An automatic weighing, filling and discharging control system

Abstract

The utility model provides a kind of automatic weighing filling discharging control system, storage bin, storage bin can store to be filled material, storage bin has first inlet and first outlet, to be filled material can enter storage bin from first inlet and discharge from first outlet;Weighing bin, weighing bin has second inlet and second outlet, second inlet can receive to be filled material discharged from first outlet, and second outlet can discharge to be filled material in weighing bin;First weight sensor, first weight sensor is connected with weighing bin, and first weight sensor can detect the weight of to be filled material in weighing bin;Transition bin, transition bin has third inlet and third outlet, third inlet can receive to be filled material discharged from second outlet, the utility model discloses a kind of automatic weighing filling discharging control system, improves filling accuracy, reduces material waste and rework cost.

Description

Technical Field

[0001] This utility model relates to the field of filling, and in particular to an automatic weighing, filling and feeding control system. Background Technology

[0002] In the current field of industrial automation production, the accurate weighing and filling of powdery and granular materials has always been a key factor restricting production efficiency and product quality. Traditional filling equipment mainly relies on mechanical weighing or volumetric metering methods, which have many technical limitations. Taking the chemical industry as an example, the filling accuracy of active pharmaceutical ingredients (APIs) directly affects drug quality. During the filling process, existing equipment often experiences overfilling or underfilling due to the inability to dynamically adjust the feeding speed in real time, resulting in not only raw material waste but also potentially affecting drug efficacy. Furthermore, the numerous manual interventions increase the risk of cross-contamination. The filling process of powdery, granular, or flake materials is crucial to both product quality and production efficiency.

[0003] However, existing filling systems have several shortcomings: Insufficient weighing accuracy: Traditional systems often use simple weight detection methods, which cannot achieve precise switching between fast and slow speeds during vibration feeding, resulting in large weighing errors. Low automation: Poor coordination between various stages from material storage and weighing to filling requires significant manual intervention, such as manually adjusting the feeding speed and manually moving material boxes, leading to high labor intensity and low efficiency. Serious material waste: Due to inaccurate feeding control, overfeeding or underfeeding often occurs, resulting in material waste and additional rework, increasing production costs. Insufficient multi-station coordination: Lack of efficient coordination between weighing, feeding, and filling stations, and low turntable positioning accuracy lead to filling position deviations, affecting product consistency. Utility Model Content

[0004] The purpose of this invention is to provide an automatic weighing, filling and feeding control system that improves the accuracy of feeding control.

[0005] To achieve the above objectives, this utility model provides the following technical solution: an automatic weighing, filling, and discharging control system, comprising: a storage bin capable of storing materials to be filled, the storage bin having a first inlet and a first outlet, the materials to be filled entering the storage bin through the first inlet and exiting through the first outlet; a weighing bin having a second inlet and a second outlet, the second inlet receiving the materials to be filled exiting from the first outlet, and the second outlet discharging the materials to be filled from the weighing bin; a first weight sensor connected to the weighing bin, capable of detecting the weight of the materials to be filled in the weighing bin; and a transition bin having a third inlet and a third outlet, the third inlet receiving the materials to be filled exiting from the second outlet, and the third outlet discharging the materials to be filled from the transition bin into a packaging box.

[0006] Furthermore, the feeding control system also includes a vibrating feeder connected to the first discharge port. The material to be filled is discharged from the first discharge port into the weighing chamber via the vibrating feeder. The vibrating feeder includes an adjustable frequency vibration motor, which can control the feeding speed of the material to be filled in the vibrating feeder.

[0007] Furthermore, it also includes a second weight sensor, which is connected to the storage silo and is used to detect the weight of the storage silo. The storage silo is equipped with a material level detection sensor, which can detect the amount of the material to be filled in the storage silo.

[0008] Furthermore, the material feeding control system also includes a first fixed frame, a second fixed frame, a third fixed frame, and a third weight sensor. The storage bin is located on the first fixed frame, the weighing bin is located on the second fixed frame, and the third weight sensor and the transition bin are both located on the third fixed frame. The third weight sensor is used to detect the weight of the transition bin.

