Weighing and batching systemIt is the core link to achieve precise feeding, ensure product quality and production efficiency. Its stability and accuracy are directly related to the quality of finished products, cost control, and production safety. To ensure the long-term "precise" operation of the system, systematic and periodic maintenance must be carried out. The following is the detailed maintenance work content:

1、 Daily maintenance (per shift or per day)

Appearance and environmental inspection

Check whether the outer shell of the weighing equipment (scale body, sensor, junction box) is clean, free of dust, oil stains, and material accumulation.

Confirm that the working environment is dry, free from vibration source interference, and has no strong electromagnetic field influence.

Check for leaks, blockages, or residual materials in hoppers, pipelines, and valves.

zero point calibration

In the empty scale state, perform zero calibration to ensure that the weighing display is zero or within the allowable error range.

Record the zero drift situation. If it frequently exceeds the tolerance, further inspection is required.

Observation of operating status

Observe whether the ingredient process is smooth and whether the feeding is too slow or too fast.

Equipment operation sound, whether there is any abnormal noise (such as motor noise, mechanical friction).

Check the control system interface for any alarm prompts or abnormal data.

2、 Regular maintenance (weekly/monthly)

Mechanical component inspection

Check the hopper and connecting components: Confirm that the hopper is not deformed or cracked, and the supporting structure is firm.

Check the soft connection: Check if the soft connection (such as silicone pad, canvas cover) is aged or damaged, to ensure that it can effectively isolate vibration.

Check the valve and actuator: Test whether the pneumatic/electric valve is flexible and in place, and whether there is any air leakage or jamming.

Weighing sensor inspection

Visual inspection: Confirm that the sensor is not deformed, corroded, or subjected to uneven force (such as being stuck).

Wiring inspection: Check whether the sensor wiring terminals are tightened, and whether the cables are worn, squeezed, or aged.

Grounding inspection: Ensure that the system is well grounded to prevent static electricity or interference.

Junction box and signal inspection

Open the junction box and check for dryness, cleanliness, moisture, and corrosion inside.

Check if the parallel connections of each sensor are correct and if the resistance values are balanced.

Simple range calibration

Use standard weights or materials of known weight for range calibration to verify whether the weighing accuracy is within the allowable range (such as ± 0.1%~± 0.5%).

3、 Quarterly/Annual Deep Maintenance

Comprehensive calibration

Professional personnel use high-precision standard weights to perform full-scale calibration of the system, ensuring that linearity and repeatability meet the standards.

Record calibration data and generate calibration reports for traceability purposes.

Sensor performance testing

Measure the input/output resistance and insulation resistance of the sensor to determine if it is aging or damaged.

Replace sensors with decreased performance if necessary.

Control system maintenance

Clean the dust inside the control cabinet and check the status of components such as PLC, weighing instruments, relays, and contactors.

Backup control programs and recipe parameters.

Check the stability of communication lines (such as RS485, Ethernet).

Comprehensive inspection of mechanical structure

Check whether the support structure and limit device of the weighing platform or hopper are intact, and whether the limit gap is appropriate.

Lubricate moving parts such as valve shafts and transmission mechanisms.

4、 Seasonal and special maintenance

Wet season: Strengthen moisture-proof measures and place desiccants inside the junction box.

High temperature environment: Check the cooling system to avoid instrument overheating.

Dust environment: Increase cleaning frequency to prevent dust from entering sensors or electrical components.

Restart after long-term shutdown: A comprehensive inspection and recalibration must be conducted.

5、 Maintain records and management

Establish equipment maintenance records, detailing the time, content, discovered problems, handling measures, calibration data, replaced spare parts, etc. of each maintenance.

Implement a preventive maintenance plan (PM) and develop maintenance cycles based on equipment usage frequency and operating conditions.

Regularly analyze maintenance data, predict potential failures, and optimize maintenance strategies.

6、 Safety precautions

Before maintenance, it is necessary to cut off power, relieve pressure, empty materials, and hang warning signs.

High altitude operations require wearing safety belts.

When using standard weights, handle them gently to prevent damaging the sensor.

Non professionals are not allowed to disassemble sensors or modify control parameters without authorization.