Material tower weight calculation method and material tower weighing system

Abstract

The invention belongs to the field of material tower weighing and metering, and provides a material tower weight calculation method and a material tower weighing system, and the method comprises the steps: determining that a part of sensors are in a damaged state based on weight signals transmitted by the sensors; calculating the layer number of the current weight of the material tower in a pre-constructed three-dimensional weighing vector map by using other sensors; reconstructing a weight value which should be output by the damaged state sensor according to the map data of the layer and the upper layer in combination with the position of the damaged state sensor; and calculating the weight of the material tower according to the weight value which should be output by the damaged state sensor and the weight values output by other sensors. The method has the advantages that the three-dimensional weighing vector map of the material tower is established, the weight value which should be output by the damaged sensor at present is calculated by utilizing the weight values of other sensors working normally and combining the position of the damaged sensor, so that the weight of the material tower is obtained, the precision required by production is kept during weighing of the material tower, and the production efficiency is improved. Therefore, the sensor does not need to be stopped for maintenance immediately after being damaged.

Description

Technical Field

[0001] The invention relates to the field of material tower weighing and metering, and in particular to a material tower weight calculation method and a material tower weighing system. Background Art

[0002] The weighing of material towers is a relatively difficult task in the weighing field. The current weight of material towers (the weight of the tower plus the weight of the materials) is generally between 10 tons and 200 tons. The material tower weighing system usually connects multiple weighing sensors, ranging from 4 to 8, and then uses a junction box to aggregate multiple signals into one. This topology has a low cost, but there is a problem. When one of the sensors is damaged, the abnormal signal will be superimposed on the normal signal, resulting in an abnormal final output signal. Usually, this abnormality is difficult to be directly identified by the system. In other words, the damage state of the weighing sensor in the past includes but is not limited to the following two situations: (1) The weighing sensor is damaged but does not know that it is damaged, and continues to output the wrong weight value to the weighing instrument; (2) The weighing instrument has determined that the weighing sensor is in a damaged state, but it is limited to alarming and cannot continue the weighing function.

[0003] At this time, the weighing accuracy error of the weighing system is very large, which seriously affects the production quality and even the operation safety. The relevant production operations need to be shut down for maintenance, resulting in huge waste. Summary of the invention

[0004] The object of the present invention is to provide a material tower weight calculation method and a material tower weighing system to solve the above problems.

[0005] In order to achieve the above object, the technical solution adopted by the present invention is:

[0006] A method for calculating the weight of a material tower comprises the following steps:

[0007] determining that some of the sensors are in a damaged state based on weight signals sent by the sensors;

[0008] Use the remaining sensors to calculate the layer number of the material tower's current weight in the pre-built three-dimensional weighing vector map;

[0009] Reconstruct the weight value that the damage state sensor should have outputted based on the map data of the layer and the layer above it and the location of the damage state sensor;

[0010] The weight of the material tower is calculated based on the weight value that the damaged state sensor should have output and the weight values ​​output by other sensors.

[0011] Furthermore, based on the comparison between the real-time output value of each sensor and the preset characteristic value of the sensor, when the deviation exceeds a threshold, it is determined that the current sensor is in a damaged state.

[0012] Furthermore, the steps of constructing a three-dimensional weighing vector map include:

[0013] Pour the standard weight substitute into the silo to perform initial calibration of the silo to obtain the initial layer and the final layer map;

[0014] Based on the change of the weight of the material tower, the weight value output by each sensor is recorded in real time to form a map of each layer from the initial layer to the final layer.

[0015] Furthermore, the number of map layers is determined based on the accuracy of the weight value.

[0016] Furthermore, each layer of map data is expressed as the following formula:

[0017] Y[m]=w[1]*x[1][m]+w[2]*x[2][m]+……+w[n]*x[n][m];

[0018] Where w[n] is the characteristic vector of the sensor, x[n][m] is the weight data output when one of the sensors works normally, Y[m] is the weight of the tower with the corresponding number of layers, m is the number of map layers, and n is the sensor number.

[0019] Furthermore, the feature vector of the sensor is determined by the location of the sensor and the relative position between the sensors.

[0020] Furthermore, based on the map data of the current layer and the layer above it, the weight value that the damage state sensor should have output is reconstructed according to the interpolation method.

[0021] The present invention also provides a material tower weighing system, comprising a plurality of sensors arranged on a material tower support, and a weighing meter connected to the sensors, characterized in that the weighing meter comprises at least one processor and at least one memory, the memory storing a computer program, and when the program is executed by the processor, the processor is able to execute the above-mentioned material tower weight calculation method.

