The hopper feeder is designed as per the flux&solid cored wire production line . the hopper feeder is an important device that fill the powder into the steel billet as per the requirement.

The function is as below

1. Servo Motor and Planetary Precision Reducer

The hopper feeder is fitted with servo motor and planetary precision reducer, which work with gate adjustment, the filler ( powder) is fed into the U- shaped billet by the dispenser.

2. Two Hopper Feeders Working in Coordination

2 hopper feeders are provided,which are working in coordination with each other.

The hopper feeder is driven by servo motor ,and they are controlled by PLC. The the operation is made on HMI .

3. Linkage Control and Weighing System

A encoder is installed on the preforming unit,which make the hopper feeder and production line linkage.

The filler ( powder) is fed into the U-shaped billet as per the speed of preforming .

The hopper feeder is fitted with weighing system, which detects the real-time change in the filler ( powder) weight .

The amount of filler ( powder) in the cored wire is calculated as per lose-in-weight, so that the quality and qualification rate of flux cored wire is ensured.

4. Laser Sensor Detection System

The hopper feeder is fitted the imported laser sensors, it can detects the filler ( powder) height and levelness in the U-shaped billet .

The height and levelness of filler ( powder) is shown on the touch screen in real -time curve.

The filler ( powder) feeding status can be visually observed during production , the filler ( powder) lowest level can be set.

So that the quality and qualification rate of flux cored wire is ensured.

5. Stainless Steel Hopper

The hopper is made of 304 stainless steel .it has rust-resistance and non-magnetism.

6. Feeding Gate Adjustment

The feeding gate is adjusted by a micrometer head and equipped with a locking device, ensuring precision, reliability, and parameterized operation.

7. Electrical Control System Touch Screen

The touch screen of electrical control system, shows:

• the filler ( powder) weight in hopper

• Insufficient filler ( powder) alarm in the hopper

• steel strip speed

• running speed

• filling amount of filer

• malfunction.

8. Powder Filling Curve Control System

The unique powder filling curve control system of the flux-cored wire production line automatically compensates and matches the filling speed at different production speeds.

This eliminates variations in powder loss rate at different speed stages and ensures uniform powder filling during acceleration, deceleration, high-speed, and low-speed operation.

9. The electrical control system diagram

10. Two Type Hopper Feeder Options

We can provided two type hopper feeder for your option. The customer can choose one of them.

Option 1: Two or More Hopper Feeder Arranged Side by Side

Two or more hopper feeder are arranged side by side, feed different filler ( powder) into the U-shaped billet sequentially.

In this configuration, the filler ( powder) remain in distinct layered zones within the tube.

Option 2: Vertical Arranged Dispenser

The hopper feeders are consists of two sets of filling belts arranged vertically—one above the other.

In this configuration, the fine powder is placed on the upper belt and the coarse powder on the lower belt.

The fine powder is sprinkled over the coarse particles, and the blended powder mixture is then fed into the steel tube via the conveying belt(dispenser).

11. The Bought Out Component of Hopper Feeder

• Servo motor: 0.75 kW, DELTA

• Servo planetary reducer: FENG HUA (Taiwan)

• Guide rails and slides: AANTE

• Encoder: OMRON

• PLC: SIEMENS

• Touch screen (HMI): 10-inch color, KUNLUN TONGTAI

• Laser sensor: KEYENCE

• Bearings :FAG

2.Feature of the hopper feeder of the flux&solid cored wire production line

(1)

4 substitute removable hoppers should be provided the removable hopper with at least 0.3M³.

(2)

In the manufacture of two-component wire, two dispensers are used.

Setting the dispenser #2 to the specified flow rate of the first component is performed by starting the line (with the dispenser #1 closed for the second component), bringing it to operating speed, stopping and weighing 1 p. m. of wire, as well as weighing its contents.

After obtaining the required weight of the first component in 1 line meter of wire, the dispenser #1 for the second component is opened and the above procedure is repeated to determine the total filling of the wire.

(3)

The hopper for receiving and feeding filler to the dispenser (hopper-feeder) must be made of stainless steel, mounted on rubber supports, and have a mechanism for interrupting the filler supply during the dispenser repair.

(4)

The dispenser must ensure a uniform intake of filler in all operating modes of the line and ensure smooth adjustment of the filler intake.

(5)

It is necessary to provide cleaning units for the gutter shelves after compaction with filler.

The set bulk density of the filler on the dispenser and the readings of the laser filling level meter must correspond to the specified bulk mass of the filler at the wire outlet from the last calibration stand.