[0009] Furthermore, the first weight sensor is mounted on the second fixed frame, the weighing bin is connected to the second fixed frame via the first weight sensor, the second weight sensor is mounted on the first fixed frame, and the storage bin is connected to the first fixed frame via the second weight sensor.

[0010] Furthermore, the material feeding control system also includes a fourth fixed frame and a filling interface. The filling interface is located on the fourth fixed frame, and the material to be filled in the transition chamber can be discharged into the packaging box through the third discharge port and the filling interface.

[0011] Furthermore, the feeding control system also includes a first feeding valve and a second feeding valve. The first feeding valve can control the opening and closing state of the second discharge port, and the second feeding valve can control the opening and closing state of the third discharge port. The first feeding valve has a first feeding motor, which can control the opening and closing state of the first feeding valve. The second feeding valve has a second feeding motor, which can control the opening and closing state of the second feeding valve.

[0012] Furthermore, the feeding control system also includes a controller, a frequency converter, and a relay. The controller controls the operating status of the first feeding motor and the second feeding motor through the relay. The controller controls the operating status of the adjustable frequency vibration motor through the frequency converter. The controller can also receive the detection results of the material level detection sensor and the first weight sensor.

[0013] Furthermore, the material feeding control system also includes a transport device, a portion of which is located below the fourth fixed frame, and the transport device is capable of transporting the packaging box below the filling port.

[0014] Furthermore, the material feeding control system also includes a touch screen, which is communicatively connected to the controller, allowing the controller to be operated via the touch screen.

[0015] Analysis shows that the present invention discloses an automatic weighing, filling and feeding control system, which improves filling accuracy and reduces material waste and rework costs. Attached Figure Description

[0016] The accompanying drawings, which form part of this application, are used to provide a further understanding of the present invention. The illustrative embodiments of the present invention and their descriptions are used to explain the present invention and do not constitute an undue limitation of the present invention. Wherein:

[0017] Figure 1 A schematic diagram of the structure of an embodiment of this utility model.

[0018] Figure 2 A schematic diagram of the weighing chamber of an embodiment of this utility model.

[0019] Figure 3 A schematic diagram of the structure of the storage bin according to an embodiment of this utility model.

[0020] Figure 4 A schematic diagram of the structure of the transition chamber according to an embodiment of this utility model.

[0021] Explanation of reference numerals in the attached drawings: 1. Storage bin; 2. Vibrating feeder; 3. Weighing bin; 4. First weight sensor; 5. Transition bin; 6. First discharge valve; 7. Second discharge valve; 8. First fixed frame; 9. Second fixed frame; 10. Third fixed frame; 11. Fourth fixed frame; 12. Filling interface; 13. Second weight sensor; 14. First rigid lifting rod; 15. First fixing rod; 16. First connector; 17. Second fixing rod; 18. Second connector; 19. Third weight sensor. Detailed Implementation

[0022] The present invention will now be described in detail with reference to the accompanying drawings and embodiments. Various examples are provided by way of explanation of the present invention and not by way of limitation. In fact, those skilled in the art will recognize that modifications and variations can be made to the present invention without departing from the scope or spirit of the invention. For example, a feature shown or described as part of one embodiment may be used in another embodiment to produce yet another embodiment. Therefore, it is desirable that the present invention encompass such modifications and variations that fall within the scope of the appended claims and their equivalents.

[0023] In the description of this utility model, the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," and "bottom," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and do not require that this utility model be constructed and operated in a specific orientation; therefore, they should not be construed as limitations on this utility model. The terms "connected," "linked," and "set up" used in this utility model should be interpreted broadly. For example, they can refer to a fixed connection or a detachable connection; a direct connection or an indirect connection through intermediate components; a wired connection, a radio connection, or a wireless communication signal connection. Those skilled in the art can understand the specific meaning of the above terms according to the specific circumstances.

[0024] The accompanying drawings illustrate one or more examples of the present invention. The detailed description uses numerals and letters to refer to features in the drawings. Similar or analogous reference numerals in the drawings and description have been used to refer to similar or analogous parts of the present invention. As used herein, the terms “first,” “second,” “third,” and “fourth,” etc., are used interchangeably to distinguish one component from another and are not intended to indicate the location or importance of a single component.

