The core working principle of the sorting scale
Simply put, a sorting scale is an automated assembly line system that continuously dynamically weighs each product, compares the weight with a preset standard range, and finally classifies the products into different categories based on the comparison results.
The basic workflow is: loading → conveying → dynamic weighing → data comparison → sorting execution → classification and storage.
2、 Basic steps for using a sorting scale
Although different brands and models of sorting scales have different operating interfaces, the basic logic is the same. The following is a general operating procedure:
Step 1: Check and prepare before starting up
Safety check: Ensure that the power cord is well connected, the emergency stop button is not pressed, and there are no obstacles around the scale body.
Mechanical inspection: Check whether the conveyor belt is intact and whether the tension is appropriate; Check if the sorting device (such as push rod, lever, flap, blowing nozzle, etc.) is functioning properly and if there is any jamming.
Cleaning and hygiene: Especially in the weighing platform (scale pan) area, it must be kept clean and free of dust and debris adhesion to avoid affecting weighing accuracy.
Step 2: Startup and Preheating
Turn on the power switch, and the system will perform a self-test.
Let the device run idle for 5-15 minutes for preheating, especially for high-precision sorting scales that are sensitive to environmental temperature. Preheating is crucial to ensure that electronic components reach a stable working state.
Step 3: Product parameter settings
Enter or select the product information to be tested on the touch screen human-machine interface (HMI) of the device:
Product name/code: Easy to manage multiple product formulas.
Target weight: The ideal nominal weight of the product (such as 100g).
Upper and lower threshold: Set an acceptable range of weight deviation.
Upper limit (Over): Maximum allowable weight (such as 102g), overweight will be excluded.
Under: Minimum allowable weight (such as 98g), under weight will be excluded.
You can also set more detailed grading, such as setting multi-level zones for "qualified", "slightly light/slightly heavy (defective)", "severely out of tolerance (scrap)", etc.
Selection of sorting method: Select the exclusion method, such as air blowing, push rod, swing arm, etc.
Step 4: Calibration (the most important step)
Calibration is the lifeline to ensure accuracy. Standard weights that have been certified by metrology must be used.
Enter the calibration menu: usually in system settings or advanced settings.
Zero point calibration (zeroing): During the operation of the empty belt, perform zero point calibration to ensure accurate tare weight.
Range calibration (span calibration): Gently place a known weight standard weight (such as 100g, 500g) on a running weighing platform (with specialized tools or positions for placing weights), input the actual weight of the weight, and the equipment will automatically calculate and save the calibration coefficient.
Attention: The calibration frequency should be determined based on usage. It is recommended to conduct a quick check every shift or every few hours, and complete calibration should be performed regularly.
Step 5: Trial operation and fine-tuning
Put in a small amount of product for trial operation.
Observing the sorting effect: Check whether the removal action is accurate and timely. Has the product really been assigned to the correct area.
Fine tuning parameters:
Advance/Delay Removal Time: If the removal action is too early or too late, the "Removal Delay" time needs to be adjusted to ensure that the product is just moved when it reaches directly above the removal device.
Speed matching: Adjust the conveyor belt speed to ensure that the product is stable on the weighing platform. If the speed is too fast, it will cause unstable weighing.
Step 6: Formal production and monitoring
Start continuous production.
The operator needs to conduct regular spot checks on the sorting results, retest the weight of qualified and rejected products using a static scale, and verify the accuracy of the sorting scale.
Pay attention to the operation status of the equipment, clean up scattered products in a timely manner, and keep the environment clean.
Step 7: Shutdown
Stop feeding and let the equipment run empty for a moment to ensure that all products have been processed.
Shut down normally according to the operating procedures.
Perform daily maintenance, such as cleaning equipment and oiling moving parts.