Weighing automation system with intelligent distribution of livestock and poultry feed

Abstract

A system is presented as a weighing automation system with intelligent distribution of livestock and poultry feed. The system is designed to optimize the processes of production, weighing, distribution, monitoring and management of feed in the livestock and poultry industries. In the present design, different feed formulations are registered according to different species of livestock and poultry, the system automatically adjusts and executes the composition of raw materials based on the defined formula, and the processes of production, weighing, mixing, grinding, storage and distribution of feed are also automatically monitored and controlled. Therefore, the innovative features of the present design include integration in the management of production processes, weighing and distribution of feed, image processing for automatic and accurate recording of vehicle specifications and input / output materials, intelligent and real-time control of silos, mills, weighing systems and energy consumption, the possibility of setting variable production formulas, product tracking and data recording, and the ability to be presented in different versions based on the capacity of the factory (basic, advanced, integrated). This system, while eliminating human errors, reducing energy consumption, increasing accuracy in feed formulation, and improving product quality, has the ability to comply with global standards such as ISO and BRC, and will also be effective in improving competitiveness and exporting products. Therefore, it can take an effective step in this direction and in resolving some related problems.

Description

Description of the invention Title of the invention (as stated in the declaration) Scale automation system with intelligent distribution of livestock and poultry feed Technical background of the relevant invention This invention relates generally to the new technology industries in the livestock and poultry feed industry, and specifically to the industry of weighing systems, feed distribution, and production process monitoring in broodstock and day-old broiler chicken breeding units. Technical problem and stating the objectives of the invention In general, in the livestock and poultry feed industries, the process of weighing and distributing raw materials is considered a critical step in the final quality of the product. However, many production units still use traditional and unintelligent systems for weighing and distributing feed. These methods are usually human-based, lack sufficient accuracy, are untraceable, and lack the ability to record, analyze, and continuously monitor data. One of the most common problems in this area is human error in calculating the weight of materials, which leads to unbalanced and unscientific consumption of raw materials. On the other hand, the lack of an integrated system to control the feed production process causes inconsistency between different parts (silo, mill, weighing system, etc.) and reduces productivity. Lack of accurate information recording and poor reporting are also related problems that disrupt quality management, product traceability, forecasting raw material needs, and optimal decision-making. Due to the lack of accurate monitoring, lack of process optimization, and imprecise formulation, energy and resources are consumed at a high rate.Other problems in this area include the heterogeneity of the final product and the inability to respond quickly to changes in the market or production conditions, which leads to reduced quality, decreased customer satisfaction, and increased waste. In addition, non-compliance with international standards also challenges the export of products and reduces brand reputation. The main objective of the present project is to design and implement an intelligent automation system for weighing and feed distribution. The present project is designed with a focus on further optimization and to increase the accuracy of the intelligent system, and by utilizing modern technologies in the field of hardware (load cells, sensors, cameras) and software (image processing, database, data analysis), it can perform all stages of weighing, distribution, recording, control and reporting accurately, continuously and intelligently. A description of the state of the prior art and the history of developments related to the claimed invention. Given that in many livestock and poultry feed production units, the processes of weighing and distributing feed are carried out manually or with semi-automatic systems, this leads to human errors, increased waste of resources, reduced accuracy in raw material consumption, non-compliance with production formulas, and ultimately reduced quality of the final product. The present design presents a comprehensive hardware and software system that enables precise weight control, feed distribution, continuous monitoring, data collection, reporting, and reduction of energy consumption in an intelligent and integrated manner. A number of inventions that have addressed this issue include: In the domestic invention titled Sorting Machine for Fruits with Gasoline Drive with Registration Number 85253, it refers to an invention that the fruits that can be used in this machine are fruits that are almost round and hard, such as green tomatoes, nectarines, plums, walnuts, etc. The resulting product is in the form of a machine with dimensions of 4 × 1 × 1 (length, width and height) meters. The user can pour his sorted product of different sizes into the machine through an inlet funnel and the sorted fruits in 3 sizes small, medium and large are discharged from the 3 outputs of the machine. After being poured into the inlet funnel, the fruits are guided with a gentle slope towards the first sieve. The sieves are vibrated by a crank system (flywheel) that works with the driving force of a gasoline engine. The crank system is actually a flywheel that receives the rotational motion of the motor shaft through a pulley and belt and converts it into reciprocating motion. The crank shaft is connected to the screen chassis and causes the screen (screen) to reciprocate.After the fruits enter the first screen, the small-sized fruits pass through the holes of the first screen and are separated from the machine by a separator located under the first screen. The remaining fruits are guided to the second screen due to the gentle 5-degree slope of the screens and the reciprocating motion of the crank system, and in the second screen, fruits with medium diameters are removed from the second screen. Finally, the largest-sized fruits are removed through the outlet installed at the end of the second screen. As a result, the operation of this design is generally different from the present design. In the domestic patent entitled "Packaging device with leak testing capability, converting carton sheet into ready-made box and sorting and arranging packages with trapezoidal mechanism" with registration number 104687, it refers to an invention that, by adding three new mechanisms in the form of three units including leak control unit, carton box production unit and sorting and arranging unit to the packaging device, has centralized the control and cartoning steps of snack packages in one device. The integrated packaging device is designed using the integration technique in two floors, which performs all packaging steps including weight and length measurement, leak testing and identification of defective packages (low and high-inflated