This system is designed for the automated and precise batching of raw materials used in friction materials (automotive brake pads). It can continuously perform automatic weighing of various materials and discharge all weighed materials into a mixing machine.

I. Overall System Architecture 

The overall architecture of this system comprises three tiers: the ground level, the automated batching level, and the hopper feeding level. 

First Floor: Mixing Machine Installation Level; used for installing the mixing machine. 2 Tai, press 4 Taiwan planning, reserved 2 One mixing station. 

Second floor: Automated batching floor; typically installed 36-48 Only the material bin and 2 Taiwanese ingredient cart. 

Third floor: hopper feeding level; all hoppers are equipped with automatically opening and closing hopper covers. 

System Architecture Diagram:

Reference Design Drawing for the Ingredient Line:

The overall system configuration is shown in the reference photograph:

Second Floor: Automated Batching Level – Reference Photo:

The hopper is arranged in a double-row configuration, with feeding devices installed beneath it. These feeding devices include screw feeders and belt feeders, each equipped with a control valve at the discharge outlet to prevent material from spilling out after feeding has ceased. 

A hole is drilled in the center of the rail at the platform level, equipped with a discharge interface for the batching car that connects to the feed inlet of the mixing machine, and a separate maintenance access port is provided for the standby batching car. 1 One. 

Some hoppers are equipped with electric and pneumatic discharge-promoting devices, which are operated via manual control buttons. 

Three floors ： Material Feeding Layer Reference image:

This level serves as the material feeding level. A feeding passage is provided between the two-row arranged hoppers to facilitate pedestrian access and the passage of hand trucks, and the hopper feed openings are designed as 45° The hoppers are tilted, with their openings all facing the feeding chute, allowing operators to easily feed material into the hoppers. 

The automatic cover on the feed inlet is controlled by the barcode-based batching management system for automatic opening, and its closing is operated via a manual push button. 

A dust collection system shall be installed on this floor, with dust collection interfaces provided at the feed inlets of each material bin. 

Steel staircases are installed on both the ground floor and the second floor to provide access to the upper levels.

II. Functions of the Batching System 

2.1 1. Control Functions:

1 1. Computer control system: The control room is operated via a computer, featuring Chinese-language menus and graphical displays. The screen dynamically shows the position of the batching vehicle and the real-time batching weight, providing a clear, at-a-glance overview of the entire batching line status on the industrial control computer’s display. Wireless communication is used between the automated batching vehicle and the industrial control computer for data transmission. 

The system employs a dual-computer electrical control architecture, which reduces the polling time required by a single host computer to manage wireless communication with multiple slave units, thereby enhancing the efficiency, reliability, and batching accuracy during simultaneous operation of two batching vehicles. Each of the two batching vehicles is independently controlled by its own industrial PC, and a single industrial PC can simultaneously control the feeding devices for all material bins.

2 1. Automated batching: Define and store recipes on the computer; the batching vehicle automatically travels to and from designated locations according to the recipe, stops beneath each material bin to collect and verify the weighed materials, and then moves to the discharge position to automatically unload the materials.

3 , faults and alarms; when the system experiences an occasional fault, it can automatically initiate the corresponding procedures or measures. ( For example, the monitor may display recommended actions, alarms, pauses, requests for manual intervention, emergency shutdowns, and other alerts. ) and provides information such as the fault type and fault location. 

The system is equipped with the necessary safeguards to prevent operator error: a audible and visual alarm is activated prior to any movement of the batching vehicle; in emergency situations, both the batching vehicle and the feeding device can be brought to an immediate stop.

4 , metrological management; computer storage 500 For each recipe, the system automatically records the results of each batching operation, and administrators can use a password to print daily and monthly reports.

2.2 1. Ingredient cart: quantity 2 Taiwan   

1 1. Material car quantity structure 

Ingredient Cart Configuration 3 A weighing hopper, including a large hopper scale. 1 Taiwan, automatic weighing scale 2 Taiwan.

The main hopper scale has a net capacity of 500 kg and is used to verify that the batching vehicle’s automatic metering system is operating normally.