[0025] like Figures 1-4 As shown, according to an embodiment of the present invention, an automatic weighing, filling, and unloading control system is provided, comprising the following structure:

[0026] Storage silo 1 is capable of storing materials to be filled. Storage silo 1 has a first inlet and a first outlet. The materials to be filled enter the storage silo 1 through the first inlet and exit through the first outlet. As an initial storage unit, its first inlet receives external materials to be filled, and its first outlet conveys materials to the weighing silo 3 via a vibrating feeder. The silo body adopts a conical bottom design to ensure no material residue is discharged.

[0027] Specifically, the feeding control system includes a vibrating feeder 2, which is connected to the first discharge port. The material to be filled is discharged from the first discharge port into the weighing chamber 3 via the vibrating feeder 2. The vibrating feeder 2 includes an adjustable frequency vibration motor, which can control the feeding speed of the material to be filled in the vibrating feeder 2. The vibration frequency of the adjustable frequency vibration motor is dynamically adjusted by a PLC: in actual operation, high-frequency and fast feeding can be used in the initial stage. When the first weight sensor 4 detects that the material is close to the target value, the PLC automatically switches to a low-frequency and slow-speed mode to ensure weighing accuracy. The motor amplitude can be adaptively adjusted according to the material characteristics (such as particle size and density): for example, low-amplitude high-frequency vibration is used for easily dusty powdery materials, while high-amplitude low-frequency vibration is used for granular materials. The vibrating feeder 2 breaks through the limitations of traditional timed or single-speed feeding, and optimizes vibration parameters in real time through weight feedback to solve the problems of overfilling or underfilling.

[0028] Specifically, it also includes a second weight sensor connected to the storage silo 1. The second weight sensor detects the weight of the storage silo 1. A level detection sensor is installed inside the storage silo 1 to detect the amount of material to be filled. The level detection sensor can be deployed on the side wall of the storage silo 1. When the level detection sensor detects the presence of material in the storage silo 1, it triggers the vibrating feeder 2 to operate, feeding the material to be filled from the storage silo 1 into the weighing hopper 3. When there is no material in the storage silo 1, the PLC pauses the vibrating feeder 2 to prevent the equipment from running idle. This achieves fully automated system operation, reduces manual intervention, and avoids equipment damage caused by idle operation.

[0029] Weighing chamber 3 has a second inlet and a second outlet. The second inlet receives the material to be filled from the first outlet, and the second outlet discharges the material to be filled from the weighing chamber 3. Weighing chamber 3 is the core metering unit; its second inlet receives material from storage chamber 1, and its second outlet outputs material to transition chamber 5. A first weight sensor 4 is connected to the weighing chamber 3 and can detect the weight of the material to be filled within it. The chamber body of weighing chamber 3 is rigidly connected to the high-precision first weight sensor 4, enabling real-time monitoring of changes in the weight of the material within the chamber, forming a closed-loop control basis.

[0030] Furthermore, the material feeding control system includes a first fixed frame 8, a second fixed frame 9, a third fixed frame 10, and a third weight sensor. The storage bin 1 is located on the first fixed frame 8, the weighing bin 3 is located on the second fixed frame 9, and the third weight sensor and the transition bin are both located on the third fixed frame. The third weight sensor is used to detect the weight of the transition bin. The material feeding control system also includes a fourth fixed frame 11 and a filling interface 12. The filling interface 12 is located on the fourth fixed frame 11, and the material to be filled in the transition bin 5 can be discharged into the packaging box through the third discharge port and the filling interface 12.

[0031] The first fixed frame 8 supports the storage silo 1 and adopts a truss steel structure. Shock-absorbing pads can be added to isolate the stability of the silo from ground vibrations. The frame can be pre-installed with forklift slots for easy relocation of the entire machine. The first weight sensor 4 is embedded in the top plate of the second fixed frame 9, and the weighing silo 3 is suspended below the first weight sensor 4, ensuring that the external force on the weighing silo 3 is only the weight of the material. Protective railings are installed around the frame to prevent operational collisions. The third fixed frame 10 supports the transition silo 5, and the fourth fixed frame 11 integrates the filling interface 12. Buffer gaps are maintained between each frame to allow for independent disassembly and maintenance of faulty silos.

