Hexagon Crusher Monitor

Hexagon Crusher Monitor is a family of radar‑based monitoring solutions offering blockage detection for primary crushers, and level measurement across primary, secondary and tertiary crushers. It delivers real‑time insight to improve throughput, automation, and truck utilisation.

Visibility into crusher feed and blockages

Delivers real-time insight into crusher fill levels to stabilise feed and support automation, with early blockage detection to reduce downtime across crushing operations.

An interactive mining experience

Interactively explore your own life-of-mine journey to see how Hexagon leads to safer, more productive, more sustainable and more profitable mines across the entire mine site lifecycle, or contact us to discuss your unique challenges.

Main benefits

Improved crusher availability

Early detection of blockages and accurate fill level insight help prevent unplanned stops, keeping crushers running longer and more consistently.

Improved feed and throughput

Continuous monitoring of dump pocket fill levels supports stable feeding, smoother crusher operation and improved throughput across varying ore types.

Reduced truck queuing

Real-time visibility into dump pocket status and fill levels reduces unnecessary truck waiting, improving truck utilisation and overall site efficiency.

Radar-based insight for crusher operations

Hexagon Crusher Monitor is a family of radar‑based monitoring solutions designed to improve visibility, stability and performance across the crusher circuit. The solution family provides continuous insight into dump pocket fill levels, material build‑up and blockage conditions, supporting more consistent and automated crusher operation.

Using high‑speed 2D and 3D radar sensors, Crusher Monitor delivers reliable measurement in harsh mining environments where dust, fog and water spray limit the effectiveness of cameras and laser systems. Contactless radar sensing enables accurate monitoring without manual inspections in hazardous areas, supporting safer operations and advanced automation.

By providing real‑time visibility into crusher conditions, the solution helps operators stabilise feed, intervene early to prevent blockages and maintain consistent throughput. Radar‑derived data integrates directly with Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition (SCADA) systems, enabling control strategies that reduce unplanned downtime and improve utilisation of both crushers and haul trucks.

The Hexagon Crusher Monitor solution family currently includes primary crusher 2D level monitoring, primary crusher 3D blockage detection, and secondary crusher or tertiary choke‑feed level monitoring.

Features

Radar-based blockage detection

Fast‑updating radar sensors continuously monitor material build‑up in the dump pocket, enabling early blockage detection and rapid response before unplanned crusher stoppages occur.

Multi-quadrant fill level monitoring

2D and 3D radar sensors measure fill levels and material contours across multiple dump pocket quadrants, providing detailed insight into material distribution and crusher feed conditions.

Industrial integration and visibility

Radar data is processed and made available through PLC and SCADA systems, enabling integration into existing control environments and supporting informed crusher operation decisions.

Resources