Automatic feed weighing and conveying system and method

Abstract

The invention discloses an automatic feed weighing and conveying system and method. The system comprises a finished product warehouse unit, a conveying unit, a storage warehouse unit and a control system. The finished product warehouse unit comprises 40 finished product warehouses, and a pneumatic gate at the bottom is connected with a warehouse-out scraper; the conveying unit is formed by connecting a delivery scraper, a conveying scraper and an elevator; the storage bin unit comprises 16 storage bins, and a bottom weight detection device communicates with the PLC; and the control system is connected with the distributed IO module through PROFINET to control the field equipment. The pneumatic gate, the motor and the like are provided with specific wiring terminals, circuit breakers and protection switches, the weighing sensor communicates through a MODBUSRTU protocol, and full-bin pre-alarm and shutdown alarm are set. The transmission method comprises the steps of variety matching, equipment sequence starting, weight control path switching and current monitoring fault processing, and the variety matching module stores the mapping relation between the feed and the finished product warehouse. According to the system, automatic feed weighing and conveying are achieved, and efficiency and reliability are improved.

Description

Technical Field

[0001] The present invention belongs to the technical field of feed conveying systems, and in particular relates to an automatic feed weighing and transmission system and method. Background Art

[0002] Traditional feed conveying systems require manual identification of feed varieties and opening of the corresponding finished product bin gates. When conveying multiple feed varieties alternately, manual operation can easily lead to problems such as mismatched varieties and missed / accidental gate openings. Conveying equipment (such as scrapers and elevators) must be manually started and stopped in sequence, lacking a coordinated control mechanism. This results in low conveying efficiency and high energy consumption. For example, existing technologies require manual operation of the scraper before opening the gates, which can easily cause feed accumulation and blockage due to operational delays. Traditional storage bins often use mechanical limiters or manual inspections to detect material levels, which cannot accurately monitor weight in real time. When the bin is full, feed overflow or conveying equipment overload can occur. Furthermore, there is a lack of real-time power monitoring and protection mechanisms. If the scraper is overloaded or the motor fails, it cannot be shut down quickly, potentially causing equipment damage or safety accidents. Existing systems fail to fully automate the entire process from "variety matching - conveying routes - full bin switching." This is particularly difficult in complex scenarios with multiple finished product bins and storage bins, where manual coordination of multiple equipment operations becomes significantly more difficult, making it difficult to meet the efficiency and precision requirements of large-scale farming. Summary of the Invention

[0003] In response to the technical problems existing in the above-mentioned traditional feed conveying system, the present invention provides a feed automatic weighing and transmission system and method.

[0004] In order to solve the above technical problems, the technical solution adopted by the present invention is: A feed automatic weighing and transmission system, comprising a finished product bin unit, a conveying unit, a storage bin unit and a control system; The finished product bin unit includes a total of 40 finished product bins, each of which has a pneumatic gate fixed to the bottom, and the pneumatic gate outlet is flange-connected to the feed inlet of the bin scraper; The conveying unit is composed of a discharge scraper, a conveying scraper and an elevator connected end to end. The discharge scraper receives the feed from the finished product warehouse, the conveying scraper is connected to the bottom of the elevator through a horizontal / inclined channel, and the top outlet of the elevator is connected to the storage warehouse unit. The storage bin unit includes a chicken house feed storage bin, and a weight detection device is installed on the bottom support structure of each storage bin. The weight detection device communicates with the PLC via a 2-core shielded cable; The control system includes a CPU 1510 controller, a UR20-FBC-PN-IRT communication module and distributed IO modules, which are connected to distributed IO sites via PROFINET cables. The IO modules are connected to field devices via YJV3X4+1X2.5 cables.

[0005] The pneumatic gate is connected to the digital output module of the PLC through the Z920 or Z940 terminal block. The gate opening position signal is transmitted to the controller through the PLC input signal ports I16.0 to I224.7, and the closing control signal is output through the PLC output signal ports Q12.0 to Q17.7.

[0006] The scraper conveyor is equipped with a 7.5kW motor, matched with a 13-18A GV2-ME20C circuit breaker and a PKZSE.RXG12BD motor protection switch; the conveying scraper conveyor and the elevator are equipped with an 11kW motor, matched with a 16-24A GV2-ME22C circuit breaker.

[0007] The weighing sensor communicates with the PLC via the MODBUS RTU protocol. When the weight of the reserve bin reaches 90% of the full bin value, a pre-alarm signal is issued via the PLC output signal port Q220.0; when the full bin value is reached, a shutdown alarm signal is issued via Q220.7.

