The blender will blend at a maximum rate when the lower mass flow weigh hopper has a very low weight of material. As the weight of material increases in the mass flow weigh hopper, the controller will adjust the blender feeders output to match the calculated processing machine rate. The blender will adjust in so that it is running a very closely matched rate to the extruder and readjust the ingredient hopper outputs accordingly.

The processing rate and the blending rate displayed on the blender control will not match exactly for any extended period of time as the dynamics of the extrusion process produces a continuously changing rate for the extruder. The blender will follow this dynamic changing rate very closely. The learned processing rate is accurate enough for mono-layer extrusion yield control or co-extrusion layer thickness control.

If the extruder is slowed or stopped suddenly, the blender will reach the high weight point in the lower mass flow hopper, slow down, and stop the metering devices so the weigh hopper will not overfill.

Manual Backup Control System

Every continuous blender is equipped with a secondary manual backup control system. This allows the blender to be switched over to manual operation. In this mode, the feeder speeds are adjusted manually, and the blender will run, blending volumetrically. The lower mass flow weigh hopper is equipped with a proximity sensor mounted on the upper level of the hopper. This is for the manual operation to cycle the metering augers if the level of material in the weigh hopper reaches a high level.

This secondary control will allow the blender to be operated to provide production in the event of a control failure. After correction, the blender can be switched back into automatic operation.

When the blender is running in steady automatic mode, simply check the motor voltages (or) frequency readouts and record them. Then the drives can simply be “dialed in” for emergency volumetric operation.

Continuous Loss-in-Weight Blenders

Chapter 4: Operation

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Sterling SLC 5/04, 100, 600, 015, 060 specifications Manual Backup Control System
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060, SLC 5/04, 015, 600, 100 specifications

Sterling 100,600,015 SLC 5/04,060 is a robust and versatile industrial automation controller designed to meet the demands of various industrial applications. As part of the Sterling lineup, this model is particularly known for its reliability and advanced features that enhance operational efficiency.

One of the main features of the Sterling 100,600,015 SLC 5/04,060 is its modular architecture, which allows users to customize the system based on their specific needs. The controller supports a wide range of I/O modules, providing flexibility in expanding or modifying the system as production requirements change. This modularity ensures scalability, making it suitable for both small-scale and large-scale applications.

The controller operates on the well-established Allen-Bradley SLC 500 platform, which is known for its stability and ease of use. With a processing speed of 100 kHz, the SLC 5/04,060 can handle multiple tasks simultaneously, ensuring precise control over processes. This speed is complemented by a large memory capacity, allowing for complex programming and data storage without compromising performance.

In terms of communication, the Sterling 100,600,015 SLC 5/04,060 features multiple communication ports, including RS-232 and RS-485 interfaces, making it compatible with various devices and systems. This capability enables seamless integration with existing networks, as well as the implementation of modern network protocols like Ethernet for greater connectivity and data transfer efficiency.

The controller is also equipped with advanced diagnostics capabilities, enabling users to monitor system performance in real-time. This feature not only helps in quick troubleshooting but also aids in predictive maintenance strategies, reducing downtime and optimizing productivity.

In addition to its hardware features, the Sterling 100,600,015 SLC 5/04,060 supports a range of programming languages, including ladder logic, structured text, and function block diagrams. This versatility allows engineers and technicians to choose the most suitable approach for their specific projects, making the development process more intuitive and efficient.

Overall, the Sterling 100,600,015 SLC 5/04,060 is a powerful and adaptable solution for industrial automation, combining advanced technology with ease of use, making it an ideal choice for businesses seeking to enhance their operational capabilities and efficiency.
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