The pre‑weighing, material‑type‑specific mobile railcar automatic batching system, with its high precision, robust dust‑proof design, and exceptional flexibility, is ideally suited for applications involving a wide variety of raw materials ( 20  Medium-sized and larger manufacturing enterprises that produce three or more product variants, employ precision formulations, operate in dusty production environments, and require frequent formula changes.

I. Overall System Architecture 

The overall architecture of this system adopts a three-tier structure, comprising the mixing and portioning layer (ground floor), the automated batching layer, and the hopper feeding layer. In total… 2 The ingredient carts are aligned on the same straight line, totaling 20 A double-row layout for the material bin. 

The entire system includes: 2 Taiwan automatic weighing batching car, 20 a hopper ( 4 Only the large hopper +16 Only a small hopper), 16 Taiwan small electronic hopper scale, 4 NTU electronic hopper scale, 20 The batching and feeding system, together with the complete control system, ensures that all materials are pre‑weighed in the hopper scale before being discharged into the batching car.

II. Core Operating Principle: Mobile “One Vehicle, Multiple Storage Units” 

The most significant innovation of this system lies in breaking away from the traditional fixed “one silo, one scale” configuration. By deploying a mobile weighing carriage that travels along rails, it enables a single carriage to serve multiple silos. To enhance batching efficiency, the system is designed with a pre‑weighing mode at each silo’s electronic scale and a secondary re‑weighing step when the batching carriage collects materials. 

Ground layer (mixing layer): Install the mixer and receive the discharge from the batching trolley. 

Automatic batching layer (core layer): Install the mobile batching and weighing cart and its track. The cart travels automatically along the track, positioning itself beneath the designated hopper to receive material from the box-type electronic hopper scale and perform a secondary weighing. 

Feed layer of the hopper (top layer): Arrangement 20 A storage bin used to hold various raw materials, such as graphite, iron powder, and resin. 

Workflow: 

All electronic hopper scales automatically weigh materials according to the recipe requirements. -> The ingredient cart automatically travels to the target storage bin. ->  Discharge from the hopper-type electronic scale beneath the storage bin. ->  Vehicle Dynamics / Static weighing re-verification ->  The trolley moves above the mixer. ->  Automatic unloading.

III. System Equipment Configuration 

Level 1: Mixing and portioning level, For installation 6 Taiwanese mixing machine and associated equipment such as vibrating screens. 

Second Floor: Automated Batching Level ;

1 , Ingredient Cart: Quantity: 2 Taiwan 

Configuration 2 Automatic batching carts, with each cart equipped with… 1 Hopper scale, maximum net capacity 400kg To ensure clean discharge, the scale is equipped with a vibrating device that automatically shakes to clear any material buildup during discharge.

2 , Screw feeder: Quantity 20 Taiwan 

Includes a large-spiral feeder 4 Taiwanese small screw feeder 16 Tai, 4 A large material bin is equipped with a large screw feeder, 16 A small hopper is equipped with a small screw feeder. Each screw feeder’s inlet is fitted with a maintenance gate valve (to facilitate maintenance), and its outlet is fitted with a pneumatic shut-off valve (to prevent material from sliding out of the discharge port after the screw feeder has stopped feeding). 

3 , Electronic hopper scale: Quantity 20 Taiwan 

16 A small electronic hopper scale is installed beneath the screw feeder of the small material bin (totaling…). 16 Taiwan), 4 A large electronic hopper scale is installed beneath the screw feeder of the main material bin (totaling…). 4 Tai), used for the automatic weighing of materials in each storage bin prior to material pickup by the batching vehicle. 

4 , Large material bin: Quantity 4 one 

System Settings – Large Material Bin 4 units, with a hopper capacity of approximately 1.5 m³ 。

5 , Small material bin: Quantity 16

System Settings – Small Material Bin 16 units, with a hopper capacity of approximately 1.0 m³ 。

6 , Discharge opening: Quantity 6 one 

Holes are drilled in the rails on the second-floor platform, and fittings are installed. 6 A discharge outlet is connected to the feed inlet of the mixer, with a transition hopper and the mixer installed below the discharge outlet.

IV. System Control Functions 

1 , Computer control functions: Dual-computer electrical control system, equipped with an industrial PC. 2 Tai, 

The system features a Chinese-language menu and graphical display, with the screen dynamically showing the position of the mobile batching cart and the real-time weight of the batched materials. The status of the entire batching line is clearly visible at a glance on the industrial control computer’s display. Data is transmitted wirelessly between the automated batching cart and the industrial control computer. 

