20 The hopper pre-weighing and mobile railcar automatic batching system, with its high precision, robust dust-proof design, and high flexibility, is best suited for applications involving a large variety of raw materials ( 20  Medium-sized and larger manufacturing enterprises that handle three or more product varieties, require precise formulation, operate in dusty production environments, and frequently switch formulations.

I. Overall System Architecture 

The overall architecture of this system comprises three tiers: the mixing and portioning layer (ground level), the automated batching layer, and the hopper feeding layer. In total, 2 The ingredient carts are aligned in a straight line, totaling 20 A double-row layout for the material bins. 

The entire system includes: 2 Taiwan automatic weighing and batching vehicle, 20 a material bin ( 4 Only the main hopper +16 only a small material bin), 16 Taiwan small electronic hopper scale, 4 NTU electronic hopper scale, 20 The batching and feeding unit, together with the complete control system, ensures that all materials are pre-weighed by the hopper scale before being discharged into the batching truck.

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

The most significant innovation of this system is the departure from the traditional fixed “one silo, one scale” configuration. Instead, it employs a mobile weighing cart that travels along a track, enabling “one cart to serve multiple silos.” To enhance batching efficiency, the system is configured with pre-weighing at the electronic scales of each silo, followed by re-weighing when the material is transferred to the batching cart. 

Ground Level (Mixing Layer): Install the mixing machine to receive the discharge from the batching cart. 

Automatic batching layer (core layer): Install a mobile batching and weighing cart along with its track. The cart automatically travels along the track, positions itself beneath the designated silo, receives material into the box-type electronic hopper scale below, and performs a secondary weighing. 

Feed layer of the hopper (top layer): Arrange 20 A storage bin for holding various raw materials (such as graphite, iron powder, resin, etc.). 

Workflow: 

All electronic hopper scales automatically weigh materials according to the recipe requirements. -> The ingredient cart automatically moves to the target storage bin. ->  Discharging from the hopper-type electronic bin scale below the material bin ->  Vehicle Dynamics / Static weighing of duplicate nuclei ->  The cart moves above the mixing machine. ->  Automatic unloading.

III. System Equipment Configuration 

Level 1: Mixing and Portioning Level, For installation 6 Taiwanese mixing machines and associated equipment such as vibrating screens. 

Second Floor: Automated Batching Level 

1.Ingredient Cart: Quantity: 2 Taiwan 

Configuration 2 Taiwanese automatic batching vehicles, with each vehicle equipped with 1 Hopper scale, maximum net capacity 400kg To ensure clean discharge, the weighing platform is equipped with a vibration device that automatically vibrates to clear any material buildup during discharge.

2.  Screw feeder: Quantity 20 Taiwan 

Includes a large helical feeder 4 Taiwanese and small screw feeders 16 Taiwan, 4 A large material bin is equipped with a large screw feeder, 16 A small hopper is equipped with a small screw feeder, and each screw feeder’s inlet is fitted with a maintenance gate valve (to facilitate maintenance of the screw feeder), while its outlet is equipped with a pneumatic shut-off valve (to prevent material from sliding out of the outlet after the screw feeder stops 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 (a total of 4 Taiwan), used for the automatic weighing of materials in each bin prior to material pickup by the batching vehicle. 

4. Large material bin: quantity 4 one 

System Settings: Large Material Bin 4 One, the hopper volume is approximately 1.5 m³ 。

5. Small material bin: Quantity 16

System Settings – Small Material Bin 16 One, the hopper volume is approximately 1.0 cubic meters 。

6.  Discharge opening: Quantity 6 one 

A hole is drilled in the middle of the steel rail on the second-floor platform, and it is equipped with… 6 A discharge outlet is connected to the feed inlet of the mixing machine, with a transition hopper and the mixing machine installed below the discharge outlet.

IV. System Control Functions 

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

The computer features a Chinese-language menu and graphical display, with the screen dynamically showing the position of the mobile 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. Data is transmitted wirelessly between the automated batching vehicle and the industrial control computer. 

2. Automatic batching; 

Formulas are configured and stored on the computer; the electronic hopper scale performs automatic weighing; the batching cart automatically travels back and forth to the designated positions according to the formula; the batching cart can automatically approach the electronic hopper scale beneath the material bin for material collection and weight verification; and it can also automatically move to the discharge position for automatic unloading. 

3.  faults and alarms; 

When the system experiences an occasional failure, it can automatically take appropriate steps 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; 

A computer can store up to 500 For each recipe, the system automatically records 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 is all within the range of ±0.1% , dynamic weighing accuracy is less than or equal to ±0.5% , Display precision: ±5g 。

6. Large Electronic Hopper Scale 

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

7. Ingredient Cart  

Ingredient Cart 2 Taiwan, each vehicle is equipped with 1 A weighing hopper, used for material storage in the batching vehicle and for automatic measurement or automatic verification of whether the received materials meet the specified requirements; the maximum capacity of the weighing hopper. 400kg , Minimum Indicating Value 0.1kg 。

Material cart travel speed: 5 ~ 30m /min , The variable-frequency drive system enables quick and smooth positioning and stopping. 

Dust-control measures for the material car: Both the inlet and outlet of the weighing hopper on the material car are equipped with automatic telescopic interfaces to prevent dust from escaping. 

Power Supply and Communications 

The batching vehicle is powered via a three-phase power supply slip ring, while the industrial control computer (the host computer for this system) and the lower-level controller on the batching vehicle exchange signals wirelessly. 

8. Feeding Device   

20 All feeding devices beneath the material bins are screw feeders, all equipped with variable-frequency drive control. Based on the required single-discharge quantity, the pre-set feeder operates at two fixed speed settings—fast and slow—to ensure smooth discharge of each material type and to meet the specified weighing accuracy requirements. 

9.Dust-proof structure 

The design takes into account dust pollution of the environment: both the feed inlet and discharge outlet of the batching vehicle are equipped with sealed, telescopic interfaces, enabling airtight connection with the hopper discharge opening and the ground-level discharge outlet during material feeding or discharging. 

An automatically controlled bin gate is installed at the feed inlet of the transfer hopper above the mixer. When the batching vehicle arrives and begins discharging, the gate opens automatically; when the vehicle departs, the gate closes automatically, thereby preventing dust from the transfer hopper from spreading upward. The automatic gate is also equipped with a manual override function, allowing operators to open or close the gate via a push button in special circumstances. 

An automatic telescopic coupling is installed at the discharge outlet of the transfer hopper above the mixer to automatically connect with the mixer’s feed inlet during material feeding. 

A dust-collection system is installed on the three-layer feeding section, with the dust-collection interface on the hopper connected via suction ducts to a dust collector or the workshop’s central dust-collection main. 

10. Error Correction and Security 

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

The cart collects materials and re-weighs the total formulation weight for verification; an over-tolerance alarm is triggered. If a material exceeds the tolerance and is therefore nonconforming, manual intervention can be used to discharge the nonconforming material from the cart to a designated discharge point. 

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. 

11. hand / Automatic function 

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

V. Main Application Areas 

Food additive and preservative company :   Specifically used in the food deoxidizer industry, deoxidizers /  Freshness-preserving agent production primarily involves compounding powdered materials such as reduced iron powder, activated carbon, diatomaceous earth, and inorganic salts. This process demands multiple formulations, high precision, significant dust generation, robust traceability, and food-grade compliance—requirements that align exceptionally well with this system. 

Powder Metallurgy Enterprises: 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.