Intelligent dosing and batching systems

In industries such as plastics, chemicals, food, and building materials, the automated conveying and proportioning of powder and granular materials is a key link in the production process. The demand for the construction and renovation of intelligent batching systems continues to grow. These systems often involve numerous storage tanks distributed across different areas, with long signal wiring distances, placing high demands on deployment flexibility and signal reliability. Remote I/O modules that can be installed near field devices and expanded on demand have become the mainstream choice for automation control in intelligent batching systems. This case study focuses on an intelligent batching control system, demonstrating the application practice of Solidot PN5R Series All-in-One I/O Modules.

Solidot Products Used in This Case

PN5R-1616B

I. Equipment Introduction

The intelligent batching control system is a key piece of equipment in the field of automated conveying and proportioning of powder and granular materials, widely used in plastics, chemicals, food, building materials, and other industries. The entire system typically consists of multiple storage tanks (silos), pneumatic/pressure conveying units, weighing and metering units, batching and mixing units, and a supervisory control system. It can automatically complete material extraction, conveying, metering, and proportioning according to preset recipes, achieving continuous, lightly manned stable production.

The overall process covers the following stages: (process stages listed)

II. Solidot Solution

This intelligent batching control system uses a Siemens PLC as the core controller, with each storage tank distributed across different areas of the workshop. Given the scattered nature of the tanks and the large number of field signal points, this project focuses on two key requirements in automation control, addressed by the Solidot PN5R Series All-in-One I/O Modules:

Requirement 1: Optimize wiring and save costs The Solidot PN5R Series All-in-One I/O Modules ( PN5R-1616B ) are adopted, connected to the Siemens PLC via PROFINET to build a distributed control architecture. Each module is installed near its corresponding storage tank, placed inside the existing waterproof and dustproof junction boxes of the tanks. Field signals are connected locally, and actuators are driven locally.

Requirement 2: Optimize on-site maintenance and line expansion The PN5R series modules feature channel‑adjacent LED indicators for quick on‑site inspection and maintenance. Combined with diagnostic alarms, disconnection detection, and automatic recovery from module abnormalities, fault localization and troubleshooting become more convenient. For future line expansion, new I/O module nodes can be added to the daisy‑chain link for flexible and controllable integration.

III. System Architecture

Control Layer: The Siemens PLC serves as the core controller, responsible for recipe management, batching logic scheduling, and data processing, and communicates in real time with the I/O modules at each tank via PROFINET.

Network Layer: The PN5R-1616B has two RJ45 communication ports supporting line topology. Modules distributed across the tanks are cascaded along the line and connected back to the control cabinet through a single bus cable, resulting in a clear network structure that is easy to expand.

Field Execution Layer: One PN5R-1616B is installed near each tank to locally collect digital input signals such as level switches, position/proximity sensors, and valve feedback, and to drive actuators such as feed valves and discharge valves.

Note: The PN5R-1616B module has an IP20 protection rating. In this solution, the existing waterproof and dustproof junction boxes of the tanks are used for on‑site protection. If deployment is required outside cabinets or in the field, an optional dust cover can be used to meet protection requirements.

IV. Application Results

V. Solidot PN5R Series All-in-One I/O Module

The Solidot PN5R Series All-in-One I/O Module integrates communication and I/O functions in a single unit, featuring a PROFINET industrial Ethernet bus interface.

The module has a compact horizontal design and supports both DIN35mm standard rail clip‑on and fixed mounting methods. An optional dust cover enables installation outside cabinets. It includes short‑circuit protection, reverse polarity protection, surge protection, disconnection detection, diagnostic alarms, automatic recovery from module abnormalities, and online firmware upgrades. The innovative channel‑adjacent LED indicator design makes channel status clearly visible, facilitating on‑site inspection and maintenance.

It is widely used in applications such as intelligent batching, material conveying, packaging, and 3C electronics, where distributed I/O deployment and simplified on‑site wiring are highly required.