2 , Automatic batching; 

On the computer, recipes are configured and stored; the electronic hopper scale performs automatic weighing, and the batching cart moves back and forth to the designated positions according to the recipe. The batching cart can automatically dock beneath the electronic hopper scale under the material bin for receiving and verifying measurements, then proceed to the discharge station to unload automatically. 

3 , faults and alarms; 

When the system encounters an occasional malfunction, it can automatically initiate appropriate procedures or measures. ( Such as displaying recommended actions, alarms, pauses, requests for manual intervention, emergency shutdowns, and so on on the monitor. ) and indicates information such as the fault type and fault location. 

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

4 , Metrology management; 

A computer can store at most 500 For each recipe, the system automatically logs the results of every batching operation, and administrators can use a password to print daily and monthly reports. 

5 , Small electronic hopper scale 

Quantity: 16 Tai, maximum range 40kg , the static weighing accuracy of each is equal to the range’s ±0.1% , dynamic weighing accuracy is less than or equal to ±0.5% , Display accuracy: ±5g 。

6 Large electronic hopper scale 

Quantity: 4 Tai, maximum range 120kg , the static weighing accuracy of each is equal to the range’s ±0.1% , dynamic weighing accuracy is less than or equal to ±0.5% , Display accuracy: ±20g 。

7 , Ingredient Cart  

Ingredient cart 2 Tai, each vehicle is equipped with 1 A weighing hopper is used to store materials in the batching vehicle and to automatically measure or verify whether the received materials meet the specified requirements. The maximum capacity of the weighing hopper is… 400kg , minimum indication value 0.1kg 。

Ingredient cart travel speed: 5 ~ 30m /min , By using a variable-frequency drive system, positioning and stopping can be achieved quickly and smoothly. 

Dust-control measures for the material car: Both the receiving and discharging ports of the weighing hopper on the material car are equipped with automatic retractable seals to prevent dust from escaping. 

Power supply and communications 

The batching car is powered by a three-phase power supply via a conductive rail system, while the industrial control computer (the host computer in this system) and the lower-level controller on the batching car exchange signals wirelessly. 

8 , Feeding device   

20 The feeding devices beneath each hopper are screw feeders, all equipped with variable-frequency drive control. Depending on the quantity of material to be discharged in each batch, the feeders—pre‑set to one of two fixed speed settings—are operated at either a faster or slower rate, ensuring smooth discharge of each material type and meeting the required weighing accuracy. 

9 Dust-proof structure 

The design takes into account dust‑related environmental pollution: both the feed and discharge ports of the batching vehicle are equipped with sealed, retractable interfaces, enabling airtight connections to the hopper’s discharge opening and the ground‑level discharge outlet during loading or unloading. 

An automatically controlled hopper door has been installed at the feed inlet of the transfer bin above the mixer. When the batching cart is in position and discharging, the door opens automatically; when the cart departs, the door closes automatically, thereby preventing upward dust dispersion from the transfer bin. This automatic door retains a manual override: in special circumstances, operators can use a push-button to open or close it. 

An automatic telescoping interface is installed at the discharge outlet of the transfer hopper above the mixer, enabling automatic connection to the mixer’s feed inlet during material loading. 

The three‑layer feeding system is equipped with a dust‑collection system; the dust‑extraction port on the hopper can be connected via a suction hose to a dust collector or to the workshop’s central dust‑extraction ductwork. 

10 , Error Correction and Security 

During the batching process, there is a very low probability that the electronic hopper scale beneath the bin may register a weighing error exceeding the allowable limit. In such cases, the system automatically triggers an alarm and pauses operation, allowing operators to either replenish material via the control buttons or manually discharge excess material, ensuring the batching process can proceed to completion while meeting the specified accuracy requirements. 

The trolley collects materials and performs a secondary weighing to verify the total formulation weight; an alarm is triggered if the deviation exceeds the tolerance. When a material batch fails to meet the specification, manual intervention allows the nonconforming material in the trolley to be discharged at a designated discharge point. 

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

11 , hand / Automatic function 

The electronic hopper scale, batching cart, and all feeding devices are designed with manual–automatic switching capability, enabling convenient mode changes to accommodate commissioning and situations requiring manual operation. 

V. Major Application Areas 

Food additive and preservative company :   Specifically used in the food deoxidizer industry, deoxidizers. /  Preservative production primarily relies on blending powdered materials such as reduced iron powder, activated carbon, diatomaceous earth, and inorganic salts. With its strong demand for multiple formulations, high precision, significant dust generation, robust traceability, and food-grade compliance, this system is highly compatible. 

Powder metallurgy enterprise: A manufacturer of cemented carbides, magnetic materials, and metal structural components. 

Fine Chemicals /  New Materials Company: Enterprises that produce specialty ceramics, catalysts, battery materials, and other products require precise blending of multiple powdered raw materials.