[0022] Furthermore, the material tower is placed on a material tower support, and all sensors are on the same horizontal plane.

[0023] Furthermore, the signal output by each sensor is independently transmitted to the weighing instrument. When the weighing instrument does not receive the signal from any sensor, it is determined that the corresponding sensor is in a damaged state.

[0024] Compared with the prior art, the present invention has at least the following beneficial effects:

[0025] 1. Use digital weighing sensor and set the address number uniquely. Once the sensor is damaged, the instrument can identify the location of the damaged sensor, solving the problem that the damaged weighing sensor of the early material tower cannot be identified.

[0026] 2. By establishing a three-dimensional weighing vector map of the material tower, using the weight values ​​of other normally working sensors and combining the position of the damaged sensor, adjusting the weights of related sensors, and calculating the weight value that the damaged sensor should currently output, the weight of the material tower can be obtained, so that the material tower weighing can maintain the accuracy required for production, so that there is no need to immediately stop production for repairs after the sensor is damaged. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0028] Figure 1 It is a framework diagram of a material tower weighing system in the prior art;

[0029] Figure 2 is a schematic diagram of the material tower weighing system provided in this embodiment being installed on the material tower;

[0030] Figure 3 is a framework diagram of the material tower weighing system provided in this embodiment;

[0031] Figure 4 is a flow chart of the steps of the material tower weighing calculation method provided in this embodiment;

[0032] Figure 5 is a flowchart of the steps of constructing a three-dimensional weighing vector map provided in this embodiment;

[0033] Figure 6 It is a schematic diagram of the three-dimensional weighing vector map provided in this embodiment. DETAILED DESCRIPTION

[0034] It should be noted that, in the description of the present invention, “plurality” means at least two, such as two, three, etc., unless otherwise clearly and specifically defined.

[0035] In the present invention, unless otherwise clearly specified and limited, the terms "connection", "fixation", etc. should be understood in a broad sense. For example, "fixation" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements, unless otherwise clearly defined. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0036] In addition, the technical solutions between the various embodiments of the present invention can be combined with each other, but it must be based on the fact that ordinary technicians in the field can implement it. When the combination of technical solutions is contradictory or cannot be implemented, it should be deemed that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0037] The following are specific embodiments of the present invention, and the technical solutions of the present invention are further described in conjunction with the accompanying drawings, but the present invention is not limited to these embodiments.

[0038] In the prior art, multiple sensors are first connected to a junction box, which is a resistor network, and finally aggregated into a signal output to the weighing instrument, such as Figure 1 As shown in the figure, if any one of the sensors is damaged and has no signal output, the maximum impact on the total signal received by the weighing instrument is only one-fourth (the material tower with 4 sensors). One-fourth of the signal change is within the range of the material tower, and it is difficult for the system to identify the abnormality.

[0039] Moreover, if the sensor is damaged, the weighing error will be large. The feeding and discharging of the production process are controlled by weight. If the weight is inaccurate, it is naturally impossible to accurately control it, which may cause roof collapse accidents or empty running accidents due to insufficient materials. At the same time, since the sensor needs to be replaced during maintenance, and because the weight of the material tower itself and the material is very large, the sensor is under great pressure, and it is very difficult to disassemble and install. After replacing the sensor, calibration is also difficult. The vibration caused by the operation of mechanical equipment such as motors and mixers under heavy pressure is also the cause of frequent failures.

[0040] like Figure 2 and Figure 3 As shown, the material tower weighing system provided in this embodiment includes a plurality of sensors arranged on a material tower support and a weighing meter connected to the sensors. Four digital weighing sensors are selected and connected to the weighing meter through a digital bus, and the material tower is placed on the weighing sensors and the material tower support, and the levels of the four sensors are adjusted so that all sensors are on the same horizontal plane.

[0041] Each sensor has a number, and the signal of each sensor is transmitted independently to the weighing instrument. If a sensor is damaged and has no signal output, the weighing instrument will not receive the signal of this sensor, so the weighing system can identify that the sensor is damaged.

[0042] Of course, the real-time output value of the sensor received by the weighing instrument is compared with the preset characteristic value of the sensor stored in the weighing instrument. When the deviation exceeds the threshold, it is also determined that the current sensor is in a damaged state.

[0043] Therefore, this embodiment adopts a digital weighing sensor and uniquely sets an address number. Once the sensor is damaged, the weighing meter can identify the location of the damaged sensor, solving the problem that the damaged weighing sensor of the material tower cannot be identified.

