Tarlac State University

College of Engineering and Technology

Department of Mechanical Engineering
Romulo Blvd., Brgy. San Vicente, Tarlac City, 2300 Philippines

Weighing, Feeding and Batching Systems

Vanessa M. Martinez
Neil Karlo M. Lozano
Nixon Daren A. Lozano
Arvi Millado
Group 7
ME-5C

Engr. Elmer P. Tolenada

Professor
Industrial Scales
The measurement predates many of the other important measurements encountered in industrial
instrumentation. In fact, the weighing commodities for purposes of trade goes back to antiquity.
Steelyard
- Also known as the Roman Balance
- Is an unequal-arm portable weigh beam having single bar whereon the applied load is
counterpoised by positioning a poise on the long arm.
- Sometimes furnished with a plurality of load pivots, fulcrum pivots or poises.

Danish Steelyard
- the applied load is balanced by the weight of the long arm and a fixed counterpoise; the fulcrum
is movable and its position when equilibrium is obtained indicates the weight value of the applied
load.

Weighmaster’s Steelyard
- was used to describe a refinement of the steelyard.
- a scale used officially for determination or arbitration of weights.
Determination of weight through the use of levers and counterweights persisted. Most modern industrial
and commercial scale relied on levers, pivots, bearings, and counterweights.
Improvements were made thereafter.

 Mechanical Scales- measured the weight over an exceedingly wide range- from grains or grams
to several thousand tons.
  Pneumatic and Hydraulic load cells appeared

Strain Gage Load cell was made.

 Major shortcoming for mechanical scales is not their accuracy/ruggedness but they are heavy and
bulky in nature.

 As early as 1940’s, scale engineers pioneered many of the principles used in batching systems.

 Combination of electrical and magnetic equipment and ladder logic, batching and bulk weighing
as well as continuous weighing for mass production lines were developed.

 In 1960’s, some of the methods were still used but it was during this time that the abandonment
of mechanical scales and full replacement with electronic systems begins to be adapted.
Components of Weighing Devices
1. A load receiving element

- May be platter, scoop, platform, hopper, tank, hood section of conveyor, section of railway
truck, section of roadway, bag holder.
- Any device that momentarily captures the load to be measured.
 2. An indicating, recording, controlling means.
The load may be indicated through
1. Positioning of poise on a beam
2. Outputs from strain gage or load cells.
3. Position of an indicator on a circular/graduated chart
4. Optical projection and magnification of a section moving chart.
5. Conversion of values to digits.

3. A sensing or
measuring and
transmitting
apparatus to couple
components 1 and 2
Mechanical Scale Engineering
Levers
In a mechanical scale, the load is reduced by levers so that the smaller counterbalancing forces
can be used. For a lever in equilibrium,
load x load arm = power x power arm
Load arm- distance from the fulcrum to the point of application of the load measured perpendicularly to
the direction of load force.

Power arm- distance from the fulcrum to the point of application of the power measured perpendicularly
to the direction of power force.
Multiple of the System
power arm
Multiple=
load arm
load
Mechanical Advantage=
power
Classes of Lever

Counterbalancing Means
In a mechanical-type beam or weigh beam scales, the load is measured by counterbalancing the
force exerted by the load, this force generally being reduced through a lever system by moving one or
more poises on a bar or weigh beam until the weight of the poises times their distance from the fulcrum
equals the force due to the load times its distance from the fulcrum.

Pendulum Scales
In a pendulum-type automatic indicating scale, the force due to the load is counterbalanced by the
rotation of a bent lever.
Spring Scales

In spring scales, the deflection of a spring is generally helical in form, is used to measure the
load.
Dashpots
Generally, a dashpot is used in both pendulum and spring type automatic indicating scales. The
dashpot consists of a plunger moving in an oil-filled cylindrical housing. An adjustable orifice controls
the rate of oil past the plunger so that the oscillation of the scale system will be damped and thus speed up
the weighing operation. The dashpot also protects the indicating mechanism from the shock of suddenly
applied loads.

