Automatic Batching Control System: Three Batching Modes, Functions, and Features

An automatic batching system is an automated batching equipment used in industrial (such as iron smelting batching, concrete batching for construction) and agricultural (such as feed batching) production. It typically consists of an automatic batching electrical control system, controlled feeding devices (equipment), and a monitoring system.

Batching Modes of Automatic Batching Systems

1. Static Batching Mode: Suitable for sites without continuous batching requirements, allowing batch-by-batch batching with time intervals between batches. These sites have less stringent requirements on batching time but strict requirements on the composition ratio of each batch, with the material ratio relatively fixed within a certain period according to process requirements. Each batch consists of multiple materials, achieving much higher batching accuracy than dynamic batching. Static batching systems generally use weighing-type hoppers, weighing-type bins, etc., as metering equipment.

2. Dynamic Batching Mode: Applicable to sites with continuous batching requirements, emphasizing high continuity in batching and generally not allowing intermediate stops. The proportion of various materials is strictly required. Dynamic batching systems typically employ weighing-type belt feeders, weighing-type screw feeders, etc., as metering equipment.

3. Combined Static-Dynamic Mode: Some industries have special batching needs, requiring a combination of static and dynamic modes to meet final process requirements. According to the batching process requirements, a parallel control flow can be adopted to satisfy both high-precision micro-batching and continuous batching of larger proportions of materials. This saves batching time and meets the requirements for batching speed and accuracy, achieving efficiency, precision, environmental protection, and adaptation to ambient temperatures, while avoiding direct hazards to manual on-site operations from toxic gases, dust, etc.

Main Functions of Automatic Batching Systems

1. Monitoring: Detecting and monitoring instantaneous and cumulative flow rates during the belt scale batching process.

2. Screen Display: Displaying the operational status of relevant control parameters and real-time batching curves and tables on a computer monitor.

3. Printing Management: Printing batching reports at any time for storage and retrieval.

4. Communication: Enabling bidirectional data and information exchange between the industrial control computer, PLC, and instruments.

5. Data Processing: Automatically processing collected signals and outputting corresponding control values.

6. Control Function: Automatically controlling the normal operation of equipment based on preset values before operation, including PID adjustment.

7. Alarm Function: Providing alarms through screen displays and audiovisual signals for parameter overlimits or abnormal equipment status.

Features of Automatic Batching Systems

1. Structural Features: The automatic batching system enables decentralized control and centralized management; the upper and lower computers are relatively independent, with manual, automatic, and semi-automatic switching functions. When online, they exchange information based on specific protocols; offline, a single scale can independently achieve closed-loop process control.

2. Improved Stability and Environment: The upper computer is located away from the operating site, enhancing system stability and improving the operator's working environment. The lower computer uses a programmable controller, which is highly resistant to interference, easy to program, and capable of long-term reliable operation in harsh environments.

3. High Precision and Flexibility: Employing PID adjustment improves batching accuracy, and the system can automatically modify material ratios based on production requirements.