packages), removal of defective packages from the cycle, sorting packages in specific rows, making carton boxes, transferring packages into carton boxes, closing box doors, and gluing doors automatically in the smallest space. Therefore, it is completely different from the present design. In the domestic invention titled Rice Sorting Device Based on Color Recognition with registration number 98561, it refers to an invention that separates rice based on color recognition. In this way, rice containing mouse droppings, small stones, and additional items are guided to the sorting by elevators and there, it is guided uniformly in front of the cameras by a vibrator, the rice is identified by the cameras, and then various commands are used by central boards and ejectors for rice sorting, and finally the rice is guided cleanly and uniformly to the packaging stage. Therefore, it is generally different from the present design. The domestic patent entitled Portable Gravity Sorter for Spherical Products with Telescopic Stands, registration number 103598, refers to an invention for round fruits. In this device, gravity is used to move the fruits from the feeder to the sorter. To solve the problem of lack of portability, the origami method is used, in which the desired device is designed as a foldable one. To build it, a feeder is designed to hold and send products to the sorter plates, a chassis for installing the feeder and the sorter plates along with telescopic stands, six retractable and telescopic stands for balancing the device on uneven terrain, and finally the sorter plates for separating products. As a result, it is completely different from the present design. Providing a solution to an existing technical problem along with an accurate, sufficient, and integrated description of the invention In this report, an intelligent scale automation system with intelligent distribution of livestock and poultry feed is presented. The proposed system is a comprehensive solution consisting of hardware and software equipment that performs the weighing and distribution process of feed in an intelligent, accurate, and controllable manner. This system includes a hardware part and a software part, the hardware part of which includes a digital scale equipped with accurate load cells, an Indicator device for displaying the instantaneous weight, an automatic vehicle detection camera and image recording, industrial control equipment including PLC, PID system and energy consumption measurement systems, temperature, humidity and material level sensors in silos, and its software part also includes production management software with the ability to define feed formulas, record and process data in real time, a central monitoring system with smart alerts, daily, monthly and annual reporting capabilities in the form of graphs and tables, a web-based user interface for remote access, and connection to warehouse and transportation management systems. The design of this system as a new method can well provide the possibility of managing and controlling the desired components and many other features in an intelligent system with high accuracy and speed. This intelligent system is a set of hardware and software and is designed and built in the form of a central unit. This set includes parts such as an automatic identification camera, weight indicator, central controller, production management software, web user interface, sensors and database and reporting, in which the identification camera is installed at the entrance to the weighing unit and records the vehicle license plate number and its specifications by automatic imaging. Image data is used to control the entry and exit of vehicles and match it with the information recorded in the system. A digital scale is a precise industrial weighing system using a load cell, which measures the net and gross weight of raw materials or products with high accuracy. This information is instantly transferred to the software system. The weight indicator is a digital display that shows the current weight on the scale to the operator.This device is connected to the load cell and the main software and updates the information in real time. The central controller (PLC Controller) is the central processing unit of the system, which is responsible for managing automation operations, receiving data from sensors and sending commands to executive equipment such as motors and solenoid valves. The production management software is the main software of the system, which is responsible for analyzing data, executing feed production formulas, storing information, issuing reports and controlling automation processes. The web user interface is a web-based management panel for viewing and controlling the system status remotely. This module allows factory managers to access the system and check data from any location. Sensors include sensors for measuring temperature, humidity, material levels in silos and energy consumption of equipment. This information is recorded in real time and transmitted to the central controller and software. In the database and reporting section, all data from the production and weighing process are stored.The system is capable of generating daily, monthly, and annual analytical reports on material consumption, production rate, errors, and overall production line efficiency. According to the explanations provided, in this system, weighing equipment and sensors are first installed. Measuring equipment including load cells, digital displays (indicators), and related sensors are installed at key points of the input and output lines of materials. This equipment is responsible for accurately measuring the weight of raw materials and the final product. Then, the image processing system is installed and commissioned. At the scale location, video control cameras are installed to identify vehicles, record license plates, and record the weighing operation visually. The data obtained from this system is transferred to the central software. The comprehensive production process management software, including modules for defining the production formula, real-time monitoring, reporting, and recording of input data, is also installed on the factory server. This software has the ability to connect directly to hardware equipment and is managed through a graphical user interface. After going through all the steps mentioned, different feed formulations appropriate for different types of livestock and poultry are registered in the system by the technical manager.The intelligent system automatically adjusts and executes the raw material composition based on the defined formula. The system automatically monitors and controls the production, weighing, mixing, grinding, storage and distribution processes of the feed. In case of any error or discrepancy, the necessary warnings are issued and the defined corrective actions are applied. All information related to the production processes, weighing, energy consumption and equipment performance is continuously recorded in the database. The system has the ability to generate analytical reports in different time intervals and present them in various formats (graphic, numerical and comparative). Therefore, the overall function of the aforementioned intelligent system is that after the raw materials or vehicle enter the weighing area, the system automatically detects the device and records the information using the installed cameras. Then, the load cells measure the weight and the data is sent to the software system. Based on the formula defined for each production line, the software calculates the amount of feed and controls the distribution through industrial equipment. It should be noted that all data is stored and reporting and performance evaluation are possible at any time. The implementation of the aforementioned system increases production accuracy, reduces resource waste, eliminates human errors, and improves the quality of the final product. It also allows for complete traceability of operations and compliance with international standards. Explanation of shapes, maps and diagrams Figure 1: Shows an overview of the aforementioned intelligent system. Figure 1 (number 1): shows the feed tank. Figure 1 (number 2): Shows the conveyor belt. Figure 1 (number 3): shows the scale. Figure 1 (number 4): shows the vehicle. Figure 1 (number 5): Shows the digital display. Figure 1 (number 6): The camera shows the image processing. Figure 1 (number 7): Shows the central control system. Figure 2: The block diagram shows the aforementioned intelligent system. A clear and precise statement of the advantages of the claimed invention over prior inventions. 