In processing industries such as feed, chemical, and food, the accuracy of automatic batching systems directly determines the stability of product quality. However, many manufacturers often face issues like large batching errors and poor repeatability in actual production—not only leading to raw material waste, but also affecting the consistency of product composition.
What exactly is batching accuracy? Which factors influence it? And how can we systematically improve accuracy control?
I. What is Batching Accuracy? Both Static and Dynamic Metrics Matter
Batching accuracy refers to the error range between the actual batching quantity and the preset quantity in an automatic batching system. It is divided into two categories:
Static accuracy: The error between the actual batching quantity and the theoretical value when batching stops and the system is stationary.
Dynamic accuracy: The deviation between the real-time material output and the set value during the batching process.
Static accuracy reflects the "precision" of the equipment system, while dynamic accuracy reflects the "stability and responsiveness" of system operation. Together, they determine the actual production batching level.
II. Key Factors Affecting Batching Accuracy: Equipment and Process Are Indispensable
To achieve high-precision batching control, the following links must be systematically considered:
Core Equipment Selection Determines the Accuracy Ceiling
The performance of batching augers, weighing hoppers, load cells (sensors), weighing instruments, and frequency converters directly restricts the accuracy of the entire system. In particular, the resolution, anti-interference ability, and installation quality of load cells are the "heart of the scale".
Weighing Hopper Design: Prevent Residue
Common square weighing hoppers are prone to material accumulation, leading to cross-contamination between batches and error transfer. A round weighing hopper design with a smooth, dead-angle-free inner wall is recommended to significantly reduce residue.
Installation and Commissioning Are Invisible Accuracy Guarantees
Load cells must be uniformly stressed and symmetrically arranged to avoid eccentric loading.
Signal lines need shielding to prevent electrical interference.
The weighing body must be installed horizontally and stably, with mechanical vibration minimized.
Process Design Affects Fluency and Accuracy
The position and form of the material inlet into the hopper are also extremely important. An ideal design should ensure smooth material flow with minimal impact, avoiding severe shaking or accumulation of the weighing body.
Control System Response and Algorithms
The program processing speed, signal sampling frequency, and PID parameter adjustment of PLC or industrial computers also significantly affect dynamic accuracy, especially in high-speed continuous batching.
III. Conclusion: Accuracy Control Is a Systematic Project
The level of batching accuracy does not depend on a single piece of equipment, but on the combined effect of mechanical design, electrical supporting facilities, installation and commissioning, and control strategies. Only by strictly standardizing each link, selecting reasonably, and debugging finely can long-term, stable, and high-precision automatic batching production be achieved.
Sihyde (Qingdao Sihyde Automation Equipment Co., Ltd.) is a non-standard automation system integration company with application, design, and manufacturing capabilities in automatic batching, robotic palletizing, intelligent logistics conveying, and intelligent control systems. The company's equipment is widely used in carton packaging, refractory materials, auto parts, chemical and pharmaceutical, rubber products, powder metallurgy, friction materials, power energy, new materials, and other industries. Sihyde continuously improves products with sustained innovation, providing high-quality non-standard customized automation products, which are widely praised by users!
