is built with highly durable industrial-grade components. Preventive maintenance is limited to cleaning the external protections of the equipment and optics, and replacing bulbs if they burn out. At the software level, the system evolves through remote updates included in the support plan, ensuring that the technology never becomes obsolete, as well as through periodic recalibrations described in a Technical Annex to the product.

Get a closer look to AI-Soil Analyzer and discover how our product will improve your business

Still have questions about the product? Schedule your demo with our experts

(1)The data reflects how our client currently uses the system. Keep in mind that this information is shared based on mutual understanding. We’ve also estimated potential cost savings using details from our clients, keeping everything within the agreed terms and conditions. We recommend contacting us for detailed information. (2) This is a simplified explanation of the product’s functionality and may not fully represent the complete process involved. These representations are intended for the purpose of clarity and ease of understanding. We recommend contacting us for detailed information. (3) All images used in this website are for illustrative purposes only.