Automatic Bead Mixing Equipment
Automatic mixing equipment that blends beads of different diameters in a set ratio, controlled by PLC with recipes per product type.
Solution Overview
Benchtop model with 14 bins feeding beads independently; the test-bead and mix-bead pipelines do not interfere with each other
The automatic bead mixing equipment is a desktop unit, convenient to place on the existing workbench on site without major changes to the bench. The equipment is controlled by PLC, with a touch screen interface for parameter setting and model program recall; it can freely switch between the required mixing ratios of large and small steel balls and displays current production information and alarm information in real time. The equipment has two bead discharge channels: one for bead testing and one for bead mixing; the two channels can discharge beads separately or simultaneously after a program is selected, without interfering with each other in production use. There are 14 bead storage bins in total, and each bin can feed beads independently.
The complete machine dimensions are L×W×H = 1460mm × 280mm × 900mm, the control method is PLC, air pressure 0.5~0.7 MPa, voltage 220 V ± 10%, and cycle time is 107 pcs (steel balls) / 29~31 s (at 0.6 MPa air pressure).
Because the incoming steel balls carry oil, the oil migrates downward and accumulates as the balls pile up in the material bin, and it may enter the machine interior along with the ball feeding process and create oil stains. The countermeasure is to use a large number of downward oil collection holes inside the material bin to gather the oil into an oil collection base, which then channels it to an oil guide groove, ultimately discharging the oil from the 14 material bins to an oil collection box outside the equipment.
Solution configuration
Material bin, piping, air supply and oil collection form the complete machine in four directions
Bead Storage Bins
- 14 material bins in total
- Nos. 1-13: -6 um to +6 um
- No. 14: common bead diameter -20um
- Each material bin feeds beads independently
Dual-Channel Bead Discharge
- Test bead tube
- Mixed bead tube
- Beads can be dispensed individually
- After a program is selected, both can dispense beads at the same time without interfering
Air Supply and Operation
- Three-Channel Air Inlet Design
- Three sets of air inlet pressure regulating filters
- 10-inch touchscreen
- Equipment control buttons and foot switch
Oil Collection and Structure
- Material bin oil guide groove
- Oil collection holes in the material bin and oil collection base
- Pressure relief and oil collection device for the bead feed pipe
- External oil collection box
process Workflow
From bead feeding in the material bin to discharge, the two channels work separately or at the same time per program
- 01 Bead Storage in Bins
- 02 Independent bead feeding
- 03 Select the test-bead / mixed-bead program
- 04 Three-Channel Air Supply
- 05 Test bead tube discharge
- 06 Mixed bead tube discharge
- 07 Interfaces with the nut
- 08 Handheld Bead Feeding Assembly
- 09 Oil drains through the oil guide groove into the oil collection box
Critical Stages
Independent Bead Feeding and Oil Collection Are the Two Key Points of This Equipment
14 Material Bins with Independent Bead Feeding and Mixing Ratio
The equipment has 14 shot storage bins. Bins 1-13 range from -6 um to +6 um, and bin 14 is a common shot diameter of -20 um. Each bin can feed shot independently, and calling up the machine model program on the touch screen freely switches the mixing ratio of large and small steel shot required.
- Bins 1-13: -6 um to +6 um
- Bin 14: common bead diameter -20 um
- Each material bin feeds beads independently
- Bead mixing ratio can be switched freely in the program
Dual-Tube Bead Dispensing: Trial Beads and Mixed Beads Do Not Interfere
The equipment discharges steel balls through two pipes: one for test balls and one for mixed balls. The two pipes can discharge separately, or discharge at the same time once a program is selected, without interfering with production use. Of the three air inlets, one supplies air blow to the cylinder moving parts and the ball-throwing mechanism, and the remaining two supply air to the test-ball main pipe and the mixed-ball main pipe respectively, ensuring the discharge speed of the large pipes.
- Test bead and mixed bead channels are independent
- Beads can be dispensed separately or simultaneously
- Three air inlets supply air separately
- Maintains the bead output rate of the large channel; test bead and mixed bead programs can run at the same time
Oil Collection Design
Incoming steel balls carry oil, and the oil migrates downward as they pile up. Inside the bin, a large number of downward oil-collection holes gather the oil into an oil-collection base, which directs it to an oil guide groove, and the oil from all 14 bins is finally discharged to a collection box outside the equipment, reducing oil contamination inside the machine.
