Automatic feed weighing and conveying system and method

Abstract

The application discloses a kind of feed automatic weighing transmission system and method, system includes finished product warehouse unit, conveying unit, reserve warehouse unit and control system.Finished product warehouse unit contains 40 finished product warehouses, bottom pneumatic gate is connected to warehouse scraper;Conveying unit is composed of warehouse scraper, conveying scraper and hoist link;Reserve warehouse unit contains 16 reserve warehouses, bottom weight detection device is communicated with PLC;Control system is connected with distributed IO module control field equipment by PROFINET.Configuration specific wiring terminal, circuit breaker and protection switch for pneumatic gate, motor and the like, weighing sensor is communicated by MODBUSRTU protocol, and full warehouse early warning and shutdown alarm are provided.Transmission method includes variety matching, equipment sequence start, weight control path switching and current monitoring fault handling, and variety matching module stores the mapping relationship between feed and finished product warehouse.The system realizes feed automatic weighing transmission, improves efficiency and reliability.

Description

Technical Field

[0001] This invention belongs to the technical field of feed conveying systems, specifically relating to an automatic feed weighing and conveying system and method. Background Technology

[0002] Traditional feed conveying systems require manual identification of feed types and manual opening of corresponding finished product silo gates. When multiple feed types are conveyed alternately, manual operation is prone to problems such as feed type mismatch and gates being missed or accidentally opened. The starting and stopping of conveying equipment (such as scraper conveyors and elevators) requires manual sequential operation, lacking a coordinated control mechanism, resulting in low conveying efficiency and high energy consumption. For example, in existing technologies, the scraper conveyor must be started manually before the gate is opened, which can easily lead to feed accumulation and blockage due to operational delays. Traditional storage silos mostly use mechanical limit switches or manual inspections to detect material levels, failing to accurately monitor weight in real time. When the silo is full, feed overflow or conveying equipment overload can easily occur. Furthermore, the lack of real-time power monitoring and protection mechanisms means that when the scraper conveyor is overloaded or the motor fails, it cannot be stopped quickly, potentially causing equipment damage or safety accidents. Existing systems fail to achieve fully automated control of the entire process from "feed type matching - conveying path - full silo switching," especially in complex scenarios with multiple finished product silos and multiple storage silos. The difficulty of manually coordinating the operation of multiple devices increases significantly, making it difficult to meet the high-efficiency and precision requirements of large-scale farming. Summary of the Invention

[0003] To address the technical problems of traditional feed conveying systems, this invention provides an automatic feed weighing and conveying system and method.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows:

[0005] An automatic feed weighing and conveying system includes a finished product storage unit, a conveying unit, a storage unit, and a control system;

[0006] The finished product storage unit includes a total of 40 finished product storage bins. Each finished product storage bin is fixed to the bottom with a pneumatic gate. The outlet of the pneumatic gate is connected to the feed inlet flange of the scraper conveyor.

[0007] The conveying unit consists of an outflow scraper, a conveying scraper, and an elevator connected end to end in sequence. The outflow scraper receives finished feed from the warehouse, the conveying scraper is connected to the bottom of the elevator through a horizontal / inclined channel, and the top outlet of the elevator connects to the storage warehouse unit.

[0008] The storage unit includes chicken coop feed storage bins. Each storage bin has a weight detection device installed on its bottom support structure. The weight detection device communicates with the PLC via a 2-core shielded cable.

[0009] The control system comprises a CPU 1510 controller, a UR20-FBC-PN-IRT communication module, and a distributed IO module, which is connected with the distributed IO station through a PROFINET cable, and the IO module is connected with the field equipment through a YJV3X4+1X2.5 cable.

[0010] The pneumatic gate is connected with a digital output module of the PLC through a Z920 or Z940 terminal, the gate opening signal is transmitted to the controller through an I16.0 to I224.7 input signal port of the PLC, and the closing control signal is output through a Q12.0 to Q17.7 output signal port of the PLC.

[0011] The out-bin scraper is configured with a 7.5kW motor, a GV2-ME20C circuit breaker with a 13-18A rating, and a PKZSE.RXG12BD motor protection switch; the conveying scraper and the elevator are configured with an 11kW motor, and a GV2-ME22C circuit breaker with a 16-24A rating.

[0012] The weighing sensor communicates with the PLC through a MODBUS RTU protocol, and when the weight of the reserve bin reaches 90% of the full bin value, a pre-alarm signal is sent through a Q220.0 output signal port of the PLC; when the weight reaches the full bin value, a stop alarm signal is sent through a Q220.7 output signal port of the PLC.

