Weighing and batching system

Weighing and batching systemBy using automation technology to achieve precise weighing, mixing, and conveying of materials, its core work includes five modules: weighing control, material conveying, mixing processing, data management, and safety control. The specific tasks are as follows:

1. Weighing control

Dynamic weighing:

The system monitors the weight of materials in real-time through high-precision weighing sensors (such as strain gauges and electromagnetic force sensors), using a "coarse weighing+fine weighing" mode to ensure accuracy.

Rough weighing stage: Feed at a faster rate to 80% -90% of the target value, reducing the time for a single weighing.

Precision weighing stage: When approaching the target value, reduce the feeding speed (such as using a frequency converter to control the screw speed), and achieve a final weight error of ≤± 0.1% -0.5% through pulse feeding.

Multi material ratio:

According to the formula requirements, multiple materials are weighed sequentially, and the system automatically calculates the cumulative weight and adjusts the feeding sequence to avoid cross contamination of materials.

Compensation function:

In response to differences in material fluidity (such as powder scattering and particle accumulation), the system compensates for weighing errors through algorithms to ensure that the actual weight is consistent with the set value.

2. Material transportation

Feed control:

The material is transported from the storage bin to the weighing hopper through pneumatic valves, electric valves, or screw conveyors, supporting continuous or intermittent feeding.

Anti blocking design: Install vibrators or airflow assist devices in the conveying pipeline to prevent material clumping and blockage.

Unloading control:

After weighing is completed, the system opens the discharge valve (such as butterfly valve, ball valve) to discharge the material to the mixer or the next process.

Sealed design: The discharge port adopts a soft connection or airtight structure to reduce dust leakage.

3. Mixed processing

Mixing method:

Select the type of mixer based on material characteristics (such as dual axis blade type, vertical screw belt type, V-type mixer), ensuring a uniformity of ≥ 95%.

Time control:

The system preset a mixing time (such as 5-15 minutes), monitors the mixing status through a timer or sensor, and automatically stops after reaching the set time.

Online detection:

Some systems are integrated with near-infrared spectrometers or online sampling devices to detect mixing uniformity in real time and dynamically adjust mixing parameters.

4. Data management

Batch record:

The system automatically records each batch of ingredient data (such as material name, batch number, actual weight, weighing time, operator) and generates electronic reports.

Traceability function:

Support querying historical data by batch number and time range, linking production orders and quality inspection results, and achieving full process traceability.

Interface integration:

Integrate with ERP and MES systems through protocols such as OPCUA and Modbus to achieve production plan issuance and data uploading.

5. Safety control

Over limit alarm:

When the weighing value exceeds the set upper or lower limit, the system triggers an audible and visual alarm and suspends feeding to prevent material waste or equipment overload.

Shortage detection:

Monitor material inventory through level switches or weighing hopper weight changes, and automatically prompt for replenishment or switching to backup material bins when there is a shortage of materials.

Emergency stop function:

Equipped with an emergency stop button, immediately cut off the power supply in case of abnormalities (such as leaks or equipment failures) to ensure the safety of personnel and equipment.

2、 Maintenance details of weighing and batching system

To ensure the long-term stable operation of the system, maintenance needs to be carried out from four aspects: daily cleaning, regular maintenance, calibration verification, and fault handling. The specific details are as follows:

1. Daily cleaning

Cleaning of weighing module:

After daily production, clean the dust and material residue on the surface of the weighing hopper and sensor with a soft bristled brush or compressed air to avoid weighing errors.

Do not use hard objects to scratch the sensor to prevent damage to the strain gauge or electromagnetic force balancing device.

Cleaning of conveying pipelines:

Disassemble the conveying pipelines (such as screw conveyors and vibrating feeders) every week, rinse the interior with high-pressure water guns or specialized cleaning agents to prevent material adhesion and blockage.

Clean and dry to prevent residual moisture from corroding metal parts.

Cleaning of mixer:

After each batch of production, use a scraper or vacuum cleaner to clean the residual materials on the inner wall and blades of the mixer to avoid cross contamination.

Perform a deep cleaning once a month, disassemble the mixer and soak it for cleaning, and check the wear of the propeller blades.

2. Regular maintenance

Lubrication maintenance:

Spiral conveyor: Add lithium based grease to bearings and chains every month to reduce friction and noise.

Mixer: Replace the lubricating oil of the main shaft bearings every quarter and check whether the sealing rings are aging.

Valve: Apply silicone oil to the moving parts of pneumatic and electric valves every six months to prevent sticking.

Replacement of vulnerable parts:

Sensor: Check the linearity and repeatability of the weighing sensor annually, and replace it if the error exceeds 0.1%.

Seals: Replace the O-ring and skeleton oil seal of the conveying pipeline and mixer every six months to prevent leakage.

Belt/Chain: Check the tension of the belt and the wear of the chain every quarter, and adjust or replace them in a timely manner.

Electrical inspection:

Check the wiring terminals for looseness every month, and use an insulation resistance meter to test the grounding resistance of the motor and sensor (should be ≤ 4 Ω).

Clean the dust inside the control cabinet every six months and check whether the cooling fan of the frequency converter and PLC module is running normally.

3. Calibration verification

Weighing calibration:

Standard weight calibration: Use M1 level weights (such as 10kg and 20kg) to calibrate the weighing module at four points (unloaded, half loaded, fully loaded, and overloaded) every quarter, and record the calibration curve.

Material comparison calibration: Weigh and test actual materials every month, compare the system display value with the manually weighed value, and recalibrate when the error exceeds 0.3%.

System verification:

Conduct a full process validation every six months, simulate production conditions to run the system, and check whether the feeding, weighing, mixing, and unloading processes meet the process requirements.

Generate a report after verification and archive it for future reference.