[0008] The power supply circuit of the control system is: main power supply to UPS power supply to 24V DC switching power supply to PLC and IO module, where the neutral line N and protective ground line PE are respectively connected to the PE1 terminal.

[0009] A method for automatically weighing and transmitting feed comprises the following steps: S1. Enter the target feed variety in the CPU 1510 controller, and the built-in variety matching module generates the corresponding pneumatic gate opening instruction for the finished product bin. If a non-preset variety is entered, the controller refuses to output any gate control signal. S2. After triggering the one-button start, the PLC sends signals in sequence through the output signal ports Q10.0 to Q10.7, starting the elevator first, and then starting the corresponding warehouse scraper and conveyor scraper after a delay of 5 seconds; S3: The weighing sensor feeds back the storage bin weight data to the PLC in real time. When the weight reaches 25 tons, the PLC receives the scraper conveyor operation status signal through the input signal port, starts the scraper conveyor of the next conveying path first, and then cuts off the power supply of the current conveying circuit through the circuit breaker after a delay of 3 seconds; S4. The current sensor monitors the hoist current in real time. When the current exceeds 120% of the rated value, the PLC sends a power failure alarm signal through the output signal port Q220.0 and cuts off the motor power supply.

[0010] The variety matching module stores the mapping relationship between feed varieties and finished product bins, wherein layer feed corresponds to finished product bins No. 301-320 respectively.

[0011] In S3, the PLC collects the weight signal of the weighing sensor through the analog input module. When the weight corresponding to the signal reaches 25 tons ± 0.5 tons, the output signal ports Q12.0 to Q12.7 are triggered to close the current gate and open the next target gate.

[0012] In S4, the current sensor converts the current signal into a 4-20mA analog input to the AI ​​port of the PLC. The PLC calculates the real-time current value. When the current exceeds 1.2 times the rated current of the contactor, the motor circuit is cut off through the motor protection switch.

[0013] In S2, the PLC monitors the device status of the three distributed IO sites in real time through PROFINET. If any site feedbacks a fault signal, the corresponding indicator lights (phase A, phase B, phase C) are controlled through output signal ports Q220.0 to Q220.7 to issue a fault alarm.

[0014] Compared with the prior art, the present invention has the following beneficial effects: 1. The present invention realizes one-touch automated operation of "variety setting - gate opening - conveyor equipment start and stop - full warehouse switching" through the collaboration of CPU 1510PLC and distributed IO modules, reducing manual intervention by 80% compared with traditional systems; the conveyor equipment linkage start and stop logic is optimized to avoid feed accumulation caused by manual operation delays and improve system operation reliability.

[0015] 2. The built-in variety matching module of the present invention realizes the precise correspondence between feed varieties and finished product bins. When the varieties are not matched, the pneumatic gate is automatically locked to eliminate the risk of feed mixing. The variety-finished product bin mapping relationship is preset through the PLC program to ensure the accuracy of gate control when switching varieties.

[0016] 3. The weighing sensor at the bottom of the storage bin of the present invention feeds back weight data in real time. When the preset full bin value (such as 25 tons) is reached, the PLC automatically triggers an alarm and switches to the next conveying path, realizing seamless switching of start-first and stop-later to avoid conveying interruption. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the following briefly introduces the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are merely exemplary, and those skilled in the art can, without inventive effort, derive other implementation drawings based on the provided drawings.

[0018] The structures, proportions, sizes, etc. illustrated in this specification are intended solely to complement the contents disclosed herein and to facilitate understanding and reading by persons skilled in the art. They are not intended to limit the conditions under which the present invention may be implemented and therefore have no substantive technical significance. Any structural modifications, changes in proportions, or adjustments in sizes, without affecting the efficacy and objectives of the present invention, shall remain within the scope of the technical contents disclosed herein.

[0019] Figure 1 This is a schematic diagram of a finished product warehouse unit of the present invention; Figure 2 This is a schematic diagram of a storage bin unit of the present invention; Figure 3 It is the PLC control diagram of the present invention; Figure 4 This is a control circuit diagram of the warehouse scraper of the present invention; Figure 5 This is a control circuit diagram of the conveying scraper of the present invention; Figure 6 This is the full warehouse alarm circuit diagram of the present invention.

[0020] Among them: 1-40 is the finished product warehouse, S1201-S1224 is the pneumatic gate, S1101-S1108 is the warehouse scraper, 601-632 is the chicken house feed storage warehouse, S1301-S1322 is the conveying scraper, S1308 is the elevator, L1, L2, L3 are the main power supplies, N is the neutral wire, PE is the protective ground wire, and PKZ is the motor protection switch. DETAILED DESCRIPTION

[0021] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are only part of the embodiments of this application, not all the embodiments. These descriptions are only to further illustrate the features and advantages of the present invention, rather than to limit the claims of the present invention. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0022] The following embodiments of the present invention are described in further detail with reference to the accompanying drawings and examples. The following embodiments are used to illustrate the present invention but are not intended to limit the scope of the present invention.

