Single Silo Single Weigh Type

Single Silo Single Weigh Type

The single silo single weigh dynamic automatic batching system is an automated batching device based on the collaborative work of sensors, controllers (such as PLCs), and actuators (such as solenoid valves and pneumatic valves). The system typically consists of a control unit, software unit, weighing unit, feeding unit, mixing unit, and conveying unit, achieving automated control of the process from raw material input to mixed output. This equipment uses microcomputer control, electronic monitoring, and digital prompts, making it easy to control and operate.

The core technology of the single-silo, single-weighing dynamic automatic batching system lies in the organic combination of "dynamic weighing" and "variable frequency feeding." The dynamic weighing algorithm can capture the weight changes of materials in real time during their descent, and combined with variable frequency feeding technology, it achieves stepped feeding of "fast feeding, medium feeding, and slow feeding." In contrast, the dynamic batching system is essentially "continuous weighing" or "continuous batching." Materials only need to be continuously conveyed normally; the instrument can simultaneously perform "feeding" and "discharging" during "weighing judgment." This mode simplifies the structure and improves batching efficiency.

Equipment Structure

The technical architecture of a single silo single weigh dynamic automatic batching system mainly consists of the following layers:

(I) Execution Layer (Feeding Section): The feeding section is the actuator that adds material from the silo (or storage tank) to the weighing equipment. Different feeding devices can be selected based on the characteristics of the material, such as electromagnetic vibrating feeders, screw feeders, and single (dual) speed solenoid valves. Screw feeders are used for free-flowing granular materials, while vibrating feeders with stirring functions are used for easily agglomerated powdery materials. The feeding actuator receives instructions from the control system to complete the quantitative conveying of materials.

(II) Sensing Layer (Weighing Section): The weighing section consists of weighing sensors, standard connectors, a junction box, and a weighing hopper. Together with the weighing instrument, it weighs the material and detects errors. The weighing sensor converts the material's weight signal into an electrical signal. The weighing sensor adopts a cantilever beam or S-shaped structure, offering high accuracy and good sealing performance. The junction box is used to collect signals from various sensors. (III) Control Layer (Material Batching Control System): The material batching control system consists of weighing instruments, a programmable logic controller (PLC), a host computer, and other control devices. The PLC, as the core of the system, is responsible for executing control programs, processing sensor signals, and outputting control commands. The host computer is responsible for the dynamic monitoring and data acquisition of the entire production line, as well as high-level management of various curves, parameters, production reports, etc. The human-machine interface provides an interactive platform for operators and the system.

(IV) Conveying Layer (Discharge Equipment): This includes discharge valves, belt conveyors, etc. Appropriate conveying methods can be selected based on industry characteristics, production process requirements, and specific material properties.

Dynamic weighing principle

The core working principle of the single silo single weigh dynamic automatic batching system is based on dynamic weighing technology. Its workflow is as follows:

(I) Continuous Feeding: The amount of material to be weighed stored in the silo exceeds the demand for a single weighing. During the weighing process, after the silo's weighing gate opens, material is continuously fed into the weighing scale. A continuous material curtain is formed between the silo and the weighing scale.

(II) Real-time Weighing: The weight of the material piled in the weighing scale is sensed by the weighing sensor. This weight is then converted into the actual weight of the material by the weighing control system. The weight of the material curtain between the silo and the weighing scale does not directly affect the weighing scale, and the control system cannot directly identify or sense the actual weight of the material curtain.

(III) Stepped Feeding Control: The system uses variable frequency feeding technology to achieve stepped feeding with "fast, medium, and slow" speeds. Fast feeding is used in the initial feeding stage to improve efficiency. When the weight approaches the target value, it switches to medium-speed feeding. When it approaches the target value again, it switches to slow feeding to ensure accuracy. This effectively solves the problem of material impact affecting weighing accuracy. (iv) AI Intelligent Control: Utilizing advanced artificial intelligence algorithms and self-learning technology, it masters high-precision batching skills. A basic database is constructed, and precise batching is achieved through a pre-analysis and decision-making system. It possesses a high-frequency signal acquisition capability of 1800 times per second. It features AI intelligent momentary weighing and weighing correction functions.

Control system architecture

The control system architecture of the single-warehouse single-weighing dynamic automatic batching system is as follows:

(I) Upper Computer Management Layer: Responsible for dynamic monitoring and data acquisition of the entire production line. Manages various curves, parameters, production reports, etc. Automatically stores key parameters such as formula information, batching data, and production time for each batch of production, forming a traceable production ledger.

(II) PLC Control Layer: As the core of the system, executes the control program. Receives signals from the weighing instruments, performs calculations and judgments. Issues control commands to the actuators based on the judgment results.

(III) Weighing Instrument Layer: Receives analog signals from the weighing sensors and converts them into digital signals. Displays weighing data in real time. Communicates with the PLC.

(IV) Actuator Layer: Includes solenoid valves, pneumatic valves, frequency converters, etc. Receives control commands from the PLC and executes actions such as feeding and discharging.

Equipment operation method

(I) Formula Management: Formulas are set via a human-machine interface or host computer. The system can store hundreds of formula parameters, enabling rapid recall and modification of formulas.

(II) Automatic Operation Mode: The system enters automatic batching mode upon startup. The system will weigh each raw material sequentially according to the set formula. No manual intervention is required throughout the process.

(III) Manual Operation Mode: The system allows manual control of the start and stop of each device. It is used for equipment debugging and troubleshooting.

(IV) Real-time Monitoring: The system displays real-time information such as material level, weighing data, and equipment operating status in each raw material silo. In case of an anomaly, the system immediately activates an audible and visual alarm and locates the fault.

Equipment maintenance methods

(I) Control System Maintenance: Regularly check the PLC controller's operating status. Regularly check the host computer software's operation. Regularly back up recipe parameters and production data.

(II) Weighing System Maintenance: Regularly calibrate the weighing sensors. Check the junction box for water ingress or moisture. Check the wiring cables for damage.

(III) Actuator Maintenance: Regularly check the operating status of solenoid valves and pneumatic valves. Regularly check the wear condition of the feeding device.

Equipment troubleshooting

Control system malfunction: Check if the PLC program is normal. Check if the communication line is intact. Check if the power supply is normal.

Weighing sensor malfunction: Check if the sensor is under even force. Replace damaged or damp sensors. Check if water has entered the junction box.

Feeding system malfunction: Check if the feeding motor is damaged. Check if the frequency converter parameters are correct. Clear any blockages.

Application of equipment in production line

Single-material warehouse weighing dynamic automatic batching systems play a crucial role in the precise batching of raw materials in various fertilizer production lines. In BB fertilizer production lines, they precisely weigh raw materials such as urea, potassium chloride, and monoammonium phosphate according to the formula. In organic fertilizer production lines, they precisely proportion well-rotted organic materials with additives. In compound fertilizer production lines, they precisely weigh nitrogen, phosphorus, and potassium raw materials according to the formula.

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Single Silo Single Weigh Type