For a variety of terrain concrete pan mixer
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September 12 08:24:32, 2025
Concrete pan mixers are essential for concrete production, designed to meet diverse requirements. These machines must not only adhere to strict technical standards but also be adaptable to various site conditions. The design of the machine and its components must be flexible, especially when it comes to technological modifications, additions, and automation systems. A high level of adaptability is crucial to ensure efficient and reliable operation in different environments.
The concrete mixing system consists of multiple integrated units and processes. At the core of this system is the mixer, which requires a robust control system to ensure safe and stable operation. This includes closed-loop motor control and indirect drive mechanisms that regulate the mixing process. Modern mixers are often equipped with consistency measurement devices, as well as microwave sensors that monitor moisture and temperature levels, ensuring accurate and consistent mixing results.
Concrete control equipment plays a vital role in managing the materials used in the mixing process. This includes concrete silos, weighing scales, and screw conveyors controlled by inverters. Radar sensors or measuring scales are commonly used to monitor material levels within the silos. To prevent dust accumulation, air filters are installed, utilizing vibration technology to automatically remove airborne particles. Additionally, pressure sensors help protect the silos from overpressure situations.
For transporting gravel, strain gauge sensors on conveyor belts measure the amount of material being discharged. If gravel trucks are used, they are controlled via frequency converters, with terminal position sensors ensuring precise placement. Sand silos may include vibrating devices to ensure accurate feeding. In more demanding applications, radar sensors are used to measure the quantity of gravel, and in some cases, they can also detect moisture levels in sand, allowing for real-time adjustments during the pre-mixing phase.
Water measurement is another critical component. Water is first measured using weighing scales with two control valves, followed by a parallel flow meter for enhanced accuracy. This ensures that the right amount of water is added to achieve the desired concrete consistency.
Additives are an essential part of the concrete production process, as different applications require specific properties. These small quantities of materials are typically added using pumps and metering scales. The B&R automation system not only optimizes the control program but also ensures that safety procedures are strictly followed. This system allows for data collection, reporting, and integration with higher-level company systems, providing valuable insights and improving overall efficiency.
Remote I/O distribution helps reduce costs and improve system performance. Using the X20/X67 system, new concrete mixers can be controlled through interconnected modules housed in a field enclosure. The X2X bus enables fast data communication, simplifying the distribution of input and output modules. By placing I/O modules where needed, wiring is minimized, leading to significant cost savings.
When creating reports, graphs, or managing databases, the system can connect via Ethernet using TCP/IP protocol. This is achieved through a PLC with an OPC server, making the control system highly scalable and flexible. Manufacturers benefit from this adaptability, allowing them to easily expand their systems as needed.
In many cases, the controller manages not only the concrete mixer itself but also other equipment involved in the production process, such as recycling systems, sand and water heating, insulation, and lighting. Thanks to B&R’s flexible and open architecture, these systems can be seamlessly integrated, meeting a wide range of operational needs. This level of integration ensures that manufacturers can efficiently manage all aspects of their concrete production process.