Hydraulic and Pneumatic Systems

Hydraulic pressure can be used to measure weight. The hydraulic system serves the same purpose
as the level systems of traditional scale, reducing the force due to the load by the use of large capsule so
that the weight is reduced to a measurable hydraulic pressure.
Pneumatic systems in which air is the force-transfer medium operate in similar principle.

Electrical and Electronic Force

For scale and balances of low capacity, electromagnetic force may be used as counterbalancing
forces. Measurement of this force can be easily translated into terms of weight (load). Majority of forced
transducers used today are strain gage load cells.
Strain gauge load cells usually feature four strain gauges in a Wheatstone bridge configuration, which is
an electrical circuit that balances two legs of a bridge circuit. The force being measured deforms the strain
gauge in this type of load cell, and the deformation is measured as change in electrical signal.

Applications and Types of Scales

1. Basic Weighing of vast variety of objects in connection with receiving, shipping and transporting
operations where weight is a variable interest. Scales are used to enforce load limit regulations in
connection with highways and railway carriers.

2. Counting, particularly of small parts, where weight can be a useful indication of the number of
pieces.

3. Calculating, where basic weight data can be automatically converted to price or value, density,
specific gravity, etc.
 4. Inspecting, to determine if containers are properly filled.

5. Pre-weighing and Filling

6. Batching and Formulating, weighing the ingredients for formulation in a process.

Scales may also be classified in terms of physical structure, as dictated by the type of load to be weighed.
1. Portable and Bench Scales
2. Floor and Deck Scales
3. Overhead track or Monorail Scales
4. Hopper and Tanker scales
5. Motor Truck Scales
6. Railway Track Scales
7. Cranes Scales
8. Other special purpose scales such as Weighing, Counting, and Drum and Bag Filling Scales.

Portable and Bench Scales

 Portable scales are equipped with casters or wheels for convenience in moving from one
location to another. Bench Scales are designed for semi-permanent locations.
 Some are constructed of stainless steel to be used in demanding environments such as meat
processing and packing.
 Mechanical and lever-type of scales are still available but most users prefer electronic load
cell designs.
 In the latter design, automatic pounds-to-kilograms switching, pushbutton tare, and printer
output are usually furnished as standard equipment.

Floor and Deck Scales

A floor scale is a great tool for measuring large loads that are too hefty to be lifted on the  scale by hand.
Most floor scales are equipped with on and off ramps that allow efficient loading and unloading. Floor
scales are well suited for industrial environments like warehouses and factories.
A deck scale is similar to a floor scale except that the frame of the scale rests on the existing floor rather
than requiring a pit and special foundation. Thus, the platform of the scale ranges from 8 to 10 in. above
floor level. This requires lifting of the load up to the level of the platform, a considerable convenience in
many applications.

Monorail Scales
Two Classes
1. Light-duty monorail scale- used in meat packing industry for motion or static weighing of
carcasses. The scale consists of a rugged, self-contained weighing unit usually supported by
existing monorail systems. Capacity of up to 1000 lb. (450 kg)

2. Heavy-duty monorail scales are used within steel mills, foundries, distribution warehouse and
other locations for weighing materials in transit. It consists of pre-assembled heavy-duty load cell
units designed to be incorporated with the user’s monorail systems. Capacity of up to 10000 lb.
(4500 kg)

Hopper and
Tank Scales
These
scales are
widely used in
the
chemical and process industries, often in connection with highly automated batching systems or in the
continuous receiving and shipping of bulk materials. Hopper scales range up to over 60,000 lb. (30 000
kg) in capacity and tank scales up to 125,00 lb. (60 000 kg)

Bulk Weighing

Railway Track Scales

Standard pit and low-profile static scales and in-motion scales are available for weighing railway
cars, locomotives and, in fact, entre trains through a consequence procedure. Railway track scale
capacities range between 100 and 200 tons (90 and 180 metric tons) with platform 8 to 10 ft (2.4 to 3 m)
wide and 60 to 125 ft (18 to 76 m) long
Crane Scales
These scales eliminate double handling by weighing and moving materials at the same time.
Generally, the configuration is a load cell contained in a strong, ruggedized assembly with a hook at the
top connected to the crane pulley and a hook at the bottom connected to the load. Crane scales range in
capacity from 1000 lb (450 kg) up to 60 000 lb (27,000 kg)

Counting Scales
A counting scale or piece counting scale can then compute the average piece weight. They do so
digitally by using a component called a strain gauge. A strain gauge can be used to measure the amount of
force that is exerted on an object. An electronic counting scale can also take into account the tare weight,
which is the weight of an empty container that may be holding the uniform parts. The scale then subtracts
the weight of the container from the overall weight of the goods.

