The operating principle of the automatic batching system in the ingredient system.

The constant-flow control in the automatic batching system employs PID regulation, while flow measurement and control combine measurement deviation correction with variable-frequency speed control. Based on the system’s process flow, this paper introduces the flow control methods and system control procedures of the batching system, and provides a detailed account of PLC selection as well as the hardware setup, parameter configuration, and software design processes involved in the PLC-based variable-frequency control of the batching system. The automatic batching system is an extremely important step in the production process of fine chemical plants; the quality of the batching operation significantly impacts the overall product quality. The automatic batching control process is a multi-input, multi-output system, where each batching and conveying production line is rigorously coordinated and controlled, ensuring precise material handling.

System advantages of automated batching systems

1. The automatic batching system uses the Siemens S7-200 series Programmable Logic Controller (PLC) as its core component, featuring a compact size, high precision, and excellent stability. 2. The automatic batching system can simultaneously control multiple scales and handle various types of materials or output controls (depending on the specific process requirements). 3. It employs intelligent control over batching times, eliminating any waiting periods between different scales, thereby shortening the batching cycle and significantly improving batching speed and production output. 4. The automatic batching system runs on the WINXP operating platform, offering faster and more stable performance, real-time dynamic production visualization that clearly displays the production process, intuitive and straightforward operation, and an automatic recovery function.

What is the function of an automatic batching system?

As the level of automation in manufacturing processes continues to rise, load cells have become an indispensable and essential component in process control. Today, load cells cover virtually all weighing applications—from weighing hoppers and storage tanks to truck scales and cranes—and can also be used for automated batching and precise control of powdered and granular materials. High-precision load cells or weighing modules are suitable for online measurement and batching control in industrial environments. To facilitate easier integration into industrial measurement and control systems, we offer a variety of specifications of weighing transmitters. Additionally, we provide specialized batching controllers designed specifically for tasks such as canning, packaging, and ingredient mixing.

What are the components and features of an automatic batching system?

The batching system is centered around a microcomputer and, combined with high-power electrical equipment, forms a closed-loop system. The test objects include the weight signals from electronic scales and various digital input signals; the controlled devices encompass mechanical and electrical components such as feeders, scale hopper gates, mixer gates, and grease-addition on-off valves. Different automatic batching systems can achieve varying performance levels, but their basic requirements are as follows: static batching accuracy ≤ 0.1%; dynamic batching accuracy ≤ 0.3%; the ability to store a certain number of recipes without being affected by power outages; accurate alarm signals; each production stage equipped with interlocking protection functions to ensure continuous operation; and during production, the system must feature power-failure protection and automatic error correction.

What’s the difference between a small-ingredient batching system and an automatic batching system?

Manual batching: The system adopts a B/S architecture to enable intelligent management of batching processes, providing flexible query capabilities for production material requisition reports, completion reports, production progress reports, and more. It supports bidirectional traceability from finished products back to raw materials, as well as dynamic display of batching and feeding activities in an intuitive and visual manner. Over-limit alerts are triggered via audible and visual alarms. The use of barcodes effectively prevents incorrect raw material input. Raw material batch number barcodes and finished product batch number barcodes are fixed onto barcode blocks for repeated use. The system automatically prompts removal of measuring buckets (bags) from platform scales. Automatic batching: High-precision batching with multi-stage speed control; reliable barcode recognition ensures that no materials are added incorrectly.

Analysis of Factors Affecting Ingredient Accuracy and Preventive Measures

1. The Concept of Ingredient Accuracy: Ingredient accuracy refers to keeping the systematic error of an automatic batching system within a specified range. Ingredient accuracy is divided into static accuracy and dynamic accuracy. Static accuracy refers to the error between the actual batched quantity and the designed batched quantity when the system is in a stationary state (i.e., after batching is complete). Dynamic accuracy refers to the error between the actual batched quantity and the designed batched quantity during the batching process, i.e., under dynamic conditions. At present, the national standard specifies a static accuracy of 0.1% FS and a dynamic accuracy of 0.3% FS. 2. The Significance of Controlling Ingredient Accuracy: 2.1 The Batch Effect of Ingredient Errors on Costs

Advantages of the Automatic Ingredient Dispensing System

(1) The batching site has high dust levels and a harsh environment; (2) The proportions of each component in the formulation vary, sometimes even by substantial differences; (3) High requirements for batching speed and accuracy; (4) Formulations may frequently change and be adjusted; (5) Materials may be affected by ambient temperature and humidity.