[0013] The power supply circuit of the control system is: the main power supply is connected to the UPS power supply, the 24V DC switching power supply is connected to the PLC and the IO module, and the zero line N and the protective ground PE are connected to the -PE1 terminal, respectively.

[0014] An automatic feed weighing and conveying method, comprising the following steps:

[0015] S1, input the target feed variety in the CPU 1510 controller, generate the pneumatic gate opening instruction of the corresponding finished product bin through the built-in variety matching module, and if a non-pre-set variety is input, the controller refuses to output any gate control signal;

[0016] S2, after triggering the one-key start, the PLC sends signals through the output signal ports Q10.0 to Q10.7 in sequence, starts the elevator first, and after a delay of 5 seconds, starts the corresponding out-bin scraper and conveying scraper;

[0017] S3, the weighing sensor feeds back the weight data of the reserve bin to the PLC in real time, when the weight reaches 25 tons, the PLC receives the scraper running state signal through the input signal port, starts the scraper of the next conveying path first, and after a delay of 3 seconds, cuts off the power supply of the current conveying circuit through the circuit breaker;

[0018] S4, the current sensor monitors the current of the elevator 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.

[0019] The variety matching module stores the mapping relationship between feed varieties and finished product warehouses, wherein: layer feed corresponds to No. 301-320 finished product warehouses.

[0020] In S3, the PLC collects the weight signal of the weighing sensor through the analog input module, and when the signal corresponding weight reaches 25 tons ± 0.5 tons, the output signal port Q12.0-Q12.7 is triggered to close the current gate and open the next target gate.

[0021] In S4, the current sensor converts the current signal into a 4-20mA analog input to the AI port of the PLC, and the PLC calculates the real-time current value, and when the current exceeds 1.2 times the rated current of the contactor, the motor protection switch is cut off.

[0022] In S2, the PLC monitors the device status of the three distributed IO sites in real time through PROFINET, and if any site feedbacks a fault signal, the corresponding indicator light (A phase, B phase, C phase) is controlled to send a fault alarm through the output signal port Q220.0-Q220.7.

[0023] Compared with the prior art, the present application has the beneficial effects that:

[0024] 1. The present application realizes one-key automatic operation of "variety setting-gate opening-conveying equipment starting and stopping-full warehouse switching" through the cooperation of CPU 1510 PLC and distributed IO module, which reduces 80% of manual intervention compared with traditional systems; the logic optimization of the conveying equipment linkage start-stop avoids the accumulation of feed caused by manual operation delay, and improves the system operation reliability.

[0025] 2. The built-in variety matching module of the present application realizes accurate correspondence between feed varieties and finished product warehouses, and the pneumatic gate is automatically locked when the variety is not matched, which eliminates the risk of mixed feed in the warehouse; the variety-finished product warehouse mapping relationship is pre-set through the PLC program, which ensures the accuracy of the gate control during variety switching.

[0026] 3. The weighing sensor at the bottom of the reserve warehouse feeds back weight data in real time, and when the preset full warehouse value (such as 25 tons) is reached, the PLC automatically triggers an alarm and switches to the next conveying path, realizing seamless switching of starting first and stopping later, and avoiding interruption of conveying. BRIEF DESCRIPTION OF DRAWINGS

[0027] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following will briefly introduce the drawings needed to be used in the description of the embodiments or the prior art. Obviously, the drawings in the following description are only exemplary, and for those skilled in the art, other drawings can be obtained from the provided drawings without creative labor.

[0028] The structures, proportions, sizes, etc. shown in the specification are only used to cooperate with the content disclosed in the specification, so that those skilled in the art can understand and read, and are not used to limit the conditions that the present application can be implemented, so they do not have technical significance. Any modification of structure, change of proportion relationship or adjustment of size, without affecting the effect and purpose that the present application can produce, should still fall within the scope of the technical content disclosed by the present application.

[0029] Figure 1 The finished product warehouse unit schematic diagram of the present application is shown in the figure;

[0030] Figure 2 The reserve warehouse unit schematic diagram of the present application is shown in the figure;

[0031] Figure 3 The PLC control diagram of the present application is shown in the figure;

[0032] Figure 4 The control circuit diagram of the warehouse scraper machine of the present application is shown in the figure;

[0033] Figure 5 The control circuit diagram of the conveying scraper machine of the present application is shown in the figure;

[0034] Figure 6 The full warehouse alarm circuit diagram of the present application is shown in the figure.

