Ultimate Dynamic Checkweigher Guide: Operation, Maintenance & Tips | SameGram
If you're in manufacturing, especially in industries like food, pharmaceuticals, or logistics, ensuring every product meets exact weight specifications is crucial. A dynamic checkweigher is your go-to solution for high-speed, accurate weight verification on the production line. In this comprehensive guide, we'll dive deep into how these machines work, how to operate them effectively, troubleshoot common issues, and maintain them for long-term reliability. Whether you're a production manager looking to boost efficiency or an engineer integrating one into your setup, this article has you covered.
At SameGram, we've been at the forefront of intelligent weighing solutions for over 15 years. As a high-tech enterprise based in Dongguan, China, we specialize in non-standard customized dynamic checkweighers that integrate seamlessly with your production line. Our systems offer digital management, data traceability, and easy MES/ERP integration, helping you avoid underweight products, missing parts, and compliance headaches. Ready to upgrade? Contact us for a free consultation and sample testing.
What is a Dynamic Checkweigher?
A dynamic checkweigher is an automated machine designed to weigh products in motion on a conveyor belt, ensuring they fall within predefined weight tolerances. Unlike static scales, which require products to stop, dynamic models handle high throughput—up to hundreds of items per minute—making them ideal for fast-paced environments.
Our SameGram dynamic checkweighers, such as the Hygienic Checkweigher SCF-4523L3 Model, excel in precision and stability. They feature high-precision sensors for online weight detection or sorting, with characteristics like stable performance and simple operation. These systems are widely used in food, pharmaceuticals, chemicals, and logistics, where accuracy directly impacts quality control and regulatory compliance.
Key Benefits of Using a Dynamic Checkweigher
● Compliance and Quality Assurance: Meet standards like MID/OIML by rejecting under or overweight items.
● Efficiency Gains: Reduce waste from overfilling and minimize manual checks.
● Data Insights: Track production trends with built-in reporting for better process optimization.
● Customization: At SameGram, we tailor machines to your needs, supporting up to 20 recipes for different products.
How Does a Dynamic Checkweigher Work?
The core of a dynamic checkweigher lies in its weighing mechanism, which includes a conveyor motor, photoelectric sensors, and load cells. As products move across the scale, sensors detect their presence and measure weight dynamically. If the weight deviates from the set range, rejection mechanisms (like pushers or air blasts) remove the item.
In our systems, the intermediate weighing section is critical—its design ensures measurement accuracy despite vibrations or speed variations. For instance, our roller-based models use stainless-steel unpowered rollers for smooth, vibration-free operation. Dynamic compensation features adjust for deviations, with coefficients ranging from 1 to 100 to fine-tune results.
Core Components
● Weighing Platform: Supports weights up to the maximum range (e.g., in g or kg units).
● Photoelectric Sensors: Detect entry and exit, configurable in modes like dual, in, or out.
● Touchscreen Interface: User-friendly HMI for settings and monitoring.
● Rejection System: Customizable actions with delay and execution times.
Installation and Initial Setup
Proper installation is key to accuracy. Start by placing the machine away from vibration sources, wind, or humidity. Ensure it's level—our models have adjustable feet for this. Ground the unit to prevent electrical issues, and confirm the power supply matches 220V/50Hz (use a transformer if needed).
Step-by-Step Installation Guide
1. Site Preparation: Choose a stable, horizontal surface. Avoid hot, humid, or corrosive environments.
2. Power Connection: Plug into a dedicated outlet. Double-check voltage to prevent damage.
3. Mechanical Assembly: Secure the weighing mechanism and conveyor. Remove any shipping screws.
4. Calibration: Perform no-load (empty platform) and load (with known weights) calibrations via the interface.
5. Integration: Connect to your line using IO ports for start/stop signals.
For SameGram machines, our team offers on-site debugging and a two-year warranty. We've helped over 5,000 customers integrate these seamlessly—reach out for expert support.