Drum Filling Scales

Weigh-Batching Systems
 Weighing the ingredient for formulation in a process can be done by (1) by continuous blending,
using continuous weigh feeders, or (2) by batching definite amounts of each ingredient are weighed and
accumulated. Generally, more precise results can be obtained with batch weighing particularly when
production is large enough to justify a scale. Feeding equipment that is particularly suitable for the
material being weighed should be selected. Closely associated with the weighing operations per se are the
hoppers, hopper feeders and hopper discharging apparatus.

Belt Conveyor Scales

and Weigh Feeders
A belt conveyor scale may be looked on as a primary
element for use in the measurement of the flow rate of
bulk materials. Flow measurement is expressed in weight (lbs,
kg) per unit time (mins, hrs) rather than in units of volume (cu. Ft, cu. M).
Basic Belt Conveyor Scale
From 12 in. wide of belt it handles 0.45 kg/min. at a minimum belt speed of 1ft/min to 120 in.
wide of belts handling as much as 20,000 tons/hr. at speeds up to 1000ft/min.

 The conveyor speed and slope should not exceed that at which material slippage occurs. Accurate
weight totalization requires that material velocity matches belt velocity. This may require that the
scale be located a considerable distance from the loading point on a steeply inclined, high
velocity systems handling certain materials.
 All idlers should be of rigid frame construction with a horizontal roller section. So called "V"
rolls and "limber" rolls are not advisable.
 Conveyor length should not exceed that which assures that the belt will travel at least 3 circuits
while delivering the minimum totalized load for which accurate weight information is required.
 There shall be no tripper or moveable head pulleys in the conveyor.
  The conveyor should be equipped with a constant-tension or gravity-type take-up
The basic components used to sense the weight and speed may be mechanical, electronic, pneumatic, or
hydraulic. This info. Can be used for local or remote presentation in several ways:

 Rate indication – to show rate of material flow at any given instant

 Rate recording – for production records, downtime, over or underloading of the system, material
stoppages due to breakdown or plugged hoppers, and monitoring overall system efficiency
 Rate control – whose output signal to a final operator, such as a prefeed device, control the feed
to any particular process demand or set point
 Rate integration – to display on a continuous totalizer the weight conveyed and to produce
digital pulses
Belt Conveyor Scale Accuracy
Understanding the terminology: accuracy, repeatability and linearity
When a belt scale offers one correct measurement, that measurement is considered accurate. In
other words, if 100 tons of material is transported on a conveyor and the scale reads 100 tons, the
accuracy is perfect. But that is just one single data point. Accuracy needs to be repeatable. You need
accurate readings over and over and over again. So, if 100 tons of material is transported every day for 10
days and the scale tells you 1,000 tons have been moved, that’s perfect repeatability.
Problems/Inaccuracy
Problem #1: Inaccurate input when setting up means inaccurate output when measuring starts
Problem #2: Idlers placed too high or too low – the most common and most significant source of reduced
accuracy
Problem #3: Belt tension too high or too low – a close second as a source of reduced accuracy
Problem #4: Scale not installed in the proper location – particularly troublesome is if it’s too close to
inclines or sources of vibration
Problem #5: Poor conveyer quality or incompatible conveyer design
Testing and Calibrating Belt Scales
Three methods are used to test and calibrate a belt scale:
1. Material test – this is the most accurate and reliable method because it duplicates actual operating
conditions.
2. Test chain method – this dynamic test is second best to the material test method. chains are design to
weigh approximately the same as the material conveyed.
3. Calibrating weight test – this method does not take into account the effects of belt tension and
weighbridge deflection as the other two test methods.
Tare Adjustment
Because a conveyor belt varies in weight per running foot or meter, no less than one circuit of the belt
must be run before a tare adjustment is made. On completion of one or more circuits, the integrator
totalizer must display the same readout as before start-up. For this reason, an integrator must have the
capability of readout in the minus side for lightweight sections of the belt, as well as on the plus side for
heavier sections.
Gravimetric Feeders
The basic function of a belt scale is to continuously weigh material as it leaves a hopper, chute, or bin for
conveyance to a given location. The scale accurately weighs the material without concern for the amount
delivered per unit of time

