Solo and Reflex System Frequently Asked Questions

Solo measures material moving on conveyors or through process lines, providing repeated measurements for ongoing monitoring and process control.

Reflex measures material associated with vehicle loads, such as haul trucks, loaders, or other vehicles. It is commonly installed at receiving or discharge locations to characterize material before it enters the next processing stage.

Both systems use optical analysis to measure material characteristics, but they are designed for different ways of presenting and handling material.

Basic systems provide focused monitoring of either maximum particle size or colour.

Complete systems provide full particle size distribution (PSD) measurements, particle shape, and colour. Solo Complete also provides estimated material volume.

The appropriate configuration depends on the information required by the operation. A system intended only to identify oversize material may NOT need the additional measurements available with Complete.

Yes. Solo 6 and Reflex 6 use a common hardware platform, allowing Basic systems to be upgraded to Complete without replacing the primary measurement hardware.

Contact WipWare for upgrade options and licensing information.

No. WipFrag provides the interface used to configure and interact with Solo and Reflex, and the required system functionality is included with the hardware system.

A separate WipFrag Annual Subscription or WipWare Analysis Credits are only required when using WipFrag for standalone image analysis outside the connected system.

See the WipFrag Frequently Asked Questions for information about software subscriptions and analysis credits.

Yes. Solo and Reflex are designed for autonomous operation once installed and configured.

They collect and analyze material measurements without requiring an operator to manually process each image.

The results can be reviewed through WipFrag or connected to plant systems for trending, alarms, and process-control applications.

Solo and Reflex are used in mining and aggregates, but their applications extend to other industries handling granular or fragmented materials.

Examples include mineral processing, quarrying, cement production, forest products, agricultural materials, pellets, and other bulk-material processes.

The important consideration is whether the material and operating conditions allow the system to capture useful measurements for the intended application.

Depending on the system configuration, measurements can include:

• Maximum particle size and oversize.
• Particle size distribution (PSD).
• Percentage passing or retained at specified particle sizes.
• Particle shape characteristics.
• Colour and visible material variation.
• Estimated material volume (Solo Complete).

The measurements available depend on the Basic or Complete configuration and the selected analysis settings.

Particle size distribution describes how material is distributed across different particle sizes.

It can be expressed using a cumulative percentage-passing curve, individual size classes, or percentile measurements such as D50, D80, and D95.

For example, D80 represents the particle size below which approximately 80% of the reported distribution falls.

PSD measurements can help operations evaluate crushing performance, monitor process feed, identify changing material conditions, and compare results between processing stages.

For more information, see Understanding P80 in Crushing and Material Processing.

Solo Basic typically provides a new maximum-size or colour measurement approximately once per second.

Solo Complete performs a more comprehensive analysis approximately every four seconds.

Reflex measurements are triggered according to the vehicle or material-handling application, rather than operating solely on a fixed conveyor sampling interval.

Repeated automated measurements provide ongoing process information, but do NOT necessarily mean every particle passing the measurement location is individually analyzed.

Yes. Maximum-size monitoring can identify visible particles exceeding a configured size threshold, provided they can be reliably measured within the camera’s field of view.

Depending on the system configuration and integration, the result may be used to generate an alarm or other control signal.

The appropriate threshold should reflect the downstream equipment requirements, such as a crusher opening, screen aperture, or material-handling limit.

No, not directly. WipWare systems measure particle size, shape, volume where supported, and colour. They are NOT dedicated foreign-object detectors or chemical analyzers.

A visibly distinct object or material may produce an unusual size, shape, or colour measurement, provided it is exposed to the camera and distinguishable from the surrounding material.

However, the system cannot reliably identify buried objects or determine the chemical composition of material from its appearance.

Applications involving tramp metal or specific foreign-object detection may require dedicated detection equipment.

Colour analysis evaluates visible material against configured colour profiles.

Depending on the system configuration, this can help monitor changes in material appearance, distinguish visually different material groups, or identify unusual colour trends.

Colour measurements may provide useful process indicators, but they do NOT independently establish mineral grade, chemical composition, or contamination.

Solo Complete uses material-depth information together with the conveyor’s geometry and movement to estimate material volume and volumetric flow.

The system can compare the empty-belt reference with material depth during operation to support these calculations.

Volume information can help operators examine relationships between material flow and particle size distribution.

Where material density or weightometer information is available, these measurements may also be used in broader process calculations.

Solo is NOT intended to replace a purpose-built volumetric scanner or certified weighing system in applications requiring those capabilities.

No, not directly. Optical systems can only measure the material visible to the camera.

Smaller particles may be obscured by larger particles or too small to distinguish at the available image resolution.

Where appropriate, sieve calibration can mathematically account for differences between image-derived measurements and a representative physical sample containing the complete material distribution.

However, calibration does NOT allow the camera to directly observe hidden particles.

The measurable particle size range depends on camera resolution, field of view, lens selection, mounting geometry, material presentation, and image quality.

A wider field of view provides greater coverage but reduces the image detail available for smaller particles. A narrower field of view can improve detail but limits the area being measured.

There is no single minimum or maximum particle size that applies to every installation.