- Built-in downward oil drain hole in the material bin
- Oil collection base gathers oil stains
- Oil guide groove directs oil outside the equipment
- Oil from all 14 material bins drains to an external oil collection box
equipment Specifications and Structure
The complete machine specifications, material bin setup and structural composition given in the solution
| Item | Content |
|---|---|
| machine model | Benchtop model that fits on the existing operator table on site, with no extensive modification to the tabletop |
| Complete Machine Dimensions | L × W × H = 1460mm × 280mm × 900mm |
| Control Method | PLC control; the touchscreen interface sets specifications and recalls machine model programs |
| Air Pressure / Voltage | Air pressure 0.5 ~ 0.7 MPa; voltage 220 V ± 10% |
| cycle time | 107 pcs (steel balls) / 29 ~ 31 s (air pressure 0.6 MPa) |
| Material Bin Setup | 14 bead storage bins in total; bins 1-13 are -6um to +6um, bin 14 is for the common bead diameter -20um; each bin can feed beads independently |
| Bead Discharge Tubes | Dual channels: trial ball channel + mixed ball channel, which can dispense balls separately or, after a program is selected, simultaneously, without interfering with each other |
| Applicable Bead Diameters | 6.35mm / 4.762mm / 3.969mm / 3.175mm |
| Bead Mixing Ratio | Mixed steel ball size ratio 1:1 / 2:1 / 3:1 / 4:1 |
| Structural Components | Material bin oil guide groove and oil collection box · Ball feed pipe pressure relief oil collector · Nut connection · Handheld ball feeding assembly · Steel ball feed storage bin · Equipment control buttons · Air inlet pressure regulating filter · Nut assembly parts temporary storage box · Universal joint bracket · 10-inch touchscreen |
| Power and Air Supply Specifications | 10 A power cord · AC socket · flange connector · foot switch |
| Usage Limitations | At present each standalone machine can only handle steel balls of the same diameter, because the core ball feeding and ball dispensing mechanisms cannot be shared across different ball diameters |
| Test Bead Discharge Count | Single-diameter trial ball output is around 50 ~ 60 balls; after the trial is completed, the balls are returned to the bin, and there must be no risk of material mixing |
delivery and After-Sales
Starting from bead diameter and mixed-bead ratio, bead feeding, bead discharge and oil collection are built into one benchtop machine
- 01 Confirm ball diameter and mixing ratio
- 02 Validate the ball feeding and discharge solution
- 03 Solution design and structural design
- 04 Equipment manufacturing and integration
- 05 On-site installation and commissioning
- 06 Trial production and parameter optimization
- 07 Acceptance, delivery and training
- 08 After-sales and spare parts support
Common Question
Common Questions About Automatic Bead Mixing Equipment
What problem does this equipment solve?
It solves the automatic discharging problem for large and small steel balls mixed in proportion and for test balls. The equipment can switch freely between the required mixing ratios of large and small steel balls, the touchscreen interface displays current production and alarm information in real time, and the production operator interface is easy to learn.
How is the material bin set up?
The bead storage bins total 14: bins 1-13 are for -6 um to +6 um, and bin 14 is for common bead diameter -20 um. Each material bin can feed beads independently.
Can Test Beads and Mixed Beads Run at the Same Time?
Yes. The machine has dual ball dispensing channels, one test-ball channel and one mixed-ball channel; the two channels can dispense separately, or after a program is selected Beads are discharged simultaneously without interfering during production. Of the three air inlets, two supply air to the test-bead main pipeline and the mix-bead main pipeline respectively.
Will Oily Steel Balls Contaminate the Equipment?
The solution has a dedicated design for this: inside the material bin, a large number of downward Oil Drain Holes, collecting oil contamination into the oil collection base, then guiding it through the oil guide groove, and finally discharging the oil from the 14 bins to the equipment's external Oil Collection Box, reducing oil stains inside the machine.
What are the equipment specifications?
Complete Machine Dimensions 1460mm × 280mm × 900mm, desktop machine model; PLC control; air pressure 0.5~0.7 MPa; voltage 220 V ±10%; cycle time 107 pcs (steel balls) / 29~31 s (air pressure 0.6 MPa); fitted with a 10-inch touchscreen.
How many bead diameters can one machine handle?
Note: the proposal explicitly states Currently each standalone machine can only handle steel balls of the same ball diameter, because the core ball feeding mechanism and ball dispensing mechanism cannot be shared between different ball diameters. The applicable ball diameters listed in the solution are 6.35 mm / 4.762 mm / 3.969 mm / 3.175 mm.
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