Surfaced Mount Sensors In Concrete Mixing Plants

• Posted by Mavis Chai April 27, 2025 Filed in Technology #concrete mixing plant  43 views
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  Surface mount sensors in concrete mixing plants are typical used to monitor key parameters such as equipment operation status, material ratio, weight and pressure in real time, to ensure production efficiency and concrete quality. The following is an analysis of the application scenarios, selection suggestions and common problems of this type of sensor.

  Typical Application Scenarios Of Surface Mount Sensors

  Weighing Monitoring

  - Location

  Installed under the silo, the support structure of the mixer or the conveyor belt.

  - Function

  Real-time monitoring of the weighing of raw materials such as sand, gravel, cement, and water to ensure the accuracy of the proportioning.

  - Type

  High-precision strain gauge load cell.

  Pressure Monitoring

  - Location：Hydraulic system, pumping pipeline or mixer bearing.

  - Function: Detect hydraulic pressure, pipeline blockage or abnormal equipment load.

  - Type: Piezoelectric or piezoresistive pressure sensors

  Temperature Monitoring

  - Location: Inside the mixer, aggregate silo or cooling water system.

  - Function: Prevent concrete from overheating (in summer) or freezing (in winter), and ensure the setting time.

  - Type: PT100 thermal resistance or thermocouple.

  Vibration Monitoring

  - Location: Mixer motor, reducer or vibrating scree.

  - Function: Detect abnormal vibrations of the equipment and prevent mechanical failures.

  - Type: Piezoelectric vibration sensor.

  Key Points For Selection And Installation

  1. Environmental Adaptability

  - Protection grade: At least IP67 (dust and water resistant), higher protection is required in dusty and humid environments (such as IP68).

  - Temperature resistance range: -20℃ to 80℃ (customized for extreme environments).

  - Anti-interference capability: Select sensors with shielding layers to avoid electromagnetic interference (such as frequency converters and motors).

  2. Accuracy And Range

  The accuracy of the load cell should reach ±0.1% to 0.5%, and the measurement range should be selected based on the capacity of the silo (for example, 10 tons to 50 tons).

  The pressure sensor needs to cover 1.5 times the maximum working pressure of the equipment.

  3. Installation Method

  - Surface mount:

  It is necessary to ensure that the sensor is closely attached to the surface of the device (such as using high-strength adhesives or bolts for fixation).

  - Signal transmission: Digital signal output (such as RS485, CAN bus) is preferred to reduce signal attenuation.

  4. Brand And Maintenance

  - Recommended brands: HBM, Mettler Toledo (weighing), Omron ( pressure), TE Connectivity (temperature).

  Regular calibrate (every 3 to 6 months) and clean the senors surface to prevent material accumulation form affecting accuracy.

  Common Problems And Solutions

  1. Data drift/ Large error

  Cause: Sensor overload, temperature drift or loose wiring.

  Solution: Check if the range matches, recalibrate and reinforce the signal line.

  2. Signal Interference

  Reason: The sensor is not shielded or is close to strong electrical equipment.

  Solution: Use shield cables, run them separately and isolate them from the power lines.

  3. The Sensor Is Damaged

  Cause: Mechanical shock, corrosion or overload.

  Solution: Install a protective cover and select a stainless steel sensor.

  4. Communication Interruption

  Cause: Oxidation of the connector, protocol mismatch or incorrect PLC configuration.

  Solution: Check the terminal blocks and confirm that the communication protocol (such as Modbus RTU) matches the PLC.

  Future Trends

  - Intelligence

  Integrated with IoT functions, real-time data is wirelessly transmitted to the cloud to achieve remote monitoring and predictive maintenance.

  - Multi-parameter fusion

  Develop composite sensors (such as simultaneously monitoring temperature, humidity and pressure).

  - Low power Consumption Design

  Suitable for wireless sensors in scenarios without power supply (such as LoRa/ NB-IoT).

  Through reasonable selection and standardized maintenance, surface mount sensors can significantly enhance the automation level and production stability of concrete mixing plants. If it is necessary to further discuss the specific model or installation plant, it is recommended to provide detailed working condition parameters (such as environment, range, output signal type.)