A High-Precision Method for Warehouse Material Level Monitoring Using Millimeter-Wave Radar and 3D Surface Reconstruction

Abstract

This study presents a high-precision warehouse material level monitoring method that integrates millimeter-wave radar with 3D surface reconstruction to address the limitations of LiDAR, which is highly susceptible to dust and haze interference in complex storage environments. The proposed method employs Chirp-Z Transform (CZT) super-resolution processing to enhance spectral resolution and measurement accuracy. To improve grain surface identification, an anomalous signal correction method based on angle–range feature fusion is introduced, mitigating errors caused by weak reflections and multipath effects. The point cloud data acquired by the radar undergo denoising, smoothing, and enhancement using statistical filtering, Moving Least Squares (MLS) smoothing, and bicubic spline interpolation to ensure data continuity and accuracy. A Poisson Surface Reconstruction algorithm is then applied to generate a continuous 3D model of the grain heap. The vector triple product method is used to estimate grain volume. Experimental results show a reconstruction volume error within 3%, demonstrating the method’s accuracy, robustness, and adaptability. The reconstructed surface accurately represents grain heap geometry, making this approach well suited for real-time warehouse monitoring and providing reliable support for material balance and intelligent storage management.

Keywords

• millimeter-wave radar
• multi-feature fusion
• point cloud processing
• surface reconstruction
• volume measurement