Flow Weigher DC4: Modular inline weighing system for bulk solids
Friedrich electronic has introduced the Flow Weigher DC4. The modular weighing system provides continuous inline flow measurement from 1 to 250 m³/h in bulk handling applications.
There is plenty of movement in a bulk material handling plant – yet a crucial part of what happens often remains hidden. Grain flows out of a silo, granules pass through production, and pellets are loaded for transport. But how much material is actually moving through the plant? How consistent is the flow? And how much has already reached the receiving vehicle?
Being able to answer these questions reliably provides more than measurement data. It gives operators a clear overview and a sound basis for day-to-day decisions. A hidden material flow becomes a process that can be understood and tracked. This is where continuous bulk material measurement makes a difference.
Integrating suitable weighing technology into a plant, however, often presents challenges for operators and plant designers. Space is limited, pipe layouts are fixed, and connections may be round or rectangular. Different material properties add another layer of complexity: free-flowing grain requires a different approach to material guidance than flour, flakes or recycled materials. With the Flow Weigher DC4, Friedrich electronic has developed a weighing system that offers the flexibility to meet these demands. It combines continuous measurement with a modular design and a wide range of configuration options. The guiding principle is practical: weighing technology should fit the application and provide information where it is needed. With the DC4 series, Friedrich electronic will complement the existing DC3 series and further expand its product portfolio. This will give users additional options for finding the right solution for their bulk material handling application.
A continuous view of material flow
At the heart of the Flow Weigher DC4 is a curved measuring plate suspended from a load cell inside the weighing unit. As the bulk material passes over the plate, it exerts a force on it. The forces transferred to the load cell form the basis for measuring the material flow.
Measurement is continuous. The system operates passively, without actively moving parts. A housing manufactured to tight tolerances and an optimised material path support the weighing process.
For users, this brings material flow into view. The current throughput shows what is happening in the plant at that moment. The accumulated total indicates how much material has already passed through the measuring point. Together, these values provide useful information for assessing operations and identifying changes in everyday plant performance.
Versatility that meets real-world needs
Bulk materials vary widely, and so do the potential applications of the Flow Weigher DC4. Its range includes free-flowing materials such as grain and seeds, pulses, coffee beans, granules and pellets.
Adapted versions are also available for products that place greater demands on material guidance. These include meals, flakes, bran and flours, as well as various recycled materials. Fine-grained sands, waste materials and abrasion residues further extend the range of potential applications.
This versatility requires careful matching of the system to the task. The appropriate configuration depends on the material properties and process conditions, allowing the solution to be tailored to the application.
There is also flexibility in the choice of construction materials. The housing is made from stainless steel as standard. For specific requirements, individual housing components can be manufactured from materials such as V4A stainless steel or hardened steel. Corrosion and wear resistance can therefore be taken into account during system specification.
Plenty of flexibility – even where space is limited
In existing plants, the installation conditions often determine whether a measuring point can be incorporated at all. Where space is restricted or pipe layouts offer little scope for modification, design flexibility is essential.
The Flow Weigher DC4 is based on main housings currently available in four sizes. Each size offers three inlet variants. Connections for round and rectangular pipe cross-sections, together with outlet transition pieces, complete the modular concept.
These components can be combined to create a configuration suited to the available space and the required material path. This opens up possibilities both for new plants and for retrofitting existing processes.
The available sizes range from compact housings for confined spaces to larger versions for high throughputs. Overall, the system covers throughput rates of approximately 1 to 250 m³/h. Custom designs are also available for specific requirements.
Weighing results that make a practical difference
The achievable weighing accuracy depends on the application and is typically around 1–2%. With a highly uniform feed and stable process conditions, accuracies of around 0.5% can be achieved. Practical experience also shows that external factors affect measurement results. Unfavourable material feeding conditions, for example, can introduce additional measurement deviations. The design of the measuring point should therefore take into account conditions both upstream of and within the weighing unit. For selection and integration, this means that suitable material guidance is essential alongside throughput and connection dimensions. The system delivers weighing results that provide valuable support for the application thanks to a customized product guiding – integrated in the applied inlet type.
Information where it is needed
For measurement data to be useful in everyday operation, it must be accessible and easy to understand. The Flow Weigher DC4 therefore uses an intuitive touch panel for data evaluation and display. It shows the current throughput and provides stored totals and a preset function. Graphical recording and limit alarms are also available.
This makes material flow easy to follow at a glance. Operators can monitor throughput, read accumulated quantities and identify changes in the process.
Signals are transmitted digitally between the weighing unit and the evaluation unit. The touch panel can therefore be installed at a considerable distance from the measuring point – in a location that is accessible and suits the plant’s operating routines.
A web server also allows the user interface to be displayed on a PC. Optional fieldbus connectivity enables measurement data to be retrieved and integrated into existing PLC systems. The information can thus also be used within the plant’s supervisory control system.
Keeping track from silo to vehicle
The benefits are particularly clear during loading. As material flows from the silo into the receiving vehicle, the Flow Weigher DC4 provides information on the current throughput and the accumulated quantity. A process that otherwise takes place largely out of sight becomes visible and traceable.
Within production, this transparency also delivers practical value. Understanding material flows helps operators make sense of their processes and base decisions on actual measurements. The Flow Weigher DC4 combines a passive measuring system with an adaptable design and a clear digital display. Whether the application involves limited installation space, high throughput or demanding bulk materials, the available configurations offer scope for a suitable solution. For users, the result is above all a clearer view of what moves through their plant every day.
