Advantages and Features
The powder materials used in concrete batching plants should be used only after passing inspection according to regulations. The inspection includes fineness, setting time, soundness and other items, and requires a certain amount of time to issue the inspection report. However, in actual production, wrong material being loaded into the silo often occurs, and the practice of using materials before inspection is even more common. Therefore, this monitoring system uses the Internet and information technology to collect in‑real‑time the blowing and inspection information of the batching plant, providing alerts for violations, thereby effectively standardizing batching plant management.
The following main problems exist in the management of powder silos in batching plants:
● 1. Safety hazards during material blowing.
● 2. Wrong powder material entering the silo.
● 3. Inability to know the powder silo inventory value accurately and in a timely manner, resulting in increased labor costs, low work efficiency, environmental pollution, personal injury, and equipment accidents.
● 4. Unreliable and inaccurate traditional powder silo level measurement.
Optimized Solution for Powder Silo Management
1、Powder Silo Intelligent Material Level System
The powder silo intelligent material level sensor has advantages such as easy installation and maintenance, accurate measurement, high operational safety, and no need to stop production during installation. It is currently the world's preferred solution for real-time measurement of powder silo material levels.
1、One powder silo intelligent material level sensor is installed on each support leg to collect the force signal of the support leg.
2、One BSQ300 detection terminal is installed per silo, displaying material weight in real time.
3、Each silo is equipped with one BSQ500 and an audible and visual indicator light, displaying real-time weight and over-range alarm (upper and lower limits can be set) at the material inlet.
4、One touch screen display box is provided for each production line, displaying the current material level using numbers and bar charts.
(1) Supports Ethernet and serial communication, capable of communicating with multiple material level collection terminals.
(2) Performs filtering on the detected incoming material signal, effectively shielding invalid signals.
5、Connected to the plant's local area network, each authorized office computer (including production computers, weighbridge room computers, etc.) can view real-time material level information.
6、The mobile app allows you to check the material status in the plant at any time.
7、Optional high and low material level alarm prompts to prevent powder silo shortage or overflow.
8、Optional automatic dust removal system to avoid forgetting to turn on the dust collector due to manual operation, preventing environmental pollution caused by the pressure relief valve opening unexpectedly when dust removal is not activated.
9、High measurement accuracy: directly outputs weight information, providing accurate measurement results, avoiding the influence of changes in material form such as differences in material dielectric constant, dust in the silo, wall adhesion, bridging, and collapse. Measurement accuracy can reach ±2% of the silo's maximum weighing capacity.
10、Simple installation: uses the existing silo structure, attached to the silo legs. No high-altitude work required, no change to the original silo structure, no need for large-scale modifications such as leg cutting, no need for workers to enter the powder silo for construction, no need to stop production during installation, and no need to immediately empty the material in the silo.
11、Maintenance-free: the sensor is attached to the outside of the silo leg, not in contact with the material. It has no moving parts and is not subject to sudden impact or severe loading. Long service life and no maintenance required.
12、Automatic recording of powder silo feeding data, providing an additional measure to monitor powder material feeding.
13、Can detect the force on each support leg. If there are abnormal conditions such as severe tilting of the silo, an alarm can be triggered to avoid the risk of cement silo tipping.
14、The BSQ300 detection terminal can be linked with the dust removal system. When feeding is detected, the dust collector starts automatically, enhancing dust removal effect, reducing pressure inside the silo, preventing environmental pollution caused by accidental opening of the pressure relief valve, while also avoiding the situation where workers forget to turn on the dust collector, causing filter clogging, and in severe cases, bursting the dust collector, causing serious environmental pollution and possibly major accidents with personal injury.
Powder Silo Electronic Access Control System
The powder silo electronic blowing access control is installed at the powder silo blowing port, effectively preventing powder material from being loaded into the wrong silo, reducing management costs, ensuring concrete quality, and eliminating production accidents.
1、The weighbridge room records the specification and feeding time of the material by card swiping. The driver goes to the detection terminal under the silo and swipes the card. If the card number matches the silo number, the access control is opened.
2、After a valid card swipe, the access control flap automatically opens fully within 10 seconds; after another valid card swipe, the flap automatically closes fully within 10 seconds.
3、The powder blowing access control system has built‑in door closure detection, monitoring the door closure status in real time.
4、If the door is forced open without swiping a card or without reading the correct IC card information, an alarm is automatically triggered.
5、After blowing is completed, the driver must first swipe the card to close the access control, and then return the card to the weighbridge room. Otherwise, the system will indicate that the access control is open, and the weighbridge room will not perform tare processing for the vehicle.
6、Currently, most batching plants use the simplest mechanical lock method for the cement silo blowing port, and some have no measures at all. The cost of installing a mechanical lock is very low, but without an intelligent manager, manual locking and unlocking cannot detect the switch status, leading to situations such as failure to lock the door or blowing the wrong material. Mechanical locks are also easy to lose or left unlocked after blowing.
Powder Silo Temperature Detection System
The temperature sensor is installed at the arch breaker port, simple to construct. It performs real‑time detection of the powder material temperature inside the silo, directly contacting the powder for high accuracy. The temperature signal can be remotely displayed on a touch screen, LED screen, or work computer, improving the management level of the batching plant.
Function features:
Real‑time detection of material temperature inside the silo; the BSQ300 directly displays the temperature of each silo for easy viewing.
The temperature sensor is installed inside the lower part of the silo, making the measured value closer to the temperature of the powder as it enters the mixer.
Provides a data basis for temperature control during concrete production, avoiding non‑compliant production.
Can be connected to the plant's local area network or remote servers; real‑time temperature can be viewed via office computers, mobile apps, and browsers without geographical or time limitations.
Infrared temperature sensor: a non‑contact infrared temperature sensor installed on one side of the mixer discharge outlet. When the mixer door opens for discharging, it automatically detects the temperature of the concrete.
Function features:
Real‑time detection of material temperature inside the silo; the BSQ300 directly displays the temperature of each silo for easy viewing.
The temperature sensor is installed inside the lower part of the silo, making the measured value closer to the temperature of the powder as it enters the mixer.
Provides a data basis for temperature control during concrete production, avoiding non‑compliant production.
Can be connected to the plant's local area network or remote servers; real‑time temperature can be viewed via office computers, mobile apps, and browsers without geographical or time limitations.
Powder Silo Burst Prevention System
Silo bursting has two causes: first, due to the dust collector not being turned on or other reasons causing poor air pressure inside the silo, the safety valve cannot open in time, leading to continuously rising gas pressure and bursting caused by over‑pressure; second, due to failure of the rotary level indicator or not following the level system, the driver continues to blow material into the silo even though it is already full, causing material overfill burst. Our company's powder silo burst prevention system effectively prevents both situations.
A pressure detection sensor is installed on the top of the powder silo, performing real‑time detection of the gas pressure inside the powder silo, preventing silo burst caused by excessively high pressure due to the dust collector not being turned on or poor exhaust.
Function features:
Real‑time detection of pressure/material level weight inside the powder silo.
Double protection for pressure detection: when the pressure exceeds the safety valve setpoint, the safety valve opens automatically; when the pressure exceeds the pressure alarm value, an audible and visual alarm is provided.
Double protection for material level detection: when the material level weight exceeds the set alarm upper limit or when the rotary level switch is activated, an audible and visual alarm is provided.
After receiving the alarm, the system reminds to turn off the air compressor or automatically shuts down the low‑pressure blowing system, preventing safety accidents such as silo topping.
Can be connected to the plant's local area network or remote servers; real‑time pressure/level can be viewed via office computers, mobile apps, and browsers without geographical or time limitations.