[0032] Specifically, the first weight sensor 4 is mounted on the second fixed frame 9, and the weighing chamber 3 is connected to the second fixed frame 9 via the first weight sensor 4. The weighing chamber 3 is connected to the first weight sensor 4 via a first rigid suspension rod. The first weight sensor 4 also serves to fix the weighing chamber 3. When material to be filled is added to the weighing chamber 3, the reading of the first weight sensor 4 changes accordingly, thereby calculating the amount of material to be filled in the weighing chamber 3. Typically, one end of the first weight sensor 4 is fixed to the second fixed frame 9 via the first fixed rod, and the other end of the first weight sensor 4 is connected to the weighing chamber 3 via the suspension rod, thus simultaneously achieving the weighing and fixing of the weighing chamber 3. Usually, there are three first weight sensors 4, which are arranged around the weighing chamber 3 to enhance the stability of the weighing chamber 3.

[0033] Specifically, the weighing chamber 3 uses three evenly distributed first weight sensors 4, forming an equilateral triangle layout. When the material is unevenly distributed in the weighing chamber 3, for example, when the material is vibrated and deviates to one side, the weight data of the three sensors are fused by the controller algorithm. If the average value is taken or the deviation is compensated, the error caused by the center of gravity shift in single-point weighing can be eliminated. At the same time, the three-point support structure reduces the interference of vibration on the sensors through mechanical dispersion, making the weighing data more stable. In contrast, the material trough and the sensor vibrate synchronously, which is prone to data drift due to resonance.

[0034] The second weight sensor 13 is mounted on the second fixed frame 9, and the storage hopper 1 is connected to the first fixed frame 8 via the second weight sensor 13. The storage hopper 1 is connected to the second weight sensor 13 via the first connector 16. The second weight sensor 13 also serves to fix the storage hopper 1. When material to be filled is added to the storage hopper 1, the reading of the second weight sensor 13 changes accordingly, thereby calculating the amount of material to be filled in the storage hopper 1. Typically, one end of the second weight sensor 13 is fixed to the first fixed frame 8 via the second fixing rod 17, and the other end of the second weight sensor 13 is connected to the storage hopper 1 via the first connector 16, thus simultaneously achieving weighing and fixing of the storage hopper 1. Usually, there are three second weight sensors 13, which are symmetrically arranged around the storage hopper 1 to enhance the stability of the storage hopper 1.

[0035] The storage silo 1 is equipped with a second weight sensor 13 and a material level detection sensor, which can detect whether there is material in the storage silo 1 and the weight of the incoming material, thus directly linking the storage silo 1 and the weighing silo 3. When the weight of the storage silo 1 is lower than a preset threshold, the controller will trigger the upstream replenishment mechanism in advance, such as automatically opening the feed valve of the storage silo 1, to avoid filling interruptions due to insufficient storage. Typically, if the weight of the storage silo 1 exceeds the predetermined capacity, the sensor feedback signal will automatically reduce the frequency of the vibrating feeder 2, reducing the amount of material fed per unit time. The predetermined capacity is usually 90% of the rated capacity of the storage silo 1, preventing the weighing silo 3 from being overloaded due to excessive material inflow, while also reducing manual intervention and lowering the energy consumption and wear of the equipment during no-load operation.