[0035] Among them: 1-40 is the finished product warehouse, S1201-S1224 is the pneumatic gate, S1101-S1108 is the warehouse scraper machine, 601-632 is the chicken house feed reserve warehouse, S1301-S1322 is the conveying scraper machine, S1308 is the elevator, L1, L2, L3 is the main power supply, N is the zero line, PE is the protective earth, PKZ is the motor protection switch. DETAILED DESCRIPTION

[0036] In order to make the purpose, technical scheme and advantages of the embodiments of the present application more clear, the technical scheme in the embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only some of the embodiments of the present application, not all the embodiments. These descriptions are only for further illustrating the features and advantages of the present application, not for limiting the claims of the present application; based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0037] The specific embodiments of the present application will be further described in detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate the present application, but are not used to limit the scope of the present application.

[0038] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "connection", "connecting" should be understood in a broad sense, for example, can be fixedly connected, can be detachably connected, or integrally connected; can be mechanically connected, can be electrically connected; can be directly connected, can be indirectly connected through an intermediate medium, or can be internal communication of two elements. For those skilled in the art, the specific meanings of the above terms in the present application can be understood according to the specific circumstances.

[0039] Example 1

[0040] The feed automatic weighing and conveying system provided in the embodiment aims to realize automatic weighing and conveying of feed from the finished product warehouse to the chicken house storage warehouse, improve the efficiency and accuracy of feed conveying, and reduce the labor cost. As shown in Figure 1 、 Figure 2 The system mainly consists of four parts: finished product warehouse unit, conveying unit, storage warehouse unit and control system. Each unit cooperates with each other to complete the automatic conveying and weighing control of the feed under the coordination of the control system.

[0041] Further, the finished product warehouse unit is a storage area of the feed, which contains 40 finished product warehouses numbered 1-40. The bottom of each finished product warehouse 301-34 is fixedly connected with a pneumatic gate S1201-S1224. These pneumatic gates are connected with the digital output module of the PLC through the Z920 or Z940 terminal, which is used to control the discharge of the feed. The outlet of the pneumatic gate is connected with the inlet of the warehouse scraper S1101-S1108 through flange, which ensures that the feed can smoothly enter the warehouse scraper from the finished product warehouse. For example, when the layer feed needs to be conveyed, the pneumatic gate of the No. 301-310 finished product warehouse corresponding to the layer feed will be opened under the instruction of the control system, and the feed will fall into the corresponding warehouse scraper through the gate.

[0042] Further, the conveying unit is composed of the discharge scraper S1101-S1108, the conveying scraper S1301-S1322 and the elevator S1308, which are connected in sequence and form a channel for feed conveying. The discharge scraper receives the feed discharged from the finished product bin, which is equipped with a 7.5kW motor, a GV2-ME20C circuit breaker with a rating of 13-18A and a PKZSE.RXG12BD motor protection switch to ensure normal operation and overload protection of the motor. The conveying scraper is connected to the bottom of the elevator through a horizontal or inclined channel, and the conveying scraper and the elevator are equipped with an 11kW motor and a GV2-ME22C circuit breaker with a rating of 16-24A to meet the power requirements of long-distance and lifting conveying. The outlet of the top of the elevator is connected to the reserve bin unit to convey the feed to the reserve bin after lifting to a certain height.

[0043] Further, the reserve bin unit includes chicken house feed reserve bins 601-632 for storing the conveyed feed to provide feed reserves for the chicken house. A weight detection device is installed at the bottom support structure of each reserve bin, which communicates with the PLC through a 2-core shielded wire to transmit real-time weight data of the reserve bin to the control system. For example, when the weight of the feed in the reserve bin changes, the weight detection device converts the signal into an electrical signal and transmits it to the PLC through the shielded wire to enable the control system to monitor the weight status of the reserve bin in real time.

[0044] Further, the control system is the core of the entire system, including a CPU1510 controller, a UR20-FBC-PN-IRT communication module and a distributed IO module. The modules are connected to the distributed IO sites through PROFINET cables to realize real-time data transmission and control instruction issuance. The IO module is connected to field devices such as pneumatic gates, scraper motors, elevator motors and weight detection devices through YJV3X4+1X2.5 cables to realize control and state acquisition of the field devices. The power circuit of the control system is as follows: the main power (L1, L2, L3 three-phase) is first connected to the UPS power supply to ensure that the system can continue to operate for a period of time in case of power failure, and then converted to DC power by a 24VDC switching power supply to supply power to the PLC and IO module, wherein the zero line N and the protective ground PE are connected to the -PE1 terminal respectively to ensure the safety of the system.

