Single Silo Single Weigh Type
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Single Silo Single Weigh Type
The single silo single weight dynamic automatic batching system (also known as the single-bin, single-scale automatic batching system) is an automated batching device that can be used with BB fertilizer equipment, organic fertilizer equipment, compound fertilizer equipment, and blended fertilizer equipment. It can automatically proportion materials according to customer needs. This equipment is mainly used for weighing, distributing, and mixing multiple raw materials separately, replacing manual weighing or volumetric metering. It features high metering accuracy, fast distribution efficiency, and a high degree of automation, making it a key component of complete fertilizer production equipment.
This equipment adopts an independent configuration of “one bin, one scale,” with each raw material bin corresponding to a dedicated high-precision weighing module, avoiding raw material mixing interference from the source. The system is equipped with a dynamic weighing algorithm that can capture weight changes during material descent in real time, combined with frequency conversion feeding technology to achieve stepped feeding. This product uses microcomputer control, electronic monitoring, and digital prompts, making it easy to control and operate, ensuring accurate fertilizer product content. The equipment is suitable for weighing, distributing, and mixing multiple raw materials separately, replacing manual weighing or volumetric metering.
Equipment Structure
The single silo single weight dynamic automatic batching system mainly consists of the following core components:
(I) Storage System: This includes multiple independent raw material bins for storing various raw materials. Each bin is typically equipped with a level sensor (such as an ultrasonic level gauge or a rotary paddle level gauge) to monitor the material level and prevent shortages or overflows. The number of bins depends on the type of material in the formula, with 2-6 bins being common. Both the bin body and the weighing module are made of stainless steel with an anti-corrosion treatment.
(II) Feeding System: The feeding section is the actuator that adds material from the bins to the weighing equipment. Different types of feeding equipment 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 agitation functions are used for easily agglomerated powdery materials. (III) Weighing System: The weighing section consists of load cells, standard connectors, junction boxes, and weighing hoppers. Together with the weighing instrument, it weighs materials and detects errors. The load cells accurately measure the weight of materials to ensure accurate batching. The weighing hoppers temporarily store materials to be weighed.
(IV) Batching Control System: This system consists of weighing instruments, a programmable logic controller (PLC), a host computer, and other control devices. This system is the brain of the entire batching process, responsible for receiving sensor signals, executing control algorithms, and outputting control commands. The system control section includes the host computer, PLC controller, human-machine interface, weighing units, and low-voltage electrical components.
(V) Discharge and Conveying Equipment: This includes discharge valves and belt conveyors, used to transport weighed materials to the next process. The “zero-point method” or “loss-in-weight method” can be rationally selected for weighing and batching based on industry characteristics, production process requirements, and specific material properties.
Application range of equipment
The application field of single material warehouse receipt weighing dynamic automatic batching system mainly focuses on the fertilizer production industry. BB fertilizer (blended fertilizer) production line: It can be used in conjunction with BB fertilizer equipment to complete the automatic proportioning of various simple fertilizer particles. Organic fertilizer production line: It can be used in conjunction with organic fertilizer equipment and is suitable for the accurate measurement of organic raw materials such as livestock and poultry manure, crop straw, humic acid, and various additives. Compound fertilizer and compound fertilizer production line: It can be used in conjunction with compound fertilizer equipment and compound fertilizer equipment to complete the automatic proportioning of multiple raw materials. With its unique structural design and intelligent control technology, this system breaks the limitations of the traditional batching model and injects new development momentum into fertilizer production companies. The equipment is especially suitable for fertilizer production scenarios where there are many types of raw materials in the formula and the proportions vary greatly.
Types of available raw materials
The single-material warehouse weighing dynamic automatic batching system can handle a wide variety of raw materials. Organic raw materials include: livestock and poultry manure, crop straw, humic acid, amino acids, peat moss, etc. Fertilizer raw materials include: urea, potassium chloride, potassium sulfate, monoammonium phosphate, diammonium phosphate, and other granular or powdered fertilizers. Additives include: trace elements, biological agents, binders, and various other additives. The equipment can be flexibly configured with different types of feeding devices according to the characteristics of the raw materials. The system’s control parameters can be adjusted according to the characteristics of the raw materials, achieving stable batching for both high-humidity fermented materials and lightweight peat moss.