[0036] The third weight sensor 19 is typically a single-point weighing sensor. This type of sensor can be embedded in the third fixed frame 10. The bottom of the transition chamber 5 has an extended second connector 18, which connects to the third weight sensor 19, thus enabling the third weight sensor 19 to detect the weight of the transition chamber 5. The transition chamber 5, equipped with the third weight sensor 19, forms a "three-segment weight chain" with the sensors in the storage chamber 1 and weighing chamber 3. The weight loss value of the storage chamber 1, the weight gain value of the weighing chamber 3, and the weight gain value of the transition chamber 5 can be compared in real time. If the weight loss value of the storage chamber 1 deviates from the weight gain value of the weighing chamber 3 by more than a certain percentage, the sensor in the weighing chamber 3 is deemed abnormal. If the weight gain value of the weighing chamber 3 deviates from the weight gain value of the transition chamber 5 by more than a certain percentage, it can be determined that the transition chamber 5 is leaking material or that the first discharge valve 6 is malfunctioning, thereby pinpointing the source of the error. The controller automatically adjusts the target weight of the subsequent weighing chamber 3 based on the three weight deviations, forming a closed-loop process. The transition chamber 5 has a third inlet and a third outlet. The third inlet receives the material to be filled from the second outlet, and the third outlet discharges the material to be filled from the transition chamber 5 into a packaging box. As a buffer transfer unit, its third inlet receives material from the weighing chamber 3 via a flexible connection, and its third outlet conveys material to the packaging box, which serves as the target carrier for the material to be filled. The filling process is complete when the material to be filled is delivered into the packaging box.

[0037] Furthermore, the material feeding control system includes a first discharge valve 6 and a second discharge valve 7. The first discharge valve 6 controls the opening and closing state of the second discharge port, and the second discharge valve 7 controls the opening and closing state of the third discharge port. The first discharge valve 6 has a first discharge motor, which controls the opening and closing state of the first discharge valve 6. The second discharge valve 7 has a second discharge motor, which controls the opening and closing state of the second discharge valve 7. The first discharge valve 6 is installed at the second discharge port of the weighing chamber 3, and the second discharge valve 7 is located at the third discharge port of the transition chamber 5, and is linked to the filling interface 12. Its opening conditions are strictly limited: the controller only allows opening when the first discharge valve 6 is closed and the weight of the transition chamber 5 reaches the target.

[0038] The material feeding control system is designed with two independent feeding valves: a first feeding valve 6 and a second feeding valve 7. Material flow is controlled through strict linkage logic. The first feeding valve 6 controls the feeding from the weighing bin 3 to the transition bin 5, operating independently. The second feeding valve 7 controls the feeding from the transition bin 5 to the packaging box. In actual operation, the second feeding valve 7 is only allowed to open when the first feeding valve 6 is closed and the material weight in the transition bin 5 reaches the target, avoiding material leakage or measurement errors. The independent control of the first and second feeding valves achieves precise cutting and flow of materials in each stage of "weighing-transition-filling," reducing material residue and measurement deviations in intermediate stages. Furthermore, the material feeding control system also includes a controller, a frequency converter, and relays. The controller controls the operating status of the first and second feeding motors through relays, and the controller controls the operating status of the adjustable frequency vibration motor through the frequency converter. The controller can also receive the detection results from the material level detection sensor and the first weight sensor 4. The controller can be a Siemens S76-1200 PLC, which receives the detection results from the material level detection sensor and the first weight sensor 4 in real time, and controls the working status of the first feeding motor, the second feeding motor and the adjustable frequency vibration motor according to the received detection results.

[0039] Furthermore, the material feeding control system also includes a transport device, a portion of which is located below the fourth fixed frame 11. This transport device is capable of transporting the packaging box below the filling interface 12. The transport device is responsible for transporting the packaging box, thereby achieving automated filling operations.

[0040] Furthermore, the feeding control system also includes a touch screen, which is communicatively connected to the controller, allowing the controller to be operated via the touch screen. The operating status of the filling system can also be monitored via the touch screen.

[0041] The specific working process of this utility model is as follows: When the material to be filled is discharged into the storage bin 1, the storage bin 1 determines that there is material and then vibrates the material weighed to the target weight value by the vibrating feeder 2 and transfers it to the weighing bin 3. When the weight in the weighing bin 3 reaches the target value, the vibration stops. Then the weighing bin 3 discharges the weighed material to the transition bin 5. At this time, the packaging box is transported to the transition bin 5. The transition bin 5 puts the material into the packaging box. After the material is discharged, it stops automatically and waits for the next material discharge.