[0045] Example 2

[0046] The connection between the pneumatic gate and the PLC is as follows: Figures 3-5The pneumatic gates S1201-S1224 are connected to the PLC's digital output module via Z920 or Z940 terminals. The gate's open position signal is transmitted to the controller through PLC input signal ports I16.0 to I224.7. When the gate is fully open, the corresponding input signal is triggered, informing the controller of the gate's status. The closing control signal is output through PLC output signal ports Q12.0 to Q17.7, through which the controller sends a closing command to the pneumatic gate. For example, when a pneumatic gate needs to be closed, the controller sends a signal through the corresponding output port to control the closing action of the pneumatic gate.

[0047] The load cell communicates with the PLC. The load cell is mounted on the bottom support structure of the storage bin and communicates with the PLC via the MODBUS RTU protocol. Figure 6 As shown, when the weight of the storage bin reaches 90% of its full capacity, the PLC sends a pre-alarm signal through output signal port Q220.0 to alert the operator that the storage bin is about to be full. When the weight reaches the full capacity, a stop alarm signal is sent through Q220.7, and the control system automatically stops the relevant feeding equipment to prevent feed spillage. For example, assuming the full capacity of a storage bin is 30 tons, when the weight is detected to reach 27 tons (90% full capacity), a pre-alarm is issued; when it reaches 30 tons, a stop alarm is issued and feeding is stopped.

[0048] The configuration of motors, circuit breakers, and protective switches is as follows: The 7.5kW motor of the outgoing scraper conveyor is matched with a 13-18A GV2-ME20C circuit breaker and a PKZSE.RXG12BD motor protection switch. The GV2-ME20C circuit breaker can promptly cut off the power supply and protect the motor in the event of an overload or short circuit; the PKZSE.RXG12BD motor protection switch provides more comprehensive protection for the motor, such as phase loss protection and overload protection. The 11kW motor of the conveying scraper conveyor and elevator is matched with a 16-24A GV2-ME22C circuit breaker. The rated current range of this circuit breaker is suitable for the operating current of the 11kW motor and can effectively protect the safe operation of the motor.

[0049] Example 3

[0050] Specific implementation steps of the automatic feed weighing and transmission method:

[0051] Step S1: Input the target feed variety and match it with the finished product warehouse.

[0052] The target feed variety is input in the CPU 1510 controller. The variety matching module built in the controller stores the mapping relationship between the feed variety and the finished product bin, in which the layer feed corresponds to the No. 301-320 finished product bin. The variety matching module generates the pneumatic gate opening instruction of the corresponding finished product bin according to the input feed variety. For example, when the layer feed is input, the module will generate the corresponding pneumatic gate opening instruction in the No. 301-310 finished product bin. If the input is a non-pre-set variety, the controller will refuse to output any gate control signal to prevent misoperation from causing the wrong feed to be transported.

[0053] Step S2: Equipment start-up sequence control

[0054] After triggering the one-key start, the PLC sends signals through the output signal ports Q10.0 to Q10.7 in sequence. First, the elevator S1308 is started, and after a delay of 5 seconds, the corresponding bin scraper S1101-S1108 and the conveying scraper S1301-S1322 are started. Such a start-up sequence is to ensure that the elevator runs first to form a stable conveying channel, and then the scraper is started to convey the feed, avoiding the blockage of the feed in the pipeline. At the same time, the PLC monitors the equipment state of the three distributed IO sites in real time through PROFINET. If any site feedbacks a fault signal, the corresponding indicator light (A phase, B phase, C phase) is controlled to issue a fault alarm through the output signal ports Q220.0 to Q220.7, which facilitates the operator to discover the equipment fault in time.

[0055] Step S3: Reserve bin weight control and conveying path switching

[0056] The weighing sensor converts the weight signal into an analog quantity through the analog input module (UR20-4AI-UI-16) and inputs it to the PLC. The PLC collects the weight signal and calculates the corresponding weight value. When the signal corresponds to a weight of 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. At the same time, the PLC receives the scraper running state signal through the input signal port and starts the scraper of the next conveying path first, and after a delay of 3 seconds, the power supply of the current conveying loop is cut off through the circuit breaker to realize the smooth switching of the conveying path, ensuring continuous conveying of the feed without interruption. For example, when the weight of the feed in one reserve bin reaches about 25 tons, the system automatically switches to the conveying path of the next reserve bin.