[0044] At the same time, the weighing instrument includes at least one processor and at least one memory, and the memory stores a computer program. When the program is executed by the processor, the processor can execute the tower weight calculation method, such as Figure 4 As shown, the method comprises the following steps:

[0045] S1, determining that some of the sensors are in a damaged state based on the weight signals sent by the sensors;

[0046] S2, using the remaining sensors to calculate the layer number of the current weight of the material tower in the pre-built three-dimensional weighing vector map;

[0047] S3, reconstructing the weight value that the damage state sensor should have outputted according to the map data of the layer and the layer above it and the location of the damage state sensor;

[0048] S4. The weight of the material tower is calculated based on the weight value that the damaged state sensor should have output and the weight values ​​output by other sensors.

[0049] Therefore, when the weighing instrument detects that the sensor is damaged, the weighing instrument will alarm to prompt that a certain sensor is damaged. At this time, emergency weighing needs to be started according to production needs. At this time, the weighing instrument will shield the weight data output by the damaged sensor, and then call the three-dimensional weighing vector map of the material tower. From this, the intelligent algorithm is used to deduce the weight value that the damaged sensor should have output. This is equivalent to virtually reconstructing a good sensor and adding it to the weighing system. Finally, the weight of the material tower is calculated using the weight value of the reconstructed virtual sensor and the weight values ​​of the remaining normal sensors.

[0050] Among them, after the three-dimensional weighing vector map of the material tower is established, the instrument can perform weighing calculations normally when the sensor is damaged, so it is very important to establish a three-dimensional weighing vector map of the material tower. Figure 5 As shown, the steps to construct the map include:

[0051] T1. Pour the standard weight substitute into the material tower to calibrate the material tower for the first time, so as to obtain the initial layer and the end layer map;

[0052] T2. Based on the change in the weight of the material tower, the weight value output by each sensor is recorded in real time to form a map of each layer from the initial layer to the final layer.

[0053] During the construction process, the premise is that both the sensor and the weighing instrument are in normal condition. First, the operator needs to calibrate the material tower, enter the calibration parameter menu of the weighing instrument, and adjust the relevant parameters, such as the display scale value, full scale, etc. After confirming that the material tower is empty, the calibration zero point is determined. Then pour the substitute into the material tower (for example, 50 tons of material), operate the weighing instrument to enter the loading point calibration, and enter 50 tons on the instrument (it can be 50.0 tons or 50.00 tons according to the accuracy requirements) to complete the calibration of the loading point, thereby completing the initial calibration.

[0054] After the initial calibration, we obtain two-layer maps of the material tower, namely the bottom layer Y[0] and the top layer Y[m], together with the corresponding data w[] and x[][] of each sensor.

[0055] After the initial calibration, the material tower enters normal production operation. When the weighing instrument detects that the material tower weighing is normal, it automatically enters the learning state. It will capture the characteristics of each sensor of the material tower at different weights and store them at the appropriate time. It will complete self-update when the sensor status changes reasonably.

[0056] The weight of the material tower needs to go from zero to full scale or from full scale to zero at least once to establish the required number of map layers. The more layers, the higher the accuracy. However, the capacity of the internal memory of the instrument should be considered. For example, if 100 layers are to be built, then the full scale is divided into 100 equal parts. If the full scale is 100 tons, then one layer is built every 1 ton. As production progresses, the weight of the material tower will appear one by one from 0 to full scale. If it is set to 100 layers, w[], x[][] and Y[] are recorded at each increment of full scale / 100 weight, so as to finally establish a 100-layer weighing vector map and store the map in the internal memory of the instrument.

[0057] For the sake of explanation, assume that the range of the material tower is 50 tons. During the material tower feeding process, assume that 100 kg is added. At this time, the pressure value of each sensor is recorded, and then the material is added. When 200 kg is added, the pressure value of each sensor is recorded again. This recording continues until the 50-ton point is recorded. At the same time, the instrument also records the position of the sensor and the relative position relationship. In this way, the three-dimensional weighing vector map of the material tower is completed inside the instrument. Figure 6 As shown in the figure, x[][] represents the pressure value of the sensor at different nodes, the coefficient after x contains the sensor location information, and Y represents the weight value of the material tower at this node.

[0058] The formula used to build the 3D weighing vector map of the silo is as follows:

[0059] Y[0]=w[0]*x[0][0]+w[1]*x[1][0]+……+w[n-1]*x[n-1][0];

[0060] Y[1]=w[0]*x[0][1]+w[1]*x[1][1]+……+w[n-1]*x[n-1][1];

[0061] Y[2]=w[0]*x[0][2]+w[1]*x[1][2]+……+w[n-1]*x[n-1][2];

[0062] …

[0063] Y[m]=w[0]*x[0][m]+w[1]*x[1][m]+……+w[n-1]*x[n-1][m].

