In the mixing production process of polymer materials such as rubber and plastic, the accuracy of material ratio directly determines the final performance and quality of the product. As the core equipment for achieving high-precision material ratio, the automatic weighing and batching system of the internal mixer uses advanced weighing and measurement technology and automation control methods to accurately weigh and transport various materials such as raw rubber, carbon black, and additives. It works in conjunction with the internal mixer to effectively improve production efficiency and product stability. The following will provide a detailed introduction to the automatic weighing and batching system of the internal mixer from the dimensions of system composition, working principle, technical advantages, application scenarios, and development trends.

1、 Core components of the system

The automatic weighing and batching system of the internal mixer mainly consists of five parts: material storage unit, weighing and measuring unit, conveying unit, control system, and auxiliary unit. Each part works closely together to form a complete automated batching system.

（1） Material storage unit

This unit provides dedicated storage environments for materials with different characteristics. The block shaped raw rubber is stored in a three-dimensional material bin with an automatic grabbing device for easy access in the future; Powdered materials such as carbon black and calcium carbonate are stored in sealed silos, with dust removal devices installed at the top of the silos to prevent dust from overflowing. At the same time, level sensors are installed to monitor material inventory in real time, and when the material is below the set value, an automatic alarm prompts for replenishment; Liquid additives are stored in tanks with stirring and temperature control functions to ensure uniform and stable composition of the additives, and to avoid performance being affected by temperature changes.

（2） Weighing and measuring unit

The weighing and measuring unit is the key to achieving precise batching in the system. Diversified weighing methods are adopted for different forms of materials: for block materials, a high-precision weighing platform is used in conjunction with a robotic arm to achieve precise weighing of single or multiple pieces of material; Powdered materials are measured using a weight loss scale, which is based on real-time monitoring of the rate of change in the weight of the silo over time, combined with the speed control of the screw feeder, to accurately measure the output of the material, with a measurement accuracy of ± 0.5%; The liquid additive adopts a weighing type measuring tank, combined with high-precision weighing sensors and peristaltic pumps, to achieve precise weighing and addition of trace liquids, with an error controlled within ± 0.1%. All weighing equipment is regularly calibrated automatically to ensure accuracy for long-term use.

（3） Conveyor unit

The conveying unit is responsible for safely and quickly transporting the measured materials to the mixer. Select the appropriate conveying method based on the characteristics of the material: Powdered materials are often transported using pneumatic conveying or vacuum feeding systems, and the materials are transported in a closed manner through pipelines to prevent dust leakage; Block materials are transported through belt conveyors or chain conveyors; Liquid additives are pumped through corrosion-resistant pipelines and metering pumps. Metal detection and foreign object interception devices are installed during the transportation process to prevent impurities from entering the internal mixer and affecting product quality. At the same time, the conveying pipeline adopts a quick detachable design, which is easy to clean and maintain.

（4） Control system

The control system is based on PLC (Programmable Logic Controller) or industrial computer as the core, combined with customized ingredient control software. The operator inputs the mixing formula through the human-machine interface (HMI), including parameters such as material type, ratio, and feeding sequence. The system controls the discharge device of the material storage unit, the start and stop of the weighing and measuring unit, and the operation of the conveying unit according to the preset program. During the batching process, real-time data from weighing sensors is collected to compare the actual weighing value with the set value. Once a deviation occurs, the operating parameters of the feeding equipment are automatically adjusted to achieve closed-loop control and ensure batching accuracy. In addition, the control system also has functions such as data recording, fault diagnosis, alarm prompts, etc., which facilitate production management and equipment maintenance.

（5） Auxiliary unit

The auxiliary unit includes a dust removal system, an automatic cleaning device, and safety protection equipment. The dust removal system is equipped with multiple suction ports in the material storage, weighing, and conveying processes, combined with efficient dust collectors, effectively reducing workshop dust concentration and improving the working environment; The automatic cleaning device regularly cleans the conveying pipelines, weighing equipment, etc. to prevent material residue and cross contamination; Safety protection equipment such as emergency stop buttons, overload protection devices, leakage monitoring devices, etc., comprehensively ensure the safety of equipment and personnel.