Working principle of the equipment
The working principle of the single-bin, single-weighing dynamic automatic batching system is based on the coordinated operation of sensors, controllers (such as PLCs), and actuators (such as solenoid valves and pneumatic valves). Its core workflow is as follows:
(I) Formula Setting: Operators set the required formula parameters (target weight or ratio of each raw material) through a human-machine interface or host computer. The system can store hundreds of formula parameters, enabling rapid recall and modification of formulas.
(II) Automatic Feeding: According to the formula requirements, the control system sends a start signal to the feeding actuator of the designated silo. The feeding device begins to add material to the weighing hopper. The system uses frequency conversion feeding technology to achieve stepped feeding of “fast, medium, and slow,” effectively solving the problem of material impact affecting weighing accuracy.
(III) Dynamic Weighing: Weighing sensors perceive the weight changes of the material in the weighing hopper in real time, converting analog signals into digital signals and transmitting them to the control system. The control system captures the weight changes during the material’s descent in real time through a dynamic weighing algorithm.
(IV) Precise Control: When the weighing value approaches the target value, the system automatically switches to slow feeding mode. When the set value is reached, the control system issues a stop signal and shuts down the feeding device.
(V) Discharge and Conveying: After the raw material is weighed, the discharge valve opens, discharging the material into the conveying equipment. Each raw material is weighed sequentially and then conveyed to the mixer.
Equipment operation method
(I) Pre-start Preparation: Check that there is sufficient raw material in each hopper. Check that the weighing sensors, junction boxes, and wiring cables are normal. Check that the feeding devices (screw feeder, vibrating feeder, etc.) are operating normally. Check that all components of the control system are intact.
(II) Formula Setting: Retrieve or input the required formula through the human-machine interface or host computer. Set the target weight and allowable error range for each raw material. The system can store hundreds of formula parameters, enabling quick recall and modification of formulas.
(III) Automatic Operation: Start the system to enter automatic batching mode. The system will weigh each raw material sequentially according to the set formula. During operation, the material level, weighing data, and equipment operating status of each raw material hopper can be viewed in real time.
(IV) Operation Monitoring: Operators must closely monitor the system’s operating status. When abnormal situations such as insufficient material level or equipment failure occur, the system will immediately sound an audible and visual alarm and locate the fault point.
(V) Shutdown Operation: After completing the batching task, shut down each piece of equipment in sequence. Maintain accurate records of equipment use and maintenance, and ensure proper handover procedures.
Equipment maintenance methods
(I) Daily Maintenance: Inspect the equipment daily for operational status. Observe the scale body for deformation or corrosion to avoid affecting its structural strength and lifespan. Check the load cells, junction box, and wiring cables for proper functioning.
(II) Periodic Maintenance: Regularly clean, lubricate, and calibrate the equipment to effectively prevent malfunctions. Regularly check the scale body support for deformation or corrosion. Regularly inspect the infeed/outfeed mechanism, infeed/outfeed valves, and infeed/outfeed connection mechanisms (flexible connections), etc.
(III) Calibration Management: The system should be calibrated regularly. Recalibration is required after troubleshooting any issues with the batching system.
Equipment troubleshooting
Inaccurate weighing: Check if the sensor is under even force. Replace any damaged or damp sensors. Check if the junction box is wet or waterlogged. Recalibrate the scale after troubleshooting.
Instrument display values fluctuate: Check if the junction box is wet or the circuit board is damp. Check the scale body structure design for rationality, deformation, or corrosion. Check if the scale body limit mechanism/anti-tipping mechanism is functioning properly.
No material feeding or poor feeding: Check if there is raw material in the hopper and replenish it promptly. Check if the raw material is clumped and eliminate it by sieving or other measures. Check if the solenoid valve or motor is damaged, and if there is poor contact in the circuit.
Material blockage: Adjust the feeding speed according to the material characteristics. Optimize the hopper cone angle design to be greater than the material’s angle of repose. Use a vibrating feeder with a stirring function for highly viscous materials.
Scale hopper jamming: Check if there are foreign objects in the scale hopper and clean them. Check if the scale body limit mechanism/anti-tipping mechanism is functioning properly.