Design and Selection Guide for the Control System of HZS240

• Posted by Mavis Chai December 8, 2025 Filed in Technology #Concrete Batching Plant  #control system of concrete batching plant  #automatic concrete batching plant  44 views
  click to rate

  The HZS240, a common large-scale commercial concrete batching plant, boasts a theoretical production capacity of 240m³/h and is widely used in large-scale infrastructure, commercial concrete plants, and high-strength concrete supply scenarios. In this size of batching plant, the control system is the core component determining capacity, stability accuracy, and automation level. A highly reliable control system not only ensures continuous and efficient production but also forms the foundation for intelligent and data-driven management.

   

  This article comprehensively introduces the design considerations for the HZS240 batching plant control system, covering its architecture, core functions, key technical indicators, and selection criteria. Visit lutonmachinery.com for more details on various concrete batching plant equipment.

   

  1. The Role and Importance of the Control System for the HZS240 Mixing Plant

  As the HZS240 is a large-scale twin-shaft mixing plant with a large equipment scale, high material flow rate, and complex system links, it requires a control system that:

  • High degree of automation
  • High weighing accurac
  • Fast response speed
  • Strong anti-interference speed
  • Complete data recording

  to ensure overall production.

  The key tasks undertaken by the control system include:

  • Material proportioning and weighing control (aggregate/cement/powder/water/admixtures)
  • Automatic sequence control of the mixing process
  • Formula management and production report output
  • System networking and remote monitoring

  For large plants like the HZS240, the performance of the control system directly determines the mixing plant’s production capacity and concrete quality.

   

  2. Structural Design of the HZS240 Control System

  Generally, the control system of a large-scale mixing plant consists of two levels:

  2.1 Hardware Layer

  (1) Industrial-grade PLC Controller

  The HZS240 typically uses a high-reliability, modular PLC system, such as:

  • Siemens S7-300/S7-1500
  • Schneider Modicon
  • Mitsubishi Q Series

  The PLC is the brain of the entire mixing plant, responsible for signal acquisition, logic execution, and interlock protection.

  Requirements

  • High stability
  • Fast processing speed
  • Abundant expansion modules
  • Excellent anti-interference capability

  (2) Weighing System (Load Cells + A/D Module)

  Main components include:

  • Aggregate weighing sensor
  • Cement/powder silo weighing sensor
  • Water/admixture weighing sensor
  • High-precision A/D conversion module

  The HZS240 requires high weighing accuracy, powder material error is generally controlled within ±1%, and liquid material error within ±0.5%.

  (3) Touchscreen & Industrial Computer (IPC)

  The IPC is used for the user interface, recipe management, and report output. The touchscreen is used for on-site control.

  (4) Communication Network

  • Profibus/ Profinet
  • Modbus/ Ethernet
  • Industrial Wi-Fi (optional for remote monitoring)
  • Ensure stable real-time communication for all devices.

  2.2 Software Layer

  The software platform undertakes operational logic and data management functions, mainly including:

  (1) Automatic Control Logic Program

  • Material unloading sequence
  • Mixing time control
  • Automatic feeding
  • Secondary feeding optimization
  • Peak period continuous production logic

  (2) Weighing Control Algorithm

  To meet the requirements of high flow rate and high speed, the following are needed:

  • Predictive feeding algorithm (pre-feeding system)
  • Automatic error correction
  • Dynamic correction and filtering algorithm
  • Temperature compensation mechanism

  These algorithms determine whether the HZS240 can stably achieve a production capacity of 200+ m³ per hour.

  (3) Formula Management System

  • Multiple formula storage
  • Quick switching between different concrete grades
  • Mix ratio locking, access control

  Suitable for high-frequency production mode of commercial concrete plants.

  (4) Data Recording and Reporting System

  • Daily production
  • Team output
  • Concrete grade statistics
  • Material Consumption Report
  • Fault records and maintenance tips

  Support Excel export or automatic upload to the cloud.

  3. Key Design Points of HZS240 Control System

  3.1 Efficient production cycle control

  HZS240 generally uses dual mixers dual weighing systems, and the control system needs to coordinate:

  • Synchronous feeding
  • Parallel operation across weighing buckets
  • Optimization of the rhythm of the feeding conveyor belt

  Keep the mixing plan at full capacity and unobstructed at all times.

   

  3.2 Stable weighing control and compensation mechanism

  Under high production capacity conditions, the material flow rate is fast, requiring:

  • Powder pre braking (pre feeding)
  • Double bucket parallel batching of additives
  • Real time monitoring of each weighing curve

  Ensure the stability and consistency of each pot of concrete.

  3.3 Comprehensive safety interlock design

  A comprehensive interlock design including:

  • Mixing host door not closed → prohibit starting
  • Cement spiral shutdown → automatic stop of feeding
  • Mixing motor overload → forced shutdown protection
  • Air compressor malfunction → whole station locked

  Ensure the safety of large-scale station production.

  3.4 Anti interference design

  Large stations have long lines, multiple equipment, and sever electromagnetic interference, requiring:

  • Shielded signal line
  • Independent grounding system
  • Isolation amplifier
  • Isolation Design of PLC Input Module

  Ensure long-term stability of the signal.

  1.1 Intelligent and remote diagnostic capabilities (optional)

  Modern mixed use stations are increasingly pursuing digital management, and control systems can integrate:

  • Cloud based production management (remote viewing of production/consumption)
  • Remote diagnosis (via VPN or cloud platform)
  • Abnormal alarm SMS/APP push
  • Equipment management (mixing host, pneumatic system, screw machine status monitoring)

  Further improve operational efficiency.

  4. Selection suggestion for HZS240 control system

  The following are the key selection points summarized for engineering companies or mixing plant investors:

  4.1 PLC Controller Selection

  Priority selection of international brands:

  • Siemens S7-1500 (Best)
  • Siemens S7-300 (mature and stable)
  • Mitsubishi/Schneider (Economic Plan)

  Requirements:

  Stability＞Scalability＞High speed module support

   

  4.2 High precision weighing system

  Aggregate weighing: preferably using digital high-sensitivity sensors

  Powder: Must have early braking and differential control

  Liquid: using dedicated A/D modules and buffering devices

   

  4.3 Operating Interface and Software Platform

  Suggested choice:

  • Full Chinese interface (English/Spanish interface provided for international customers)
  • Independently editable formula
  • Automatic report statistics
  • Support dual operation mode of touch screen and industrial computer

   

  4.4 System Integration Capability

  The control system must be seamlessly integrated:

  • Spiral machine
  • Fan
  • Air compressor
  • Mixing machine
  • Cement silo
  • Belt conveyor/inclined belt conveyor
  • Measuring bucket/storage bucket

   

  Ensure continuous and reliable production.

   

  4.5 Maintenance and spare parts

  • Modular design
  • Standardized wiring
  • PLC/sensor spare parts are easy to procure
  • Software supports remote upgrade

  Reduce downtime.

  Conclusion

  As a large-scale concrete mixing plant, HZS240 requires extremely high precision, speed, and stability of the control system. An excellent control system should have:

  • High reliability PLC
  • Accurate and fast weighing system
  • Complete automation control process
  • Powerful anti-interference and interlocking protection
  • Intelligent data management and remote monitoring capabilities

  After comprehensive consideration of hardware performance, software algorithms, production pace, and safety, the most suitable control system can be selected for the HZS240 mixing plant to ensure its continuous and stable operation under high-intensity conditions.