Multiple Silos Single Weigh Static Automatic Batching System

Multiple Silos Single Weigh Type

The multi-silo single-weighing static automatic batching system (also known as the multi-silo single-weighing static 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 suitable for mixing, batching, and feeding 3-8 kinds of materials. It adopts a multi-silo storage, single-weighing design, and typically supports 3-8 silos for flexible configuration, storing various raw materials such as urea, potassium chloride, monoammonium phosphate, humic acid, and decomposed organic matter.

The multi-silo single-weighing static automatic batching system differs from ordinary batching equipment by adopting an integrated design concept of "multiple silos, one weigher"—multiple raw material silos share a single high-precision weighing unit. Each silo sequentially feeds material into the same weighing hopper, and the weighing is completed one by one before the output is summed. This design significantly reduces the number of weighing sensors and the complexity of the control system while ensuring batching accuracy. The system is equipped with an intelligent PLC control system. Operators only need to input the production formula on the touch screen, and the system can automatically complete the entire process of quantitative feeding, quantitative weighing, and unified material delivery. The static batching error can be controlled within ±0.5%. This product uses microcomputer control, electronic monitoring, and digital prompts, making it easy to control and operate, ensuring precise fertilizer product content.

This equipment is suitable for the production of various fertilizers, including compound fertilizers, organic-inorganic compound fertilizers, and formulated fertilizers, and can be used in conjunction with a complete production line. It can be flexibly adapted to both pure inorganic compound fertilizer processing and organic-inorganic compound fertilizer production lines. The equipment has outstanding advantages such as simple operation, high batching accuracy, adjustable material ratios, easy installation, and portability.

Equipment Structure

The multi-silo single-weighing static automatic batching system mainly consists of the following core components:

(I) Storage System: This includes 3-8 independent raw material silos (bins) for storing different types of raw materials. Each silo 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 silo body can be made of carbon steel or stainless steel according to customer requirements, with a corrosion-resistant surface treatment.

(II) Feeding System: The feeding section is the actuator that adds material from the silos to the weighing equipment. Each silo is equipped with an independent feeding device. Depending on the characteristics of the material, various types can be selected, such as electromagnetic vibrating feeders, screw feeders, rotary valves, and pneumatic batching valves (pneumatic butterfly valves, slide gate valves). Screw feeders are used for free-flowing granular materials, while vibrators are used to assist in feeding easily agglomerated powdery materials. The feeding device receives instructions from the PLC control system to complete the quantitative conveying of materials. (III) Weighing System: This is the core of the equipment's metering system, consisting of a single high-precision load cell (or sensor group), standard connectors, a junction box, and a weighing hopper (measuring chamber). All hoppers share the same weighing unit—materials enter the weighing hopper sequentially, and the sensor monitors weight changes in real time. The load cell adopts a cantilever beam or S-shaped structure, ensuring high accuracy and good sealing performance. Flexible connections are provided at both the top and bottom of the weighing hopper to reduce frictional interference during the weighing process.

(IV) Discharge and Conveying System: This includes a pneumatic flap valve (or electric valve), a belt conveyor, etc. After all materials are batched, the pneumatic flap valve at the bottom of the weighing hopper opens, discharging the material onto the conveyor and sending it to the mixer or the next process. Batches containing dry powder must be sealed.

(V) Batching Control System: This is the brain of the entire batching process, employing a distributed architecture of "host computer + PLC system + solid batching control instrument." The host computer is responsible for the dynamic monitoring and data acquisition of the entire production line, managing various curves, parameters, production reports, and other tasks. The connections between devices utilize an RS485 fieldbus, resulting in a simple and reliable structure. The system features automatic drop correction to adapt to different material characteristics. It can store hundreds of recipes, enabling rapid recall and modification.

