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Automatic control system

Automatic controll system

Tongli’s automatic control system integrates a variety of advanced technologies to improve the automation level and production efficiency of npk organic-inorganic compound fertilizer production lines. The system includes automatic quantitative batching system, automatic packaging system, palletizing robot system, automatic bagging machine system and electronic control system. The automatic quantitative batching system can accurately control the proportion of various raw materials to ensure high precision and consistency of the ingredients; the automatic packaging system improves the packaging speed and accuracy and reduces manual intervention; the palletizing robot system optimizes logistics management through automatic stacking and improves storage efficiency; the automatic bagging machine system realizes the full automation of bagged materials and improves packaging efficiency. The electronic control system ensures the smooth operation of each link through intelligent monitoring and management, making the entire production process more efficient, energy-saving and stable.

Automatic control system

Tongli's automatic control system integrates quantitative batching, automatic packaging, palletizing robots, automatic bagging machines and electronic control systems, comprehensively improving the automation level of the compound fertilizer production line and ensuring an efficient and accurate production process.

FAQ

  • 1. How does the automatic quantitative batching system improve the efficiency of compound fertilizer production?

    Automatic quantitative batching system is used to accurately control the proportion of raw materials and improve production efficiency. By using advanced batching equipment such as double belt scales, loss-in-weight scales and belt scales, the accuracy of batching and the overall efficiency of the production line can be greatly improved.

    Double belt scale is a high-precision quantitative batching equipment that weighs different materials simultaneously through two independent belt scale systems to ensure that the amount of each raw material added meets the predetermined ratio. Its accuracy is as high as ±0.5%, which is suitable for the proportioning requirements of multiple raw materials, especially in large-scale production, it can effectively improve the batching accuracy and reduce material waste.

    Loss-in-weight scale uses the change of material flow to automatically adjust the feed rate, which is particularly suitable for accurate measurement of powdered or granular materials. Loss-in-weight scale has a high dynamic response speed and low measurement error, which can ensure the stability and consistency of each batching, thereby improving the stability and continuity of production. Its accuracy is usually ±0.2%, which is suitable for refined management.

    Belt scale measures the flow of materials in real time during belt transportation and performs quantitative calculations based on the belt speed. This method can not only improve the batching speed of bulk materials, but also ensure high-precision operation under high load. The accuracy of the belt scale is generally ±0.5%, and it can adapt to different conveying speeds and material flows, which is suitable for large-scale compound fertilizer production lines.

    Through these high-precision quantitative batching equipment, the automatic quantitative batching system can not only ensure the accurate proportion of each raw material, but also significantly improve the batching speed and production efficiency, reduce the error and time cost of manual operation, and maximize the overall production capacity of the production line.

  • 2. How does the automatic packaging system ensure the accuracy and speed of compound fertilizer packaging?

    Through advanced equipment and technology, the automatic packaging system can achieve rapid and high-precision packaging of compound fertilizers, significantly reduce manual intervention and improve production efficiency. Core technologies include gross weight scales, dual cylinder scales and servo motor scales, each of which plays an important role.

    The gross weight scale uses a high-precision sensor to monitor the weight of each packaging bag in real time and ensure accurate measurement during the packaging process. Its design can quickly adapt to different materials, especially in the packaging of granular or powdery materials such as compound fertilizers, and can maintain high weighing accuracy (within ±0.2%) to ensure that each bag of product meets the specified weight.

    The dual-cylinder scale controls the sealing process of packaging bags through dual cylinders, improving the speed and stability of packaging. In the production of compound fertilizer, the double-cylinder scale can achieve efficient packaging of more than 60 bags per minute, and with the help of air pressure, it can quickly and evenly fill materials, ensuring that the packaging bags are sealed intact and avoiding leakage or excessive filling.

    Servo motor scales use servo control technology to accurately control the flow and filling speed of materials. By precisely adjusting the motor’s speed and motion trajectory, the servo motor scale can achieve fast and accurate material conveying and bagging, and has strong adaptability and can handle a variety of materials of different weights and types. Its high efficiency and accuracy make the compound fertilizer packaging process more stable, and the error range can be controlled within ±0.1%.

