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We design BatchTron controllers for unattended operation. You order your mix from one or more DEMAND STATIONS located throughout the plant. We position them next to casting stations or bucket filling positions. They save precious time because the controls are where they are needed.
Give priority to your critical stream without starving anyone else.
Mix designs and batch sizes are pre-chosen at the BatchTron controller at the start of operation. The demand stations, ordering stations or batch call stations each call for their particular batch whenever the holding bin is empty or a bucket is placed for filling. Optional BATCH SIZE switches can change the amount delivered to meet changing production needs, eliminating the need to go to the control panel. MOBILE CONTROL allows roving personnel to order ahead when meeting heavy production requirements in wet cast operations. We can manufacture any DEMAND STATIONS or MIXER CLEANOUT STATIONS in regular or ruggedized versions. The ruggedized version encloses all switches and controls behind a hinged transparent cover to protect against the splashes, dust and dirt that stop other systems from working.
Standard controls, most stations
Each demand station has a 'Priority' Switch. PRIORITY - LOW mode prepares a batch when a Bin Low or Bucket In Place signal is received. If the mixer is empty it will be mixed and if the Bin Low or Bucket In Place signal is still received, will be discharged
PRIORITY – HIGH mode weighs the next batch and holds it, either in the scales or in the mixer. When the bin low/bucket in place signal is received, the batch is dumped into the mixer (if held in the scales). When the scales are empty, a further batch is weighed and held. This accelerates the delivery of mix to the chosen location, allowing it to take precedence over other less critical operations. These other demands are serviced on a first-come, first-served basis as soon as the current high priority batch is complete. Because of this logic, the controller does not starve other stations of mix.
PRIORITY – OFF mode cancels any further demands from that station.
DEMAND IN PROCESS lamp (in Priority switch) – illuminates while a batch is being prepared for the station and flashes when scales are ready for discharge / discharging.
MIXER FULL lamp – illuminates when mixer is filled and flashes when mix is ready for discharge.
EMERGENCY STOP button – push to stop, twist and pull to restart; we fit this control on all demand stations. We configure it to stop either the whole batch plant or only the parts connected with the demand station, such as conveyors and mixer doors.
Controls specific to Wet Cast (slump concrete)
Demand stations for wet-cast concrete, using bucket transportation: BUCKET IN PLACE button - Used to indicate presence of a bucket at the discharge position; illuminates when pressed and requests a batch. Alternatively, an external ultrasonic sensor senses presence of the bucket and requests a batch automatically. Batch is discharged into bucket as soon as mixing is complete, provided bucket is still in place
BUCKET READY lamp (in Bucket in Place button) – illuminates when BUCKET IN PLACE button is pressed, extinguishes when mixer discharges into bucket and locks out further discharges, preventing a second batch being dumped on top of the first. Second press on button extinguishes lamp.
BATCH CALL button – illuminates and directly requests a batch when pressed, regardless of whether the bucket is ready. We do not often provide this button, since impatient operators make calls for batches before the bucket is free. This, in turn, can hold the mix too long in the mixer. You can request it, however.
Mixer Cleanout Station has manual controls for mixer maintenance
Installed next to mixers, manual control stations allow personnel to lock out automatic operation during cleaning and maintenance. Because normal operation is halted, personnel can control all mixer functions. This eliminates the need to operate the mixer functions from the control panel.
Controls include mixer motor, hydraulic pump, discharge open/close, scale discharge open/close as well as other functions when appropriate.