See Understanding Size Ranges in Conveyor Belt Analysis for practical examples.

The agreement between optical measurements and physical sieving depends on the material, particle size range, image quality, sampling method, and calibration.

Because optical measurements are based on visible particles, while physical sieving evaluates collected material by mass, their results may differ.

A site-specific comparison using representative samples is the most useful way to establish the relationship between the two methods.

That said, WipWare technology has been used in dozens of peer-reviewed, real-world fragmentation and comminution studies over decades.

WipWare does NOT recommend assuming a universal percentage accuracy for every material and installation.

No, not necessarily.

Sieve calibration is useful when an operation needs image-derived particle size distributions to correspond more closely with laboratory sieve results.

However, many applications only require consistent monitoring of relative particle size changes or direct maximum-size detection. These can provide useful information without sieve calibration.

For systems configured only for maximum-size or colour monitoring, full PSD sieve calibration is generally NOT relevant.

The process involves capturing an image of representative material, collecting a matching physical sample, and comparing the image-derived PSD with laboratory sieve results.

WipFrag’s calibration tools allow the operator to enter laboratory sieve values and evaluate mathematical adjustments using Rosin–Rammler or Swebrec distribution models.

The selected parameters are then applied to the automated system.

For a detailed explanation, see System Sieve Calibration: Matching Optical Analysis with Laboratory Results.

The laboratory should provide sieve opening sizes, the weight retained on each sieve, and cumulative percentage passing.

The selected sieve series should cover the material’s relevant particle size range, including the larger sizes and critical process-control thresholds.

Recognized test sieve standards include ASTM E11 and ISO 3310-1.

The laboratory or Process Control Department should determine the appropriate standard and sieve series for the application.

There is no universal recalibration interval.

The calibration should be reviewed if significant changes occur in camera position, image scale, lighting, analysis settings, material characteristics, or operating conditions.

Periodic comparisons with representative physical samples can help determine whether the existing calibration remains suitable.

A consistent process may NOT require frequent recalibration, while changing material or installation conditions may justify more regular checks.

WipWare typically needs information about the material, the measurement objective, and the proposed installation environment.

Useful information includes:

• Material type and expected particle size range.
• Conveyor dimensions or vehicle types.
• Installation location and available mounting space.
• Material speed, loading, and presentation.
• Lighting, dust, weather, and other environmental conditions.
• Available power and network infrastructure.
• Required measurements, alarms, and integration outputs.
• Representative photographs of the material and proposed location.

This information helps determine the appropriate equipment configuration and installation approach.

A Solo installation requires a suitable mounting location, stable camera and lighting arrangement, electrical power, network connectivity for configuration and integration, and a clear view of the material stream.

The installation must also provide sufficient access for commissioning, maintenance, and any required physical sampling.

The exact mounting geometry depends on conveyor dimensions, particle size, material loading, and the measurement objective.

Reflex is commonly installed where vehicles can be measured consistently, such as a truck dump, receiving area, or another suitable vehicle-handling location.

The camera position should provide a usable view of the material during the intended measurement event.

Vehicle movement, discharge geometry, environmental conditions, and access to identification or trigger signals should be considered during application design.

A canopy helps create more consistent imaging conditions by reducing the effects of direct sunlight, changing shadows, weather, and airborne dust.

Consistent lighting is important because changes in brightness and shadow can influence particle identification.

The amount of shielding required depends on the installation. Outdoor locations and areas exposed to changing sunlight typically require more environmental control than stable indoor environments.

Yes, usually. Depending on the installation, the customer’s engineering or maintenance team may complete the physical mounting, wiring, and other installation work using WipWare’s documentation.

WipWare can also provide installation and commissioning assistance.

The installation arrangement should be established during project planning, particularly where special mounting, electrical, networking, or safety requirements apply.

Commissioning typically includes:

• Verifying power, networking, and system communication.
• Checking camera focus, exposure, and lighting.
• Establishing image scale and measurement geometry.
• Configuring analysis profiles, size classes, and outputs.
• Reviewing triggers and material-detection settings.
• Testing the system under normal operating conditions.
• Performing sieve calibration or physical-sample comparison where required.
• Checking data integration and training operators.

A system should be evaluated with representative production material before commissioning is considered complete.

WipFrag provides an interface for viewing system measurements, analysis results, particle size distributions, and available trend information.

The displayed information depends on the system configuration and selected output variables.

Yes. WipWare systems support CSV data outputs that can be used for reporting and historical analysis.

Available fields depend on the system configuration and may include timestamps, particle size measurements, user-defined size classes, colour or shape information, and other relevant system values.

The required data fields and reporting arrangements should be reviewed during commissioning.

Yes. Solo and Reflex support industrial integration through Modbus TCP and OPC UA.

These protocols allow compatible control systems to receive configured measurement values for monitoring, trending, alarms, and process-control applications.

Integration requirements should be reviewed with the customer’s controls or automation team to establish the necessary data points and communication arrangements.

Yes. Depending on the configuration, measurement values can be used to support alarms and control actions through an external PLC or other compatible equipment.

Examples include notifying operators when an oversize threshold is exceeded or when material characteristics move outside the intended operating range.

