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Automatic Batching System

 Automatic Batching System

At Weighing Solutions & Instrumentation, we provide solutions for automatic batching system. Be it a new automatic batching system requirement or automating the existing manual batching system. We fulfill both the requirements. Batching is one of the major and vital part of many industries. It plays a very very vital role in maintaining the quality as well as quantity of the output of a plant. Batching is actually taking different materials in different quantities and mixing them together to make a raw mix or a final product.

Automatic Batching system for Cement Plant.

In cement industry, for making the raw mix for making cement, Lime stone, Clay, Pet coke and Iron dust are mixed in different quantities. This raw mix is then send to the mill for final process. Automatic batching system is installed for cement industry where a batcher can feed the required quantities of the all the four raw materials into the system and the automatic bathing system will make the batches at required interval.

Hence, it maintains a continuous feed and perfect batch for the mill. The system collects required quantities of materials in collection hoppers. System discharges the material when the batch is ready in the collection hoppers onto a conveyor belt at such a interval that all the materials get mixed while being fed to the bucket elevator through conveyor belt. The material is then taken to the master hopper by the bucket elevator.

This system is completely interlocked. Suppose, if there is a fault in conveyor or bucket elevator and any one or both stop working, then the system stops unless and until they are set right. Similarly, if the master hopper reaches its full capacity, the system stops making batches unless the master hopper is emptied to a certain level.

The system is completely PLC based. The collection hoppers are fixed with very high precision load cells and are connected with specially made digital weighing controllers which communicate with PLC and gives signals and data to the PLC to perform designated tasks.

Modifications:

The cement industry is just an example and same principle can be adopted into any industry with minor adjustments or can also be completely re-designed to suit the exact requirement of the customer. The gates of main hoppers and collection hoppers can be electrical motor operated or can be Pneumatic also. Any type of modification in the system is possible. Any information can be provided on the Color Touch Screen HMI which is part of the system.

The status of the hopper gates, conveyor, bucket elevator, master hopper is displayed on the HMI. Number of batches made is also displayed. The system has both Auto and Manual mode. In auto mode, the system keeps on making batches as per the setting of the system until it is stopped by operator or any of the stop conditions appear. In manual mode, the operator can operate any gate and discharge any material in any quantity or can make batches manually also.

Batching Load cell 1_s
Load cell mounting for batching system
Batching Load cell 3_s
Load cell Mounting for Batching system
Batching Hopper 2_s
Collection Hopper
Collection hopper_1s
Collection Hopper
Motor_gearbox_1s
Motorised Gates
Motorised gate
Motorised Gates
Releae gate_1s
Material Release Gate
PLC Panel
PLC Panel
Digital weight controllers for automatic bathing system
Weight Controllers
HMI Screen_1s
HMI Screen
HMI Screen_2s
HMI Screen of Batching System

 

 

Top view of fully automatic Multi hopper batching system
Top view of fully automatic Multi hopper batching system

 

Top view of fully automatic Multi hopper batching system
Side view of fully automatic Multi hopper batching system

 

Top view of fully automatic Multi hopper batching system
Bottom view of fully automatic Multi hopper batching system
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