Technical Overview
As the core equipment of modern industrial automation solutions, the performance of batching and packaging unit directly determines production efficiency and product quality. Taking Wuxi carbon enhancer packaging equipment as an example, the unit has achieved a double breakthrough of high-precision batching and clean production by integrating intelligent weighing system and dust leakage prevention process, becoming a benchmark case for packaging machinery technology upgrade.
Technical principle of intelligent weighing system
The intelligent weighing system is the core module of the batching and packaging unit. The system adopts high-precision weighing sensor (accuracy ±0.1%) and dynamic compensation algorithm to monitor material flow in real time and adjust feeding speed. In the Wuxi recarburizer project, the equipment achieves accurate metering of mixed materials with a particle size of 0.5-5mm through the optimization of the double-screw feeding structure, and the single batch batching error is stably controlled within 0.2kg.
The technical team innovatively introduced a phased metering mode:
.Coarse feeding stage: high-speed filling of 90% of the target weight
.Fine adjustment stage: deceleration to make up the remaining 10%
.Dynamic calibration: feedback correction parameters through the vibration screen residue
This mode enables the system to shorten the batching cycle to 60% of traditional equipment while maintaining a processing capacity of 20 tons per hour.
Key points of dust leakage prevention process design
In view of the dust-prone characteristics of recarburizer powder, the batching and packaging unit adopts a three-level protection design:
1. Source control layer
The fully enclosed stainless steel silo is equipped with an anti-static coating, combined with an intelligent nitrogen filling device, to reduce the oxygen concentration of the material contact surface to below 8%, reducing dust generation from the source.
2. Process interception layer
A double-layer air-sealed structure is set at the joint between the screw feeder and the packaging port, and an isolation air curtain is formed by 0.05MPa compressed air to effectively block the dust escape path.
3. Terminal treatment layer
Integrated pulse back-blowing dust collector, using PTFE coated filter cartridge (filtration accuracy 0.3μm), with negative pressure adsorption system, so that the dust concentration in the working area is stable below 2mg/m³.
Integrated innovation of industrial automation solutions
The Wuxi carbon enhancer batching and packaging unit has built a complete industrial automation solution through three major technical upgrades:
1. Modular architecture design
The unit adopts a modular combination solution with standard interfaces, which can realize the rapid replacement of weighing, dust removal, packaging and other functions. For example, the dust removal module supports online maintenance, and it takes no more than 15 minutes to replace the filter cartridge.
2. Intelligent operation and maintenance system
The embedded PLC controller is equipped with a fault pre-diagnosis algorithm, which can warn of abnormalities of key components 12 hours in advance. Historical data shows that this technology reduces the unplanned downtime rate of equipment by 78%.
3. Cross-platform data interaction
Support OPC UA protocol to connect with MES/ERP system, upload 12 types of production parameters such as batching deviation and energy consumption data in real time, and provide data support for process optimization.
Industry application and technology extension
The technical solution of this batching and packaging unit has been verified in metallurgy, chemical industry and other fields:
·Foundry industry: used for ferrosilicon alloy powder packaging, with an average daily production capacity increase of 40%
·Battery material field: adapted to graphite negative electrode material production line, with a dust control compliance rate of 100%
·Food additive industry: completed food-grade stainless steel material transformation, passed GMP certification
With the acceleration of the process of Industry 4.0, the new generation of batching and packaging units will deeply integrate AI visual inspection, digital twin and other technologies. The technical team is developing an adaptive learning system that can automatically optimize control parameters according to material characteristics, and it is expected to complete the engineering prototype test in 2024.