  • 3. What are the applications and advantages of palletizing robot systems in compound fertilizer production?

    The palletizing robot system is widely used in NPK compound fertilizer production lines and can significantly improve the level of automation. The Tongli palletizing system is equipped with robot arms from ABB and Fanuc. The palletizing robots from ABB and Fanuc can accurately perform the stacking of materials. Palletizing, handling and sorting operations support palletizing speeds of up to 800-1,000 pieces per hour, greatly improving production efficiency.

    The palletizing robot system can be divided into two types: with pallet warehouse and without pallet warehouse. The system with a pallet library can automatically manage the access of pallets, reducing manual intervention and management costs, and is suitable for mass production and complex logistics needs; the system without a pallet library is simpler and suitable for small batch or medium-scale production lines, saving money. Save time and space for pallet management. However, it should be noted that the palletizer with a pallet library has very high requirements for the size of the pallet. The pallet must be customized with the same size and specifications to use this kind of pallet library, otherwise it will get stuck.

    Palletizers are suitable for modern compound fertilizer plants, but in Africa or other developing countries where labor costs are very cheap, it is possible not to use a palletizing system with a pallet warehouse. This mainly depends on the customer’s requirements for the automation level of the compound fertilizer plant.

  • 4. How does the automatic bagging machine system improve compound fertilizer packaging efficiency?

    The automatic bagging machine system plays a vital role in the compound fertilizer packaging process, which can significantly improve production efficiency and reduce labor costs. Through fully automated operation, the automatic bagging machine can automatically complete bag picking, bag opening, filling, sealing and other processes. The entire process does not require manual intervention, which greatly improves packaging speed. Depending on the needs of different production lines, the packaging speed of the automatic bagging machine can usually reach more than 1,200 bags per hour, significantly improving packaging efficiency.

    However, the performance of the bagging machine also has higher requirements on the bag material. Since the automatic bagging machine relies on the suction cup to suck the bag mouth to operate, the bag must have sufficient flatness and appropriate flexibility to ensure that the suction cup can smoothly absorb and fill. If the bag material is not suitable, it may cause difficulty in adsorption, affect packaging speed and accuracy, and even cause equipment failure.

    In addition, automatic bagging machines also have certain operational complexity when adjusting packaging specifications. For example, when switching from 25kg packaging to 50kg packaging, the formula settings of the bagging machine need to be manually adjusted, which involves adjusting the bag width, filling volume, and operating parameters of each component. These adjustment processes are relatively cumbersome and may require a certain amount of time and experience, making the operation more difficult. However, with the continuous advancement of technology, modern automatic bagging machine systems have gradually optimized these adjustment processes, making the operation of changing bag specifications easier and more efficient.

    In general, although the automatic bagging machine has high requirements for bag material and operation adjustment during the material packaging process, its high degree of automation can significantly improve the packaging efficiency of the compound fertilizer production line, reduce labor costs, and continues to During optimization, the convenience of adjustment operations is also constantly improving.

  • 5. What is the role and function of the electric control system in the compound fertilizer production line?

    The low-voltage power distribution system and electric control system of compound fertilizer play a vital role in the compound fertilizer production line, ensuring the efficient and stable operation of the equipment. The low-voltage power distribution system is responsible for providing a stable power supply for each device in the production line. Its voltage is generally below 380V, which is suitable for the operation requirements of most factory equipment. The system usually includes the main electric control cabinet, distribution cabinet, transformer, etc., which are used to distribute power and ensure safe operation.

    The electric control system (including the DCS control system) is the “brain” of the compound fertilizer production line. It coordinates the work of each link through intelligent monitoring and management. DCS (distributed control system) is the core component of the electric control system. It can realize the automatic control of each section and monitor various key parameters in the production process, such as temperature, humidity, pressure, flow, etc., to ensure that each link operates in the best state. Through the integrated PLC (programmable logic controller) and HMI (human-machine interface), the operator can monitor and adjust various parameters in the production process in real time.