[0057] Step S4: Elevator current monitoring and fault handling

[0058] The current sensor converts the current signal of the elevator into 4-20mA analog input to the AI port of the PLC, and the PLC calculates the real-time current value. When the current exceeds 120% of the rated value (i.e. exceeds 1.2 times the rated current of the contactor), the motor circuit is cut off through the motor protection switch PKZ, and at the same time the PLC sends out a power failure alarm signal through the output signal port Q220.0, prompting the operator that the elevator has an overload or other power failure, and timely maintenance is carried out.

[0059] In summary, the automatic feed weighing and conveying system and method realizes automatic weighing, conveying, fault detection and processing of the feed, improves the automation level and reliability of the feed conveying, and is suitable for feed supply management of large-scale chicken farms.

[0060] The above only describes the preferred embodiments of the present application in detail, but the present application is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the purpose of the present application, and all the changes shall be included in the protection scope of the present application.

Claims

1. A feed auto-weighing and conveying system, characterized by: The system comprises a finished product warehouse unit, a conveying unit, a reserve warehouse unit and a control system; The finished product warehouse unit comprises 40 finished product warehouses (1-40), each of which is fixedly connected with a pneumatic gate (S1201-S1224) at the bottom, and the outlet of the pneumatic gate is connected with the flange of the discharge scraper (S1101-S1108); The conveying unit is composed of the discharge scraper (S1101-S1108), the conveying scraper (S1301-S1307) and the elevator (S1308) in sequence, wherein the discharge scraper receives the feed in the finished product warehouse, the conveying scraper is connected with the bottom of the elevator through a horizontal / tilted channel, and the outlet of the top of the elevator is connected with the reserve warehouse unit; The reserve warehouse unit comprises chicken house feed reserve warehouses (601-632), each of which is provided with a weight detection device on the bottom support structure, and the weight detection device communicates with the PLC through a 2-core shielded wire. The automatic feed weighing and conveying system further comprises a specific automatic feed weighing and conveying method, which comprises the following steps: S1, input the target feed variety in the CPU1510 controller, generate the opening instruction of the pneumatic gate corresponding to the finished product warehouse (1-40) through the built-in variety matching module, and if a non-pre-set variety is input, the controller refuses to output any gate control signal; S2, after triggering the one-key start, the PLC sends signals through the output signal ports Q10.0 to Q10.7 in sequence, starts the elevator (S1308) first, delays for 5 seconds, and then starts the corresponding discharge scraper (S1101-S1108) and conveying scraper (S1301-S1307); S3, the weighing sensor feeds back the weight data of the reserve warehouse to the PLC in real time, when the weight reaches 25 tons, the PLC receives the scraper running state signal through the input signal port, starts the scraper of the next conveying path first, delays for 3 seconds, and then cuts off the power supply of the current conveying loop through the circuit breaker; S4, the current sensor monitors the current of the elevator 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 power supply of the motor.

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

7.

3. A feed auto-weighing and conveying system according to claim 1, characterized in that: The discharge scraper (S1101-S1108) is configured with a 7.5kW motor, a GV2-ME20C circuit breaker of 13-18A and a PKZ SE.RXG12BD motor protection switch; the conveying scraper (S1301-S1307) and the elevator (S1308) are configured with an 11kW motor and a GV2-ME22C circuit breaker of 16-24A.

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

7.

5. A feed automatic weighing and conveying system according to claim 1, wherein, The variety matching module stores the mapping relationship between feed varieties and finished product bins, wherein: layer feed corresponds to No. 1-20 finished product bins.

6. An automatic feed weighing and conveying system according to claim 1, wherein In S3, the PLC collects the weight signal of the weighing sensor through the analog input module, and when the signal corresponds to a weight of 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.

7. A feed automatic weighing and conveying system according to claim 1, wherein, In S4, the current sensor converts the current signal into a 4-20mA analog input to the AI port of the PLC, and the PLC calculates the real-time current value. When the current exceeds 1.2 times the rated current of the contactor, the motor protection switch (PKZ) is used to cut off the motor circuit.

8. An automatic feed weighing and conveying system according to claim 1, wherein, In S2, the PLC monitors the device status of the three distributed IO sites in real time through PROFINET, and if any site feedbacks a fault signal, the corresponding indicator light is controlled to send a fault alarm through the output signal ports Q220.0 to Q220.7.

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