Application range of equipment

Multi-silo single-weighing static automatic batching systems have a wide range of applications, particularly in the fertilizer production industry. BB fertilizer (blended fertilizer) production lines: Can be used with BB fertilizer equipment to automatically proportion various single-element fertilizer granules. Organic fertilizer production lines: Can be used with organic fertilizer equipment, suitable for precise metering of organic raw materials such as livestock manure, crop straw, humic acid, and various additives. Compound fertilizer and blended fertilizer production lines: Can be used with compound fertilizer and blended fertilizer equipment to automatically proportion various raw materials. Chemical industry: Can be used to mix various chemical raw materials, ensuring product quality and production efficiency. Building materials and metallurgical industry: Can be used in concrete mixing, refractory material batching, and other scenarios. This system is particularly suitable for production scenarios where the formula contains many types of raw materials with large differences in proportion.

Types of available raw materials

The multi-silo, single-weighing, static automatic batching system can handle a wide variety of raw materials. These include: fertilizer raw materials such as urea, potassium chloride, potassium sulfate, monoammonium phosphate, and diammonium phosphate in granular or powdered form; organic raw materials such as livestock and poultry manure, crop straw, humic acid, amino acids, peat moss, and well-rotted organic matter; and additives such as trace elements, bio-inoculants, and binders. The equipment can be flexibly configured with different types of feeding devices according to the characteristics of the raw materials. Each silo is independently set up, effectively preventing cross-contamination of materials during the batching process.

Working principle of the equipment

The multi-silo single-weighing static automatic batching system operates on the collaborative principle of sensors, a PLC controller, and actuators. Its core workflow is as follows:

(I) Recipe Setting: Operators set the required recipe parameters via a human-machine interface or host computer. The system can store hundreds of recipes.

(II) Sequential Feeding: After system startup, the control system sends a start signal to the feeding actuator of silo number one according to the recipe requirements. The feeding device begins adding material to the weighing hopper. When the weighing value reaches the set value for material number one, the system sends a stop signal and shuts down the feeding device.

(III) Item-by-Item Weighing: After weighing material number one, the system automatically switches to silo number two, repeating the feeding, weighing, and stopping process. Each silo completes weighing sequentially, and all materials are measured using the same weighing hopper and the same set of sensors, ensuring consistency in the weighing benchmark.

(IV) Unified Discharge: After all materials are batched, the pneumatic flap valve at the bottom of the weighing hopper opens, discharging the collected material onto the conveyor. (v) Cyclic operation: After the material is delivered to the next process, the system automatically enters the next batching cycle. The entire process can be operated continuously for 24 hours.

Equipment operation method

(I) Pre-start Preparation: Check if there are sufficient raw materials in each hopper. Check if the weighing sensors, junction boxes, and wiring cables are normal. Check if the feeding device is operating normally. Check if the pneumatic system pressure is normal.

(II) Recipe Setting: Retrieve or input the required recipe 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 recipe parameters, enabling quick recall and modification of recipes.

(III) Automatic Operation: Start the system to enter automatic batching mode. The system will weigh each raw material sequentially according to the set recipe. 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 equipment usage and maintenance records and complete shift handover procedures.

Equipment maintenance methods

(I) Daily Maintenance: Inspect the equipment daily. Observe whether the scale body is deformed or corroded. Check the load cells, junction box, and wiring cables for proper functioning. Check the working status of each pneumatic component.

(II) Periodic Maintenance: Clean, lubricate, and calibrate the equipment regularly. Regularly check the scale body support for deformation or corrosion. Regularly inspect the infeed/discharge mechanism, pneumatic valves, flexible connections, and other components.

(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 damaged or damp sensors. Check if water has entered the junction box. Recalibrate the scale after troubleshooting.

Instrument display values ​​fluctuate: Check if water has entered the junction box or if the circuit board is damp. Check if the scale's limit 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 take measures such as sieving to eliminate it. Check if the pneumatic valve or feeding motor is damaged, and if there are poor contacts in the circuit.

Material blockage: Adjust the feeding speed according to the material characteristics. Optimize the cone angle design of the hopper to be greater than the material's angle of repose. Use a vibrator to assist feeding for highly viscous materials.

Pneumatic system failure: Check if the air supply pressure is sufficient. Check if the solenoid valve is damaged. Clear any blockages in the air passages.