1. Reducing human errors in the weighing and distribution process 2. Increasing accuracy in the use of raw materials and production formulas 3.Optimizing energy consumption through real-time monitoring 4. Increase the speed of the production process and reduce interruptions 5. Intelligent control and monitoring of environmental parameters (humidity, temperature, material level) 6. Complete traceability of products from the moment of production to distribution 7. Increase productivity and reduce operating costs 8. Ability to comply with global quality and safety standards (ISO, UFAS, BRC) Description of at least one implementation method for implementing the invention In this section, the method of using the intelligent weighing automation system with intelligent distribution of livestock and poultry feed is described. To use an example of the implementation of the present achievement, in a sample implementation method, the weighing automation system with intelligent distribution of livestock and poultry feed is installed and launched in a feed production unit. The following are the steps of implementing the said system: 1. Installation of weighing equipment and sensors: Measuring equipment and related sensors are installed at key points of the material input and output lines. 2. Installation and commissioning of the image processing system: At the scale location, video surveillance cameras are installed to identify vehicles, record license plates, and record the weighing operation. The data from this system is transferred to the central software. 3. Launching automation software: Comprehensive production process management software is installed on the factory server. 4. Definition of production formulas: Different feed formulations are registered in the system by the technical manager. The system automatically adjusts and executes the raw material composition based on the defined formula. 5. Real-time production line management: The system automatically monitors and controls the processes of production, weighing, mixing, grinding, storage and distribution of feed. In case of any error or discrepancy, necessary warnings are issued and defined corrective actions are applied. 6. Data recording and analysis: All information related to production processes, weighing, energy consumption, and equipment performance is continuously recorded in the database. Explicit mention of the industrial application of the invention The present design is formulated as a scale automation system with intelligent distribution of livestock and poultry feed. The present design has wide applications in the industrial feed production and distribution chain. This system can be used as a key tool in optimizing, intelligentizing and mechanizing feed production processes in units such as livestock and poultry feed production plants, breeding centers for mother hens and day-old broilers, silos and raw material storage warehouses, large industrial livestock units, livestock and poultry feed export units and service companies in the field of installing and commissioning industrial automation. The use of this invention in livestock and poultry feed production plants allows for accurate weighing, mixing raw materials based on specified formulas, monitoring energy consumption, quality control and recording all production stages. The use of this system leads to improved production efficiency, reduced resource consumption and increased product uniformity.By using this system in breeding centers for mother hens and day-old broilers, flocks are fed based on accurate and traceable data, allowing for precise nutritional planning. Also, feed consumption and growth rate can be analyzed and managed. With the ability to monitor temperature, humidity, and raw material inventory, this system helps operators and managers to control storage conditions in silos and raw material storage warehouses and prevent spoilage or waste. In silos and raw material storage warehouses of large industrial livestock units, this system, with the ability to connect to transportation and loading systems, distributes feed in a planned manner and without human intervention. This feature reduces errors, increases safety, and improves the level of animal husbandry hygiene. Also, in livestock and poultry feed export units, the system's compliance with international standards (such as ISO, BRC, and UFAS) facilitates the export of products to global markets.In addition, the system can be used as part of industrial automation packages in design and implementation projects for new plants or renovation of old units. Overall, this invention not only meets the current needs of the livestock and poultry feed industries, but also paves the way for digital transformation in this industry by providing an intelligent and analytics-driven platform. Brief description of the invention A system is presented as a weighing automation system with intelligent distribution of livestock and poultry feed. The system is designed to optimize the processes of production, weighing, distribution, monitoring and management of feed in the livestock and poultry industries. In the present design, different feed formulations are registered according to different species of livestock and poultry, the system automatically adjusts and executes the combination of raw materials based on the defined formula, and the processes of production, weighing, mixing, grinding, storage and distribution of feed are also automatically monitored and controlled. Therefore, the innovative features of the present design include integration in the management of production processes, weighing and distribution of feed, image processing for automatic and accurate recording of vehicle specifications and input / output materials, intelligent and real-time control of silos, mills, weighing systems and energy consumption, the possibility of setting variable production formulas, product tracking and data recording, and the ability to be presented in different versions based on the capacity of the factory (basic, advanced, integrated).This system, while eliminating human errors, reducing energy consumption, increasing accuracy in feed formulation, and improving product quality, has the ability to comply with global standards such as ISO and BRC, and will also be effective in improving competitiveness and exporting products. Therefore, it can take an effective step in this direction and in resolving some related problems.

