Two scales sharing one lower garner

Location:
Champaign, Illinois

Project:
Multiple rail track load out
Integrated State Grading
Truck receiving and grading

CompuWeigh Control Systems:
(2) DWC-400 bulk weighing controllers integrated with the GMS control system
GMS-Truck scale workstation with integrated grading
SmartRead wireless rail car RF ID system
SmartLink accounting system interface to AS/400
Integrated State Grading with cumulative weighted average grades on cars loaded

Rail Load Out:
This elevator has two 250,000lb capacity scales, each capable of holding a full rail car of grain. Making the project more “interesting” is that the two scales share a common inlet and discharge so the control system needs to ensure that both scales are filling and discharging correctly because there is no emergency third hopper if there is a problem.

We were able to lower the project cost by using our inexpensive DWC-400 controllers because there was no requirement for lower garner gate control and with only one draft per car there was not a need for ultra high speed or accuracy. The two scales are fully controlled by GMS which provides all the benefits of a Windows based system.

RF id:
To provide the manager with an immediate track list a CompuWeigh SmartRead rail car RF ID system is located where the cars arrive at the facility. Since this location is distant from the Control Room the system uses wireless communications, eliminating the need to run communications conduit to the unit.

As each car passes the reader, its id is captured and GMS then consults its SmartCar database to calculate the optimum amount to load into the car. To further improve the integrity of the system, wheel sensors are included so that cars with missing or defective rail tags are automatically detected. The cars are clearly marked on the In-transit list so that the operator knows these car numbers need to be typed in.

Although not implemented with in this installation, the system is capable of calling the manager when the cars actually arrive at the facility.

A second reader, antenna and wheel sensor are located at the dump pit to ensure that the correct car is loaded. The antenna is positioned so that the next to be loaded is also identified so that when the car in front is complete, the scale can automatically start on this next car.

As the cars are loaded, a representative sample is pulled from the grain-stream and graded in an adjacent office by State certified graders. The results are then entered into a separate GMS Grading station. The elevator manager can then monitor the overall quality of the cars loaded using our SmartGrade system, which shows him the weighted average of each factor for the cars already loaded. This allows the manager to make minor adjustments to the blend rather than work in ‘crisis mode’ at the end and be forced to ‘give away’ quality product to meet the overall unit train quality.

Truck Receiving & Grading:
A close to standard GMS truck receiving and grading system is included with the system. This customer has taken the opportunity to reduce their Corporate costs of by standardizing on GMS for all their locations. They use our GMS Designer System that is significantly less expensive than the normal GMS system and allows them to modify all aspects of the program without having to be responsible for the underlying code.

All completed GMS transactions both on truck receiving and rail load out run through the SmartLink accounting interface which correctly formats the data so it can be sent directly to the corporate accounting system.