The automatic weighing scales consist of one large and one small unit, with the large scale having a capacity of 100 kg and the small scale 30 kg. To ensure clean discharge, each of the three scale bodies is equipped with a vibration device.

2、  Material cart travel speed: Equipped with a variable-frequency speed-control system for quick, smooth positioning and stopping. 

3 , Material feeding speed: ( To be determined by the supplier, provided that accuracy and efficiency are met. )

4、  Dust-control measures for the material car: Both the loading and discharging ports on the car are equipped with automatic telescopic seals to prevent dust from escaping. 

2.3 , Feeding Device    

The feeding device beneath the hopper employs a variable-frequency drive to control the screw feeder, which delivers material at two fixed speed settings—fast and slow—after being properly adjusted, thereby ensuring smooth discharge of each material type and meeting the required weighing accuracy. 

2.3 1. Dust-proof structure 

Both the feed inlet and discharge outlet of the batching vehicle are equipped with sealed, telescopic interfaces, enabling airtight connection with the hopper’s feed and discharge openings during material addition or removal. 

An automatically controlled bin gate is installed at the feed inlet of the transfer hopper above the mixing machine. The gate opens automatically when the batching vehicle arrives to discharge material and closes automatically when the vehicle departs, thereby preventing dust from the transfer hopper from spreading upward. 

A dust-collection system is installed on the three-layer feeding section, and another dust-collection system is installed at the discharge outlet connecting the first and second layers as well as in the transition hopper. This 2 All dust-collection systems are interlocked with the batching system to achieve energy savings and emission reductions. 

2.4 , Error Correction and Audio-Visual Alarm 

When the deviation during the batching process exceeds the permissible tolerance, the system automatically shuts down and triggers an alarm. Subsequently, under manual control, the material cart is moved to the correction parking position, where operators can add or remove the missing or excess materials. 

The system shall be equipped with necessary devices to prevent operator error; prior to the movement of the batching vehicle, an audible and visual alarm shall be activated. In special circumstances, both the batching vehicle and the feeding device shall be capable of emergency stop. 

2.5 , hand / Automatic function 

Both the batching car and all batching equipment are designed with manual–automatic switching functionality, enabling convenient mode changes to accommodate commissioning and situations requiring manual operation. 

2.6 1. Hopper Feeding Port Structure 

The feed inlet of the hopper is inclined, and a pneumatic bin gate is installed at the inlet, which is automatically opened and closed under the control of the barcode management system. 

2.7 1. Manual Material Weighing System 

Certain special materials in the formulation can be assigned to virtual material bins for manual weighing and error-proofing. The manual weighing system is networked with the batching computer system and integrated into the batching database for unified management, with handheld barcode scanners used to scan material barcode labels for accurate and error-free weighing. 

Reference photo of a manual scale connected to the ingredient dispensing system:

Bin Feeding Error-Proof Barcode Management System 

1 1. Overall system architecture layout: Refer to the reference photos.

2 1. Hopper inlet structure: Refer to the photograph.

The feeding port of the hopper is formed. 45° The unit is tilted, and the feed inlet is equipped with a pneumatic cover that is automatically opened by the system and manually closed via a push button. 

3 1. Barcode-based batching and warehouse management system: Refer to the photo

4 1. Barcode Computer System Functions 

This system comprises an industrial control computer system, barcode management software, and an electrically controlled silo cover system. It is primarily used to prevent errors during manual material feeding into the silo and provides basic data management capabilities. 

( 1 ) Barcode generation and printing functionality 

The system can generate and print barcode labels for materials, recording information for each material. 

The system can generate and print barcode identification cards for batching operators, recording the identity information of each operator. 

( 2 ）Features of this ingredient addition management system 

● Use a barcode system to manage material feeding: only one indicator light is illuminated at a time, and only the corresponding hopper lid is opened, thereby preventing feeding errors; furthermore, if a hopper lid is not closed, no other hoppers can be opened arbitrarily. 

● The computer records batching information, enabling traceability of batching errors. 

● Equipped with a large-screen display for feed management information, ensuring clarity and visibility; 

● The system allows users to query batching records and print simple reports.