Operating Your Dynamic Checkweigher: A Detailed Walkthrough
Operating our checkweighers is straightforward, thanks to the intuitive touchscreen. Power on, and you'll see a welcome screen before entering the main interface. Login with default credentials (equipment owner: no password; admin: 000000 or 111111) for access levels.
Main Interface Overview
● Real-Time Monitoring: Displays current weight, pass/reject counts, and alarms.
● Start/Stop Buttons: Emergency stop via red switch for safety.
● Recipe Management: Switch between up to 20 recipes. Customize names (e.g., in Chinese Pinyin, <16 characters), units (bags, boxes, bottles, etc.), and thresholds.
Setting Up Recipes
1. Navigate to "Recipe Settings."
2. Enter formula name and unit.
3. Set weight threshold (e.g., minimum for checks).
4. Adjust sorting collection time (default 0; set for delayed outputs).
5. Configure dynamic compensation (value and coefficient 1-100).
6. Define qualified ranges: Minimum and maximum weights, action delays (adjust after speed changes), and execution times.
7. Enable alarms for max quantity/weight in sorting bins (default 0 to disable).
Weighing Settings
● Calibration: No-load for empty scale; load with known weights (enter value).
● Zero Tracking: Set range (default 0) and rate (e.g., 5.4d/2.0s) for auto-adjustments.
● Continuous Alarm: Alert after N consecutive rejects.
● Precision Tweaks: Filter intensity (3-18, default 5) and coefficient (30-100, default 45).
Advanced Device Settings (Admin Only)
● Range and Display: Max range in g/kg; decimal places (1 for g, 3 for kg).
● Photoelectric Mode: No photo, dual, in, or out.
● IO Configurations: Set inputs (start/stop, photo detection) and outputs (alarms, actions). Debug by clicking ports.
● Motor Controls: Analog or RS485; correct speeds with linear measurements.
Automatic Learning Feature
For optimal accuracy:
1. Place a standard product on the scale.
2. Set learning threshold (25% of standard weight).
3. Adjust filter coefficient (>80 initially).
4. Run multiple cycles (enable times for higher precision).
5. The system auto-stops after learning.
In daily use, monitor for overflows or failures—our systems alarm and log data for review.
Troubleshooting Common Issues
Even the most reliable machines can encounter hiccups. Here's how to diagnose and fix them based on our extensive field experience.
Common Problems and Solutions
● Inaccurate Weights: Check for vibrations or dirt on sensors. Recalibrate no-load/load. Adjust dynamic compensation if deviations persist.
● No Response on Startup: Verify power (220V/50Hz) and grounding. Inspect fuses or connections. If expired (admin-set date), login as admin to reset.
● Alarms Triggering: For continuous rejects, inspect product flow or thresholds. Clear overflow alarms via IO button.
● Photoelectric Errors: Ensure sensors are clean and mode matches setup (e.g., dual for entry/exit).
● Motor Issues: If speed is inconsistent, recalibrate linear speeds or check RS485 settings.
● Data Export Fails: Insert USB, set dates, choose overwrite/append mode.
If issues persist, consult the error logs in reports. Our lifelong maintenance includes remote diagnostics.
Maintenance Tips for Longevity
Regular maintenance keeps your checkweigher running smoothly. Turn off power before any work.
Daily/Weekly Checks
● Clean conveyor and sensors with non-corrosive wipes—avoid water on electrics.
● Inspect belts/rollers for wear; replace if damaged.
● Verify calibration weekly with standard weights.
Monthly/Annual Tasks
● Lubricate moving parts per schedule.
● Check IO ports and wiring for secure connections.
● Update software if available (contact us for upgrades).
● Monitor wear cycles on components like load cells.
With proper care, our machines last years. We provide two-year warranties and on-site service to minimize downtime.
Applications and Why Choose SameGram
From food packaging to pharmaceutical bottling, dynamic checkweighers ensure consistency. Our customized solutions, like high-speed logistics models, handle diverse products with MES integration for real-time data.
Why SameGram? We're not just manufacturers—we're partners. With 15 years of R&D, 5,000+ successful cases, and fast delivery (standard models ship same-day), we deliver reliability.
