MIXTRON II MIXER MOISTURE CONTROLLER 

MixTron uses microwave technology and digital signal processing to accurately measure the moisture in the mixer.  The touch screen controller gives a choice of three different control methods, allowing you to choose the best, most accurate control for your plant and product.  Up to 30% improvement in speed compared with older resistance based methods.

• Silicon Nitride ceramic sensor faceplate, the hardest of any, and stainless steel body for longest life.  Adjustable mount compensates for mixer wear.
• Water measurement by volumetric meter or weight.
• Two-speed water valves for dosing speed plus accuracy.
• Water calculation is based on the actual material weights and the water/cement ratio for unequalled accuracy.
• PLC and touch screen based controller with graphic screen gives your batch operator a unique "window" on the mixing process.  It can run stand-alone but will also communicate with batching computer for better automation and higher accuracy.
• Can run two MixTron systems from the single controller, giving a major saving in two and three mixer plants.  The single controller connects to a separate sensor in each mixer and a separate set of water valves and meter for each mixer.  Each mixer has its own screen pages, menus and data memory, allowing each one to be customized and tuned as if it were a separate box.
• More background information - Concrete, water and moisture

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Screen View

Mixtron's screen shows the moisture graphically throughout the mixing cycle, allowing each stage to be monitored.  For the first time, the operator is able to see the mixing process in action, allowing him to know when mixing is done and to adjust the mixing parameters properly.  Mixer blade wear and adjustment can be clearly seen. 

The screen also shows raw and averaged data as an aid during setup.

MixTron II is the ultimate in water management for the concrete mixer.  MixTron’s digital microwave technology is insensitive to temperature and impurities, making it more accurate than the older resistive methods.  Measurement starts shortly after the aggregates and cement have been added to the mixer and continues until the computer has acquired a satisfactory average moisture reading.
Realizing that this process is slow, Scale-Tron has re-thought the averaging process, resulting in a faster and more accurate result.  From batch data received from the batching computer or stored in its own database, the water/cement ratio or water to total solids ratio (for dry cast) of the mix is calculated and compared with the target value for the mix design.  The difference between these two values allows the required water to be calculated.  The water is then metered or weighed into the mixer through fast flow and dribble valves to achieve high speed and a precise cutoff. The mix is released for discharge when the programmable mix time is finished. 

MixTron II goes further than any other system in use today;  it not only takes the formula weights to calculate the water amount - it uses the actual weights of both cement and aggregates to predict the water value, eliminating the errors caused by small batching variations.  The result is accurate moisture all of the time. 

MixTron II's digital microwave sensor 2240D is highly sensitive to moisture changes in the mixer.  Installed in the mixer floor or wall, it measures the material as it is mixed, passing the ever-changing moisture value to the MixTron II controller for measurement and control.  The MixTron sensor's faceplate has to endure the harsh abrasion of the aggregates as they mix.  Consequently, it uses high-tech Silicon Nitride ceramic, almost diamond hard and extremely tough.  Mixtron's faceplate is harder, tougher and thicker than anything else in the industry.  It lasts for the life of the sensor.

Windows Graphic User Interface makes setup and calibration fast and easy - see RadarTron page for details.

See more on ceramic faceplates and wear 

Mount for rotating pan mixers is an elegant solution to a difficult problem.  The MixTron Glider acts like a ski or toboggan, allowing the sensor to glide on the surface of the mix while measurements are being taken.  When measurement is finished, the Glider lifts out of the mix, reducing wear and buildup until it is time to measure the next batch.  The "ski" holds the sensor faceplate at a constant downward pressure in the mix, controlling density and eliminating air pockets that destroy accuracy.  The result is a highly stable, accurate reading that allows fast assessment of the moisture either before or during the addition of water.

The ski is fabricated from chromium carbide cladded steel, giving wear similar to the Mixtron 2240D's Silicon Nitride faceplate and ensuring many years of service before replacement.  When service is required, all parts are replaceable.                                            Click on picture to enlarge.

MixTron II’s PLC and touch screen are fully industrialized components in a sealed wall mounting cabinet, eliminating problems created by fine dust in filtered outside air.  Like our BatchTron controllers, MixTron II is extremely reliable;  typical life of these components is over 10 years.  Communication with the batching system is by serial RS232 link;  MixTron II can emulate Ludwig, Hydronix or Lesueur, ensuring full compatibility with your batch controller.  It can also operate as a stand-alone system.  Control of the water valves and communication with the water meter and other sensors is by internal PLC output relays, available in all standard voltages. All parts are standard off-the-shelf items at electrical distributors.

MixTron II’s software operates through an advanced touch screen interface.  Status indicators tell you what is happening at all stages in the mix cycle, together with the weights of materials obtained from the batching computer.  A graph of the moisture shows the progress of the mixing cycle for operator feedback;  any effects due to wear, material jams or breakage in the mixer can be observed before they become a problem.  The moisture value is updated continuously and the calculated water value is displayed before the water is added;  alarm messages are displayed when necessary.  The result is a window on your mixer performance that shows you more than you ever thought possible - and it’s simple to use.  Operators love it and your product quality will improve immediately.

Three programs to suit your operation and budget:

MasterMix gives highest speed and greatest mixer output for plants where the mixer is running batches back to back without a break for at least some of the time.  Handles dry or wet cast equally well. 

modified mixing sequence eliminates the climbing or descending readings that often prevent settling of the moisture value, allowing accurate results on almost any mixer and any mix design

MicroMix is lower in cost because it does not require a water meter or scale.  It is useful for dry cast only and takes longer to make a mix, so it has its place in lower throughput applications where the mixer usually stands idle between batches.

Fast MicroMix  gives the same short mixing cycles as MasterMix and is easier to set up.  This system requires a water meter, so is a little more costly than true MicroMix but it is as good a choice for certain applications.  Note that it only handles dry-cast (zero slump) concrete and certain types of SCC.  However, when slump concrete is made in the same mixer, the MicroMix system can be bypassed (depending on your batch controller), speeding up the operation further by using metered water.

MixTron-D digital sensor for OEM applications.  The MixTron 2240D sensor has been redesigned from the ground up, with digital signal processing to allow direct connection to a water controller.  Previously the sensor required special software to filter and smooth the signal before it could be used to measure moisture accurately.  Now this special software has been added into the sensor's electronics and a digital interface has been added, giving you the choice of a digital or analog moisture signal.  In addition, a special "terminal emulator" menu gives you the ability to read moisture values, set up and calibrate the sensor from a remote or local computer using RS232 or RS485 connection and a terminal emulator software program such as HyperTerminal, which we provide if you don't already have it.

We are working towards RoHS compliance for all Mixtron components    

More background information - Concrete, water and moisture     View MixTron slide show

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