Control Technologies

The final component in your batching system is the batching controller. In reality the manufacturers of these controllers, boards, software and microprocessors are multi-million dollar companies, such as Siemens™, Sartorius™, Hardy™, GE™ and Allen-Bradley™, whom are able to pour millions into R&D in a way, smaller, “feeder” companies cannot. Due to this 3Sigma utilizes a number of sources to provide the best possible results in meeting your integrated requirements.

What are my control options?

Plug-In Scale Input Card. Connects directly to your PLC, usually via Ethernet.
Traditional Fast/Dribble Batch Controller. Controls feeder at two speeds, volumetrically.
Loss-in-Weight Controlled Rate Batch Controller. This control uses Closed Loop Control logic to accurately control a batch at a defined rate.
Off the Shelf Batching Software Packages. Software written specific for Loss-in-Weight batching systems
PLC based Controllers with HMI packages to control the compounding system.
Line Conditioners, Digital Scale Outputs and other ancillary control options are used to optimize the batching system.

Model 3010 Batch Control

Model 5200 Control Rate

PLC Based Systems

• Controls 1 or 2 Scales, Multiple Feeders
• Fast/ Dribble operation
• Up to 55 scale readings/ second
• Auto Preact adjustment
• Auto Jog
• WaverSaver® vibration rejection
• Alarms, shutdown, timers
• Network compatible
• Wireless access
• Used in common batching applications

• Controls Multiple Scales, Feeders and Ancillary Equipment
• Allen-Bradely
• GE
• Modicon
• Siemens
• HMI Software Packages Configured per application
• WonderWare
• Intellution
• Rockwell

• Controls 1 Scale, 1 Feeder
• Controlled Rate Fast/Dribble operation
• Up to 30 scale readings/second
• Auto Preact adjustment
• Auto Jog
• Alarms, shutdown, timers
• Network compatible
• Used to batch ‘x’ lbs. over ‘y’ minutes

Line Conditioners

A-B PLC
Plug-In Modules

Model X5
Batch Control

• Maintains usable 120V (+10%/-12%) nominal output over an input range of 89 to 147V
• Protects sensitive weighing equipment from power-related performance problems Premium EMI/RFI noise filtering prevents equipment interaction, system interference, lockups and other power-related issues

• Self Contained Microprocessor based I/O Modules
• Used in place of local controller
• ControlLogix®
• CompactLogix®
• MicroLogix 1500
• Series SLC
• Series 5

• Controls multiple scales, multiple feeders
• Fast/ Dribble operation
• Up to 60 scale readings/sec.
• Unsurpassed sensitivity
• Auto preact, auto jog
• Vibration rejection software
• Alarms, shutdowns, timers
• Network compatible
• Operates with standard supervisory batch software
• Micro and Minor systems

3Sigma continues to search for the best controllers for your application. Internal testing of four different batch controllers has proven that one controller does not fit all needs.

Micros (3-100 gram batches)

One fast/dribble batch controller outperformed the other three controllers by a factor of 300-600%. This controller is generally specified for any micro batches.

Macros (>200 lbs)

The controlled rate batch controller generally yields much better results as the controller takes up to 60 samples from the scale per second and controls both the fast feed (100 PPM) and the dribble feed (5 PPM), precisely on an ongoing second-to-second basis. Maintaining a constant/controlled feed rate provides:

Controlled rate proved a better estimation of the last amount to discharge from the system, as this is based upon real time data.
Controlled rate prevents an incipient flow condition.