Feedback Control minimizes giveaway and optimizes the packaging process
Feedback Control loop
This process of Feedback Control is continuous and comprises three steps:
- Mean value calculation of the filling weights
- Comparison with the target weight
- Feedback signal to the multihead weigher
Implementation and networking
The Feedback Control function can be implemented very easily, right at the time of purchase, but just as readily at a later date. The checkweigher can be integrated into the line control or directly networked with the automation system of the production area.
What exactly is Feedback Control?
Yamato Scale’s Feedback Control comprises the communication between the checkweigher and the multihead weigher. Deviations from the mean weight value of the fill quantity are detected and a subsequent signal is sent to the multihead weigher to adjust the target weight.
How does Feedback Control work?
Over the course of the production process, deviations from target weights of the filling quantity may occur. Possible causes for such deviations may be changes in the product features or the conditions in the environment. The checkweigher monitors the weight of each individual package and calculates a weight average for a certain number of weighing operations. As soon as the system registers a deviation within this defined period, it sends a control signal to the multihead weigher. The intelligent control unit of the multihead weigher calculates the difference and automatically corrects the filling quantity.
Why do you need the Feedback Control function?
- Deviations are detected immediately and corrected in real time.
- The filling quantity is adjusted in real time.
- Your production remains flexible and automatic.
What are the advantages of the Feedback Control function?
- Fast and automatic regulation of incorrect weights
- Minimization of giveaway
- Compliance with legal weight and packaging requirements
- Resource savings
- Protection of the constant quality of your production
Example of Feedback Control
Example of Feedback Control for the weighing and packaging of 500g of chocolate-coated nuts
With an activated feedback, the checkweigher monitors the correct filling of the package. A deviation from the target weight ±0.5g over- or underweight is tolerated. A correction signal is sent to the multihead weigher if, for example, a deviation from the average weight is registered for 10 packages. In this case, the average weight can lie between 450g to 499.5g (as underweight), or between 500.5g to 550.0g (as overweight).
During the control process, several packages with overweight are detected. The weight of package A is not taken into account in the statistics, as it is above the limit of 50.0g. Such “outliers” are usually caused by external factors and are therefore neglected. The weight deviation registered in the red area is recorded and a feedback is sent to the multihead weigher. The multihead weigher adjusts the filling value in several steps until the weights reach the tolerance range of the target weight.
Without Feedback Control, you would produce a whole batch with overweight, thereby recording significant losses!
In this case, the checkweigher calculates a difference that is below the permissible average value. Again, the outliers, such as point A, are not included in the statistics, as they may have been caused by environmental influences. Feedback is given to the multihead weigher, which adjusts the filling weights in steps.
Without Feedback Control, you would, under certain circumstances, have to rework the entire batch in a time-consuming manner, as it does not comply with the European mean value system!
Manager Technical/Customer Service
“Yamato Scale’s trend control is a function that can substantially optimize your production process. The monitoring of filling weights and the adjustment of deviations in real time are a minimum of automation that should be implemented in every production process.”
These recommendations are based on 30 years of experience at Yamato Scale.
Topics in this article
Feedback control, data transfer, checkweigher, weight checker machine, control, metal detector, multihead weigher, multihead scales, automatic multihead equipment, automatic dataweigh, feeding equipment, computer combination weighers, industrial weighers, semi-automatic dataweigh, automatic gravimetric filling instruments, associative accumulation weighers, associative combination weighers, fragile goods, integrated packaging solutions