    In compound fertilizer production, the electric control system can reduce human intervention and optimize equipment operation efficiency through automatic control. For example, it automatically adjusts process parameters such as fertilizer ingredients, drying temperature, cooling rate, etc. to ensure accurate formula and maximize production efficiency. At the same time, the electronic control system can also detect and handle abnormal situations in a timely manner, issue early warning signals, avoid equipment failures, and improve equipment stability and production line safety. Through data collection and analysis, the electronic control system can also provide production data reports to help managers conduct refined management and decision-making.

    In short, the low-voltage power distribution system and electronic control system of the compound fertilizer production line realize the automation, refinement and efficiency of the production process through intelligent management, ensure the smooth and stable operation of the entire production process, and improve production efficiency and product quality.

  • 6. How does the NPK organic-inorganic compound fertilizer production line automation system optimize the production process?

    Automatic quantitative batching system: Tongli’s automatic quantitative batching system can accurately control the proportion of raw materials, and the batching accuracy can be controlled within ±0.5%. This high-precision batching control reduces human errors, ensures the consistency of the formula, and thus improves the quality and stability of the fertilizer. The system can automatically adjust the batching ratio according to production needs, reduce raw material waste, and maximize production efficiency.

    Automatic packaging system: The automatic packaging system can achieve a packaging capacity of up to 100 tons per hour through efficient packaging machinery and intelligent control, greatly improving packaging efficiency. The system can accurately complete the quantitative packaging of each bag of fertilizer, avoid human interference and errors, and ensure accuracy and consistency during the packaging process. This not only shortens the packaging time, but also reduces labor costs.

    Palletizing robot system: Tongli’s palletizing robot system can efficiently and automatically stack the packaged fertilizer bags to the designated location. Compared with traditional manual stacking, the efficiency of the robot system is improved by about 30%, while reducing the labor intensity of workers. The system can also automatically adjust the stacking method according to the production rhythm, optimize the use of storage space, and improve the intelligent level of storage management.

    Real-time monitoring and data collection: The automation system is equipped with real-time monitoring and data collection functions, which can dynamically monitor each link in the production process. Through sensors and intelligent instruments, the system can collect and analyze production data at any time, detect abnormalities in time and take corresponding adjustment measures. This monitoring function ensures the stability of production equipment and the reliability of product quality.

    Intelligent electronic control system: The intelligent electronic control system of Tongli compound fertilizer production line realizes intelligent adjustment and control of the entire production process. All equipment is coordinated and operated through the electronic control system, avoiding errors caused by manual operation. The electronic control system automatically adjusts equipment parameters according to real-time data, optimizes the production process, ensures that each link can operate efficiently, reduces downtime and maintenance costs, and improves the reliability of the production line.

APPLICATION

NPK Compound Fertilizer

NPK Compound Fertilizer

NPK compound fertilizer provides balanced nutrients (N, P, K) to support crop growth and yield.

Ammonium Sulfate

Ammonium Sulfate

Ammonium sulfate is a high-nitrogen fertilizer that promotes healthy plant growth and improves soil.

Superphosphate

Superphosphate

Superphosphate fertilizer is rich in phosphorus, boosting root development, flowering, and yield.

Potassium Chloride (MOP)

Potassium Chloride (MOP)

Potassium chloride provides essential potassium to enhance drought resistance and crop quality.

Urea Fertilizer

Urea Fertilizer

Urea is a fast-acting nitrogen fertilizer, boosting leaf growth and increasing overall crop yields.

Lime Nitrogen

Lime Nitrogen

Lime nitrogen improves soil pH and provides nitrogen and calcium for healthier crop development.

15-15-15 NPK Fertilizer

15-15-15 NPK Fertilizer

15-15-15 NPK fertilizer offers balanced nutrients to support overall plant growth and increase yield.

18-18-18 NPK Fertilizer

18-18-18 NPK Fertilizer

18-18-18 NPK fertilizer offers higher nutrient concentration, promoting strong plant growth and fruiting.