Claims

Claim What is claimed: Claim 1) Scale automation system with intelligent distribution of livestock and poultry feed, including: automatic identification cameras for image recording and vehicle recognition, installed at the entrance of the weighing unit and recording the vehicle's license plate number and specifications by automatic imaging; a digital scale, such as a precise industrial weighing system equipped with a load cell, measures the net and gross weight of raw materials or products and transmits it instantly to the software system; a weight indicating device, such as a digital display to show the current weight on the scale to the operator, communicates with the load cell and the main software and updates the information in real time; a central controller unit (PLC Controller), such as the central processing unit of the system, is responsible for managing automation operations, receiving data from sensors and sending commands to executive equipment such as motors and electric valves; and sensors, including sensors that measure temperature, humidity, material levels in silos, and energy consumption of equipment, so that information is recorded in real time and sent to the central controller andTransfer production management software. Production management software that is responsible for analyzing data, executing feed production formulas, storing information, issuing reports, and controlling automation processes. Claim 2) A system according to claim 1, in which, first, measuring equipment including load cells, digital displays and related sensors are installed at key points of the material input and output lines. Then, the image processing system is installed and commissioned. At the scale location, video control cameras are installed to identify vehicles, record license plates and record the weighing operation visually, and the data from this system is transferred to the management software. So that after the raw materials or vehicle enters the weighing location, the system automatically detects the vehicle and records the information using the installed cameras. Then, the load cells measure the weight and the data is sent to the software system. The production process management software includes modules for defining the production formula, real-time monitoring, reporting and recording information, and is installed on the factory server so that it can be directly connected to the hardware equipment. Different feed formulations are registered to suit different species of livestock and poultry, and the intelligent system automatically adjusts and executes the combination of raw materials based on the defined formula.The processes of production, weighing, mixing, grinding, storage and distribution of feed should be automatically monitored and controlled so that in case of any error or discrepancy, necessary warnings are issued and defined corrective actions are applied to the system. All information related to production processes, weighing, energy consumption and equipment performance is continuously received from the equipment, allowing the production of analytical reports at different time intervals.

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