[0042] As can be seen from the above description, the embodiments of this utility model achieve the following technical effects: Through switching between fast and slow vibration feeding and real-time weight monitoring, the weighing accuracy can reach ±0.5%, meeting the requirements of high-precision filling and reducing material waste and rework costs. The entire process from material storage, weighing, discharging to filling is automated, requiring no manual intervention and significantly improving production efficiency, by more than 30% compared to traditional systems. It adapts to filling powdery, granular, or flake materials of different particle sizes and densities, supporting multi-variety, small-batch production switching. Redundant design and fault self-diagnosis functions, such as motor overload protection and sensor abnormality alarms, ensure the stability and reliability of the system during long-term operation.

[0043] The above description is merely a preferred embodiment of this utility model and is not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An automatic weighing, filling, and dispensing control system, characterized in that, A storage bin is provided, which is capable of storing materials to be filled. The storage bin has a first inlet and a first outlet. The materials to be filled can enter the storage bin from the first inlet and be discharged from the first outlet. The weighing chamber has a second inlet and a second outlet. The second inlet can receive the material to be filled discharged from the first outlet, and the second outlet can discharge the material to be filled from the weighing chamber. A first weight sensor is connected to the weighing chamber and is capable of detecting the weight of the material to be filled in the weighing chamber. The transition chamber has a third inlet and a third outlet. The third inlet can receive the material to be filled discharged from the second outlet, and the third outlet can discharge the material to be filled in the transition chamber into the packaging box.

2. The automatic weighing, filling, and unloading control system according to claim 1, characterized in that, The feeding control system further includes a vibrating feeder connected to the first discharge port. The material to be filled is discharged from the first discharge port into the weighing hopper via the vibrating feeder. The vibrating feeder includes an adjustable frequency vibration motor, which can control the feeding speed of the material to be filled in the vibrating feeder.

3. The automatic weighing, filling, and unloading control system according to claim 2, characterized in that, It also includes a second weight sensor, which is connected to the storage silo and is used to detect the weight of the storage silo. The storage silo is equipped with a material level detection sensor, which can detect the amount of the material to be filled in the storage silo.

4. The automatic weighing, filling, and unloading control system according to claim 3, characterized in that, The material feeding control system further includes a first fixed frame, a second fixed frame, a third fixed frame, and a third weight sensor. The storage bin is located on the first fixed frame, the weighing bin is located on the second fixed frame, and the third weight sensor and the transition bin are both located on the third fixed frame. The third weight sensor is used to detect the weight of the transition bin.

5. The automatic weighing, filling, and unloading control system according to claim 4, characterized in that, The first weight sensor is mounted on the second fixed frame. The weighing bin is connected to the second fixed frame via the first weight sensor. The second weight sensor is mounted on the first fixed frame. The storage bin is connected to the first fixed frame via the second weight sensor.

6. The automatic weighing, filling, and unloading control system according to claim 4, characterized in that, The material feeding control system also includes a fourth fixed frame and a filling interface. The filling interface is located on the fourth fixed frame, and the material to be filled in the transition chamber can be discharged into the packaging box through the third discharge port and the filling interface.

7. An automatic weighing, filling, and unloading control system according to claim 6, characterized in that, The material feeding control system also includes a first feeding valve and a second feeding valve. The first feeding valve can control the opening and closing state of the second discharge port, and the second feeding valve can control the opening and closing state of the third discharge port. The first feeding valve has a first feeding motor, which can control the opening and closing state of the first feeding valve. The second feeding valve has a second feeding motor, which can control the opening and closing state of the second feeding valve.

8. An automatic weighing, filling, and unloading control system according to claim 7, characterized in that, The feeding control system also includes a controller, a frequency converter, and a relay. The controller controls the operating status of the first feeding motor and the second feeding motor through the relay. The controller controls the operating status of the adjustable frequency vibration motor through the frequency converter. The controller can also receive the detection results of the material level detection sensor and the first weight sensor.

9. An automatic weighing, filling, and unloading control system according to claim 6, characterized in that, The material feeding control system also includes a transport device, a portion of which is located below the fourth fixed frame. The transport device is capable of transporting the packaging box below the filling port.

10. An automatic weighing, filling, and unloading control system according to claim 8, characterized in that, The material feeding control system also includes a touch screen, which is communicatively connected to the controller, and the controller can be operated through the touch screen.

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