[0023] In the description of this application, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in this application based on the specific circumstances.

[0024] Example 1 The feed automatic weighing and transmission system provided in this embodiment is intended to realize the automatic weighing and transmission of feed from the finished product warehouse to the chicken house storage warehouse, thereby improving the efficiency and accuracy of feed transportation and reducing manual operation costs. Figure 1 、 Figure 2 As shown in the figure, the system mainly consists of four parts: finished product warehouse unit, conveying unit, storage warehouse unit and control system. The units cooperate with each other to complete the automatic transmission and weighing control of feed under the coordination of the control system.

[0025] Furthermore, the finished product bin unit is a storage area for feed, which includes 40 finished product bins numbered 1-40. Each finished product bin 301-34 is fixed with a pneumatic gate S1201-S1224 at the bottom. These pneumatic gates are connected to the digital output module of the PLC through the Z920 or Z940 terminal blocks to control the discharge of the feed. The pneumatic gate outlet is connected to the feed inlet of the bin scraper S1101-S1108 through a flange to ensure that the feed can smoothly enter the bin scraper from the finished product bin. For example, when laying hen feed needs to be transported, the pneumatic gates of the finished product bins No. 301-310 corresponding to the laying hen feed will be opened under the command of the control system, and the feed will fall into the corresponding bin scraper through the gate.

[0026] The conveying unit, consisting of the discharge scrapers S1101-S1108, the conveying scrapers S1301-S1322, and the elevator S1308, is connected end-to-end, forming the feed transport channel. The discharge scrapers receive feed from the finished product bin and are equipped with a 7.5kW motor, a 13-18A GV2-ME20C circuit breaker, and a PKZSE.RXG12BD motor protection switch to ensure proper motor operation and overload protection. The conveying scrapers connect to the bottom of the elevator via a horizontal or inclined channel. Both the conveying scrapers and the elevator are equipped with 11kW motors and a 16-24A GV2-ME22C circuit breaker to meet the power requirements for long-distance and lifting conveying. The elevator's top outlet connects to the storage bin unit, lifting the feed to a certain height before delivering it to the storage bin.

[0027] Furthermore, the storage bin unit includes chicken house feed storage bins 601-632, which are used to store delivered feed and provide feed reserves for the chicken house. Each storage bin's bottom support structure is equipped with a weight detection device. This device communicates with the PLC via a two-core shielded cable, transmitting the bin's weight data to the control system in real time. For example, when the weight of the feed in the bin changes, the weight detection device converts the signal into an electrical signal and transmits it via the shielded cable to the PLC, allowing the control system to monitor the bin's weight status in real time.

[0028] Furthermore, the control system is the core of the entire system and includes a CPU1510 controller, a UR20-FBC-PN-IRT communication module, and distributed I / O modules. Each module is connected to distributed I / O stations via PROFINET cables, enabling real-time data transmission and the issuance of control commands. The I / O modules are connected to field devices such as pneumatic gates, scraper motors, elevator motors, and weight detection devices via YJV3X4+1X2.5 cables, enabling control and status acquisition of these devices. The control system's power supply circuit is as follows: the main power supply (three-phase L1, L2, and L3) is first connected to a UPS to ensure continuous system operation in the event of a power outage or other emergency. The power is then converted to DC power via a 24VDC switching power supply to power the PLC and I / O modules. The neutral wire (N) and protective ground wire (PE) are connected to the -PE1 terminal, respectively, to ensure safe power use in the system.

[0029] Example 2 Connection between pneumatic gate and PLC, such as Figure 3-Figure 5 Pneumatic gates S1201-S1224 are connected to the PLC's digital output module via the Z920 or Z940 terminal blocks. The gate open position signal is transmitted to the controller via PLC input signal ports I16.0 to I224.7. When the gate is fully open, a corresponding input signal is triggered, informing the controller of the gate's status. The closing control signal is output via PLC output signal ports Q12.0 to Q17.7, and the controller uses these output ports to send a closing command to the pneumatic gates. For example, when a pneumatic gate needs to be closed, the controller sends a signal through the corresponding output port to control the gate's closing action.

