Honeycomb ceramic automated batching and mixing line
1. Smart Material Charging System: Barcode Verification & Comprehensive Dust Control
Error Prevention & Traceability: Ton bags are hoisted to the unpacking station using an electric hoist. A manual barcode scanning mechanism ensures that the unpacking gate opens only when the barcode matches correctly, effectively preventing material misfeeds and guaranteeing raw material traceability.
Advanced Dust Management: Dust generated during unpacking is managed by an independent baghouse dust collector. Filtered material is recovered to an intermediate storage bin via pulse-jet reverse blowing. Emission concentrations are significantly below national standards, substantially improving the plant environment.
Optimized Storage Features: The intermediate storage bin is equipped with vibrators and a filter screen to prevent screen blinding and material bridging. It also features a low-level alarm to prompt timely replenishment. Critical materials are further enhanced with a permanent magnetic drum separator to boost product purity.
2. Efficient Storage System: 26-silo Layout & Dual Arch-Breaking Design
Optimized Configuration: The storage system comprises 26 silos arranged in a scientifically rational 4-row layout. These are cleverly configured into four parallel production lines, enabling simultaneous and highly efficient operation.
Inventory Monitoring: Each silo includes high and low-level alarms, providing real-time inventory monitoring to prevent material run-out or overfilling.
Smooth Discharge: Bin walls integrate pneumatic bin activators and air fluidizers, effectively mitigating powder bridging and arching phenomena to ensure smooth and consistent material discharge.
3. High-Precision Metering System: Dual Variable-Frequency Screw Feeders & Self-Learning Algorithm
Vibration Isolation: The system utilizes a fixed weigh hopper structure with an independent support design, isolating it from platform vibration to maintain superior weighing accuracy.
Precision Feeding: The feeding system is equipped with dual screw feeders (both coarse and fine screws are variable-frequency controlled), enabling two-stage precision metering. This achieves a weighing accuracy of up to 0.2%, meeting the stringent demands of high-end ceramic production.
Automated Calibration: The system features an automatic calibration function, completing calibration automatically before each shift. It also supports one-touch manual calibration for convenient operation.
Adaptive Learning: A more advanced feature is the system's self-learning algorithm, which dynamically optimizes subsequent metering parameters based on previous weighing data, continuously enhancing batching consistency and stability.
4. Pneumatic Conveying System: Positive Pressure Transfer & Future Expansion Provision
Enclosed & Contamination-Free: After metering, material is conveyed to a remote mixer via a positive-pressure dense-phase conveying system. This fully enclosed operation eliminates secondary contamination.
Safety & Balance: The destination bin is equipped with a baghouse dust collector and a pressure/vacuum relief valve, ensuring safe conveying and pressure balance.
Scalability: The piping system has reserved interfaces for future expansion with additional vertical conveying lines (Line 2 and Line 3). Concurrently, the control system's program logic is pre-configured for up to 8 lines, ensuring that future capacity expansion will not require extensive software modification, thereby reducing long-term investment risk.
5. Safety and Ergonomic Design: Comprehensive Protection & Easy-Maintenance Structure
Operator Safety: Platforms are equipped with guardrails and ladders conforming to national standards, ensuring operator safety. Moving parts are fitted with protective guards, adhering to best practices for machine guarding.
Reduced Cross-Contamination: The metering scale outlet utilizes a pneumatic discharge valve structure for quick cleaning and material evacuation, minimizing the risk of cross-contamination.
Streamlined Maintenance: All inspection points are fitted with manual slide gates, facilitating convenient equipment maintenance and troubleshooting.
6. Intelligent Control System: Siemens PLC & Full-Process Data Management
Robust Control Core: The control system is centered on a Siemens PLC, paired with high-precision weighing instruments and IP65-rated electrical components for stable and reliable operation.
Integrated Management Software: The HMI/SCADA management software is divided into two primary modules: PM (Process Management) and SCADA (Supervisory Control and Data Acquisition), offering:
Recipe Management: Support for adding, modifying, copying, and deleting recipes.
Barcode Traceability: Raw materials are scanned upon receipt, enabling full process tracking.
Access Control: Password protection for different roles, safeguarding critical data.
Historical Data Query: Weighing records and consumption reports are exportable to Excel for analysis and decision-making.
Flexible Operation: The system supports bumpless manual/automatic switching, facilitating easy commissioning and emergency handling.