Accuracy of Gravimetric Belt Feeders

Normally, accuracy guarantees are specified as ± ½ % or ±1%, dependent on specific designs, of
set rate over the entire operating range. This approach is valid provided that a rate control feeder design is
used, or when the range does not exceed 4:1 for “weigh control” feeder designs.
Integrated Concept of Feeder and Bin Design
An effective feed control system obviously requires a constant supply of material. too often, bin designs
are based on storage capacity requirements without regard for the material flow characteristics.
Careful study and evaluation of the following material properties is a prerequisite to the design of any
bulk material blending system:

 Density – the material may have a wide range of bulk densities which may be caused by
variations in particle size, chemical compositions, moisture content, and a packed or aerated
condition.
 Size – a screen analysis should be made to determine a percentage breakdown of the particle size.
 Moisture content – high moisture content and a large percentage of fines indicate that the material
may tend to arch or rat hole in the storage bin.
 Temperature – many materials are very free flowing at high temperature, but when allowed to
cool at rest, they may bridge and cease flowing owing to material arching.
 Special properties – some materials require special considerations with regard to construction of
system components – because they are corrosive or abrasive, or stick, or are of a flammable or
explosive nature
Free-flowing flushy-type materials
Aerated materials often flush through most standard bin designs. These materials usually are bone
dry and very fine (-200mesh) and are in many cases conveyed pneumatically by the bulk handling system.
Typically, very free flowing materials are ground phosphate rock, ground petroleum coke, raw cement,
and bentonite.
Solid Flowmeter
Solid flowmeter are not true gravimetric devices but rather utilize impact or centrifugal force to
generate a signal proportional to material flow. The basic requirements for a solids flowmeter arise from
operating problems encountered with a belt scale or weigh feeder on dry, flushy (fluidlike) materials
involving high flow rates, heat, environment, or explosion-proof requirements.

Automatic Blending System

Batching vs In-line Blending system
Batching
In a batch-type process, a recipe is followed by adding specific amounts of ingredients in a predefined
sequence with mixing, stirring, and brewing, or processing between the addition of each components.
In-line Blending
An in-line blending system refers to a process whereby component streams (liquid, gases, powders, or
aggregates) are measured and controlled in precise relationship or ratio to each other.
Typical Blender Configuration
Factors to Consider in Designing an Automatic Blending Machine
1. Sizing a blending system
 List of all the components required to form the various products.
 List the ratio ranges for these fluids as they relate to the final products.
 Possible Increase in production rate.
2. Flowmeter selection
 Most commonly used are flowmeters that produce a digital pulse frequency in direct
proportion to the flowrate. These include turbine, PD, vortex shredding, ultrasonic, and
magnetic flowmeters.
 Flowmeters should be selected according to the mechanical requirements.

3. Control Valve Selection

 Control valves are installed in each component stream
 It is selected based on the process conditions, power source, and mechanical
considerations.

Skid Assemblies
• These are the assemblies of flow control and measurement elements in each component stream.
Blending Operation
Typical CRT Blend Controller Display
This display gives the operator all the pertinent information required to oversee the blending operation.
Such data as product names, component totals, component temperatures, flowrates, and etc

Keyboard Control
The operator configures via the control keyboard.
Data Displays
The operator can completely monitor the status of the current blending operation or examine the blender
data base that defines the blender’s operation characteristics.
 General Display. The general display gives a complete picture of the current blending operation
status and is the display the operators selects the most of the time during a blending operation.
 Master Display. This display consists of display pages of data which define master status and
base items.
Flow Control Loop Displays. Page 1 displays the loop data status of all dynamic data associated with the
selected loop. Page 2 and 3 display all flow loop data base parameters for selected loop.