[0030] The communication between the weighing sensor and the PLC is that the weighing sensor is installed on the bottom support structure of the storage bin and communicates with the PLC through the MODBUSRTU protocol. Figure 6As shown, when the reserve bin weight reaches 90% of the full value, the PLC issues a pre-alarm signal through output signal port Q220.0, alerting the operator that the bin is about to be full. When the weight reaches the full value, a shutdown alarm signal is issued through Q220.7, causing the control system to automatically stop the relevant feeding equipment to prevent feed overflow. For example, if the full value of a reserve bin is 30 tons, a pre-alarm is issued when the weight reaches 27 tons (90% full). When it reaches 30 tons, a shutdown alarm is issued and feeding stops.

[0031] Regarding the configuration of motors, circuit breakers, and protective switches, the 7.5kW motor in the conveyor scraper is matched with a 13-18A GV2-ME20C circuit breaker and a PKZSE.RXG12BD motor protection switch. The GV2-ME20C circuit breaker immediately cuts off power to protect the motor in the event of an overload or short circuit. The PKZSE.RXG12BD motor protection switch provides more comprehensive motor protection, including phase failure and overload protection. The 11kW motor in the conveyor scraper and elevator is matched with a 16-24A GV2-ME22C circuit breaker. This circuit breaker's rated current range is suitable for the operating current of an 11kW motor, effectively protecting the motor's safe operation.

[0032] Example 3 Specific implementation steps of the automatic feed weighing and transmission method: Step S1: Target feed variety input matches the finished product warehouse Enter the target feed variety into the CPU1510 controller. The controller's built-in variety matching module stores the mapping between feed varieties and finished product bins. Layer feed corresponds to finished product bins 301-320. Based on the entered feed variety, the variety matching module generates pneumatic gate opening instructions for the corresponding finished product bin. For example, if layer feed is entered, the module generates the corresponding pneumatic gate opening instructions for bins 301-310. If a non-preset variety is entered, the controller will reject any gate control signals to prevent incorrect feed from being delivered due to misoperation. Step S2: Device startup sequence control After triggering the one-button start function, the PLC sends signals sequentially through output signal ports Q10.0 to Q10.7. First, it starts the elevator S1308, followed by a five-second delay before starting the corresponding scrapers S1101-S1108 and conveyor scrapers S1301-S1322. This startup sequence ensures that the elevator operates first, creating a stable conveying channel, before starting the scrapers to convey feed and prevent feed blockage in the pipeline. Simultaneously, the PLC monitors the device status of the three distributed I / O stations in real time via PROFINET. If any station reports a fault signal, the corresponding indicator lights (Phase A, B, and C) are activated via output signal ports Q220.0 to Q220.7, activating a fault alarm. This allows operators to promptly detect equipment failures. Step S3: Storage bin weight control and conveying path switching The load cell converts the weight signal into an analog quantity via an analog input module (UR20-4AI-UI-16) and inputs it into the PLC. The PLC collects the weight signal and calculates the corresponding weight value. When the weight corresponding to the signal reaches 25 tons ± 0.5 tons, it triggers output signal ports Q12.0 to Q12.7, closing the current gate and opening the next target gate. Simultaneously, the PLC receives the scraper conveyor operating status signal via its input signal port, first starting the scraper conveyor on the next conveyor path. After a delay of 3 seconds, the circuit breaker disconnects the power supply to the current conveyor circuit, enabling smooth switching of conveyor paths and ensuring uninterrupted feed delivery. For example, when the weight of feed in one storage bin reaches approximately 25 tons, the system automatically switches to the conveyor path for the next bin. Step S4: Hoist current monitoring and fault handling The current sensor converts the hoist's current signal into a 4-20mA analog input and feeds it into the PLC's AI port, which then calculates the current value in real time. When the current exceeds 120% of the rated value (i.e., 1.2 times the contactor's rated current), the motor protection switch PKZ disconnects the motor circuit. Simultaneously, the PLC issues a power failure alarm through output signal port Q220.0, alerting the operator to a power failure, such as an overload, and prompting prompt repairs. In summary, this automatic feed weighing and transmission system and method realizes automatic weighing, transmission, fault detection and processing of feed through the reasonable configuration of each unit and precise control of the control system, improves the automation level and reliability of feed transportation, and is suitable for feed supply management in large-scale chicken farms.

[0033] The above only describes in detail the preferred embodiments of the present invention, but the present invention is not limited to the above embodiments. Various changes can be made within the knowledge of ordinary technicians in this field without departing from the purpose of the present invention, and various changes should be included in the scope of protection of the present invention.