2、 Working principle and process

After the operator inputs the production formula into the control system, the system first activates the feeding device of the material storage unit to transport the material to the weighing and measuring unit. The weighing and measuring unit accurately measures the material based on the preset weight value. Taking powdered materials as an example, the weight loss measuring scale starts working, and the screw feeder sends the material out of the silo. At the same time, the weighing sensor monitors the weight change of the silo in real time. When the reduced weight reaches the set value, the screw feeder stops feeding. After the measurement is completed, the conveying unit transports different materials to the feed inlet of the mixer in the set order and time. Throughout the entire batching process, the control system continuously monitors data from each link. In the event of any abnormalities (such as excessive weighing deviation, conveyor blockage, etc.), the alarm program is immediately activated and corresponding measures are taken to ensure the smooth progress of the batching process. After the ingredients are completed, the system records the relevant data of this ingredient, providing a basis for subsequent quality traceability and process optimization.

3、 Technical advantages

（1） High precision measurement

Through advanced weighing sensors and intelligent control algorithms, the automatic weighing and batching system of the mixing machine can overcome the influence of material characteristics (such as fluidity and density changes) and environmental factors (such as temperature and pressure fluctuations) on measurement, achieve high-precision proportioning of multiple materials, significantly improve the quality stability of the mixed rubber, and reduce the product defect rate caused by batching errors.

（2） Automation and Efficiency

This system achieves fully automated operations from material storage, weighing to transportation, without the need for manual intervention, significantly reducing batching time and improving production efficiency. At the same time, it can seamlessly integrate with the internal mixer to achieve continuous production, effectively reducing labor costs and intensity.

（3） Flexible formula management

Support the storage and quick switching of multiple formulas, allowing operators to call different formulas at any time according to production needs, meeting the production mode of multiple varieties and small batches. The system also has a recipe permission management function to ensure the security of core recipe data.

（4） Data Management and Analysis

Automatically record the material type, weight, time, and other data of each batch of ingredients, and generate detailed production reports. Through data analysis, enterprises can optimize ingredient process parameters, predict equipment maintenance cycles, and provide strong data support for production decisions.

4、 Application scenarios

（1） Tire manufacturing industry

In the tire production, the automatic weighing and batching system of the internal mixer accurately controls the proportion of natural rubber, synthetic rubber, carbon black, sulfur and other materials to ensure that the physical properties of the rubber mixture (such as strength, abrasion resistance, aging resistance) meet the standards, improve the quality and production efficiency of tire products, and meet the high-performance requirements of the automobile industry for tires.

（2） Rubber products industry

For the production of rubber products such as rubber pipes, sealing rings, and tapes, this system achieves precise addition of additives such as anti-aging agents, accelerators, and reinforcing agents, improving the elasticity, weather resistance, and sealing performance of rubber products and enhancing their market competitiveness.

（3） Plastic processing industry

In the process of plastic modification production, the automatic weighing and batching system of the mixing machine accurately measures basic resins, flame retardants, antioxidants, fillers and other materials, helping enterprises produce high-performance plastic products that meet the needs of different fields, such as automotive interior parts, electronic and electrical casings, building pipes, etc.

5、 Development Trends

In the future, the automatic weighing and batching system of the internal mixer will develop towards intelligence, integration, and green direction. In terms of intelligence, artificial intelligence and machine learning algorithms are introduced to enable the system to have self-learning and adaptive capabilities, and to automatically optimize ingredient parameters based on production data; In terms of integration, it deeply integrates with the enterprise's ERP (Enterprise Resource Planning) and MES (Manufacturing Execution System) to achieve collaborative management of production planning, material inventory, and ingredient operations; Greening is reflected in reducing equipment energy consumption, reducing dust emissions, and using environmentally friendly materials. By optimizing system design and operating modes, it promotes sustainable development in the industry.