WipWare also offers control hardware for suitable applications requiring simpler relay-based actions.

The control strategy and response to each alarm should be established and validated by the customer’s responsible engineering personnel.

Yes, where the installation provides suitable identification or external data.

Reflex results can be associated with vehicle or load information through integration with dispatch, PLC, database, or other site systems.

The exact method depends on the customer’s infrastructure and the signals available at the measurement location.

No. WipWare systems are designed for autonomous local measurement.

A continuous internet connection is NOT necessarily required for normal analysis. However, network access may be needed for configuration, remote support, data transfer, or connection to other plant systems.

The required network arrangement should be confirmed for each installation.

No. Solo is designed to measure material while the conveyor is operating.

The conveyor may need to be stopped under approved site procedures for certain commissioning, physical sampling, installation, or maintenance activities.

Normal automated image analysis does NOT require the conveyor to stop.

The primary routine maintenance requirement is to keep the camera viewing area and lighting equipment free from excessive dust, dirt, and other obstructions.

The system should also be inspected periodically for physical damage, loose components, lighting problems, and changes that could affect measurement quality.

Maintenance frequency depends on the installation environment. Dusty transfer points may require more frequent attention than cleaner, enclosed locations.

Follow the current equipment maintenance instructions and site safety procedures when cleaning or inspecting the system.

Yes. Cleaning methods should follow the recommendations for the installed equipment and its protective enclosure.

Avoid abrasive cleaning methods, excessive pressure, or any procedure that could damage the optical window, seals, electrical components, or lighting equipment.

Do NOT assume that every system component can safely be pressure-washed or exposed to unrestricted water flow.

Where the appropriate cleaning method is uncertain, contact WipWare Technical Support.

Yes, WipWare systems are designed for industrial environments, including mining and bulk-material handling applications.

However, performance depends on appropriate equipment protection, lighting, mounting, and maintenance.

Excessive airborne dust, material buildup, changing sunlight, or obscured optics can reduce image quality and affect measurements.

Site conditions should be reviewed during application design.

First, determine whether the material itself is changing or whether image quality has deteriorated.

Possible causes include:

• Changes in lighting or exposure.
• Dust or buildup on the optical window.
• Camera movement or altered image scale.
• Changes in material loading or presentation.
• Incorrect analysis settings.
• Material that differs substantially from the original commissioning conditions.

Review live images and recent analysis results before adjusting the configuration.

Smaller particles may NOT occupy enough pixels to be distinguished reliably, or they may be hidden beneath larger material.

Review the field of view, focus, material presentation, and camera resolution.

If the application requires finer measurements than the installation can reliably provide, a different camera configuration or measurement location may be necessary.

Sieve calibration can adjust a reported PSD against a physical reference, but cannot improve the camera’s optical resolution.

Optical and physical sieve measurements use different methods and may represent different portions of the material.

Differences can result from sampling, particle overlap, hidden fines, calibration, particle shape, or an unsuitable comparison between image and physical samples.

Ensure that the reference sample represents the same material as the image analysis and review whether sieve calibration is appropriate.

See the System Sieve Calibration Guide for further explanation.

Check that the system is powered and operating, and verify the relevant network connections.

Confirm that the receiving PLC, SCADA system, or other data destination is accessible and that its communication settings have NOT changed.

Review the system interface for available status or diagnostic information.

If communication cannot be restored, contact WipWare Technical Support with the system identification, a description of the problem, and any relevant error messages.

Review whether the existing measurement configuration remains appropriate.

Changes in material size, colour, loading, or presentation may affect image quality, analysis performance, or the validity of an existing sieve calibration.

Significant changes may require updated analysis profiles, revised measurement settings, or another comparison with physical reference samples.

WipWare provides technical assistance for system installation, commissioning, calibration, troubleshooting, software configuration, data integration, maintenance, and training.

Services may be delivered remotely or onsite, depending on the work required and the customer’s location.

Yes. WipWare can provide remote assistance for many software, communication, configuration, and troubleshooting issues.

Remote access to the system may help technicians diagnose problems more effectively when permitted by the customer’s IT and security policies.

Onsite service and project-specific commissioning support can be arranged when required.

Yes. WipWare provides operator and technical training as part of the system commissioning and support process.

Training typically covers accessing the system, reviewing analysis results, understanding measurement settings, and recognizing conditions that may affect performance.

Additional training can be arranged according to the customer’s requirements.

Current product information, installation resources, manuals, and technical documents are available through WipWare’s Product Documents area, with access depending on the document and customer account.

For practical commissioning or calibration assistance, consult the documentation provided with the installed system or contact WipWare Technical Support.

WipWare provides one-year limited warranty coverage for manufacturer defects, according to the terms applicable to the purchased equipment and agreement.

For details about coverage, exclusions, service arrangements, and warranty claims, refer to your provided WipWare Limited Warranty documentation or contact WipWare.

Contact WipWare or your regional WipWare representative.

Include a description of the material, the measurement objective, the proposed installation location, and any relevant operating conditions.

Photographs of the material and proposed installation area are particularly useful for evaluating an application.