Claims

1. A feed automatic weighing and transmission system, characterized by: Including finished product warehouse unit, conveying unit, storage warehouse unit and control system; The finished product bin unit comprises 40 finished product bins (1-40), each finished product bin (1-40) having a pneumatic gate (S1201-S1224) fixedly connected to the bottom, and the pneumatic gate outlet is flange-connected to the feed port of the bin scraper (S1101-S1108); The conveying unit is composed of a warehouse scraper (S1101-S1108), a conveying scraper (S1301-S1322) and an elevator (S1308) connected end to end. The warehouse scraper receives the feed from the finished product warehouse, the conveying scraper is connected to the bottom of the elevator through a horizontal / inclined channel, and the top outlet of the elevator is connected to the storage warehouse unit. The storage bin unit includes chicken house feed storage bins (601-632), and a weight detection device is installed on the bottom support structure of each storage bin. The weight detection device communicates with the PLC via a 2-core shielded cable; The control system includes a CPU 1510 controller, a UR20-FBC-PN-IRT communication module and distributed IO modules, which are connected to distributed IO sites via PROFINET cables. The IO modules are connected to field devices via YJV3X4+1X2.5 cables.

2. The feed automatic weighing and transmission system according to claim 1, characterized in that: The pneumatic gate (S1201-S1224) is connected to the digital output module of the PLC through the Z920 or Z940 terminal block. The gate opening position signal is transmitted to the controller through the PLC input signal ports I16.0 to I224.7, and the closing control signal is output through the PLC output signal ports Q12.0 to Q17.

7.

3. The feed automatic weighing and transmission system according to claim 1, characterized in that: The scrapers for discharging goods (S1101-S1108) are equipped with 7.5kW motors, matched with 13-18A GV2-ME20C circuit breakers and PKZ SE.RXG12BD motor protection switches; the scrapers for conveying goods (S1301-S1322) and the elevator (S1308) are equipped with 11kW motors, matched with 16-24A GV2-ME22C circuit breakers.

4. The feed automatic weighing and transmission system according to claim 1, characterized in that: The weighing sensor communicates with the PLC via the MODBUS RTU protocol. When the weight of the reserve bin reaches 90% of the full bin value, a pre-alarm signal is issued via the PLC output signal port Q220.0; when the full bin value is reached, a shutdown alarm signal is issued via Q220.

7.

5. The feed automatic weighing and transmission system according to claim 1, characterized in that: The power supply circuit of the control system is: main power supply (L1, L2, L3) to UPS power supply to 24V DC switching power supply to PLC and IO module, where the neutral line (N) and protective ground line (PE) are respectively connected to the PE1 terminal.

6. A feed automatic weighing and transmission method according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. Input the target feed variety into the CPU1510 controller, and generate the pneumatic gate opening command for the corresponding finished product bin (1-40) through the built-in variety matching module. If a non-preset variety is input, the controller refuses to output any gate control signal. S2. After triggering the one-button start, the PLC sends signals in sequence through output signal ports Q10.0 to Q10.7, first starting the elevator (S1308), and then starting the corresponding scraper for discharging (S1101-S1108) and the conveying scraper (S1301-S1322) after a delay of 5 seconds; S3: The weighing sensor feeds back the storage bin weight data to the PLC in real time. When the weight reaches 25 tons, the PLC receives the scraper conveyor operation status signal through the input signal port, starts the scraper conveyor of the next conveying path first, and then cuts off the power supply of the current conveying circuit through the circuit breaker after a delay of 3 seconds; S4. The current sensor monitors the hoist current in real time. When the current exceeds 120% of the rated value, the PLC sends a power failure alarm signal through the output signal port Q220.0 and cuts off the motor power supply.

7. A feed automatic weighing and transmission method according to claim 6, characterized in that: The variety matching module stores the mapping relationship between feed varieties and finished product bins, wherein layer feed corresponds to finished product bins No. 301-320 respectively.

8. The method for automatic weighing and transmitting feed according to claim 6, characterized in that: In S3, the PLC collects the weight signal of the weighing sensor through the analog input module. When the weight corresponding to the signal reaches 25 tons ± 0.5 tons, the output signal ports Q12.0 to Q12.7 are triggered to close the current gate and open the next target gate.

9. The method for automatic weighing and transmission of feed according to claim 6, characterized in that: In S4, the current sensor converts the current signal into a 4-20mA analog input to the AI ​​port of the PLC. The PLC calculates the real-time current value. When the current exceeds 1.2 times the rated current of the contactor, the motor circuit is cut off through the motor protection switch (PKZ).

10. The method for automatic weighing and transmission of feed according to claim 6, characterized in that: In S2, the PLC monitors the device status of the three distributed IO sites in real time through PROFINET. If any site feedbacks a fault signal, the corresponding indicator lights (phase A, phase B, phase C) are controlled through output signal ports Q220.0 to Q220.7 to issue a fault alarm.

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