[0064] Here, w[n-1] is the feature vector of the sensor, x[n-1][m] is the weight data output when one of the sensors works normally, Y[m] is the weight of the silo corresponding to the number of layers, m is the number of map layers, and n is the sensor number.

[0065] During the first calibration and subsequent use, the weighing instrument learns the changes in the tower weighing system while weighing, thereby gradually establishing a three-dimensional weighing vector map of the tower. The data established by the three-dimensional weighing vector map includes an empty tower (no material in the tower) until a full warehouse, and the number of layers of the three-dimensional weighing vector map can be determined according to the accuracy required for production, such as 9 or 100 layers.

[0066] Therefore, when the weighing instrument detects that the sensor is damaged, it starts the emergency weighing function, and then uses the three-dimensional weighing vector map of the material tower established when the sensor is normal to perform intelligent compensation calculations.

[0067] When entering the intelligent calculation, first use the remaining normal sensors to calculate the layer number of the three-dimensional weighing vector map where the current weight is located, and use the map data of this layer and the previous layer to simultaneously examine the current weight values ​​of the remaining normal sensors to calculate the weight value that the damaged sensor should output. At the same time, when examining the weight values ​​of the remaining normal sensors, it is necessary to consider the location information of the damaged sensor, such as Figure 2 As shown, if sensor No. 1 is damaged, then when examining the remaining sensors, the weights of sensors No. 2 and No. 3 should be greater, while the weight of sensor No. 4 should be smaller.

[0068] Finally, the weight of the material tower is calculated by interpolating the weight value of the damaged sensor and the actual weight values ​​of other normal sensors.

[0069] In addition, the material tower weighing system needs to be timed when it is in emergency weighing state to remind workers to perform maintenance at the appropriate time. There is a timer to remind workers to perform maintenance at the appropriate time (the reminder function is necessary to prevent workers from forgetting that the sensor is damaged and continue to use it. When multiple sensors are damaged and the intelligent compensation calculation does not have enough normal sensors to provide data support, production must be stopped for maintenance.

[0070] The present embodiment proposes to establish a three-dimensional weighing vector map of the material tower, and then use the three-dimensional weighing vector map of the material tower to perform intelligent compensation calculation, so as to achieve high-precision compensation for the weighing error caused by the damaged sensor, so that the weighing of the material tower maintains the accuracy required for production, so that there is no need to immediately stop production for repair after the sensor is damaged, thus solving the problem of production stoppage caused by sensor damage. And because the sensor can continue to weigh after it is damaged, and it also has a timing function for the emergency weighing state, it can wait until the planned maintenance time to repair it together, thereby reducing temporary repairs and the number of repairs.

[0071] The specific embodiments described herein are merely examples of the spirit of the present invention. Those skilled in the art may make various modifications or additions to the specific embodiments described or replace them in similar ways, but they will not deviate from the spirit of the present invention or exceed the scope defined by the appended claims.

Claims

1. A method for calculating the weight of a material tower, characterized in that: Includes steps: determining that some of the sensors are in a damaged state based on the weight signals sent by the sensors; Use the remaining sensors to calculate the layer number of the material tower's current weight in the pre-built three-dimensional weighing vector map; Reconstruct the weight value that the damage state sensor should have outputted based on the map data of the layer and the layer above it and the location of the damage state sensor; The weight of the material tower is calculated based on the weight value that the damaged state sensor should have output and the weight values ​​output by other sensors.

2. A tower weight calculation method according to claim 1, characterized in that: By comparing the real-time output value of each sensor with the preset characteristic value of the sensor, it is determined that the current sensor is in a damaged state when the deviation exceeds a threshold.

3. A tower weight calculation method according to claim 1, characterized in that: The steps to construct a three-dimensional weighing vector map include: Pour the standard weight substitute into the silo to perform initial calibration of the silo to obtain the initial layer and the final layer map; Based on the change of the weight of the material tower, the weight value output by each sensor is recorded in real time to form a map of each layer from the initial layer to the final layer.

4. A tower weight calculation method according to claim 3, characterized in that: The number of map layers is determined based on the accuracy of the weight value.

5. A tower weight calculation method according to claim 3, characterized in that: The map data of each layer is expressed as the following formula: Y[m]=w[1]*x[1][m]+w[2]*x[2][m]+……+w[n]*x[n][m]; Where w[n] is the characteristic vector of the sensor, x[n][m] is the weight data output when one of the sensors works normally, Y[m] is the weight of the tower with the corresponding number of layers, m is the number of map layers, and n is the sensor number.

6. A tower weight calculation method according to claim 5, characterized in that: The characteristic vectors of the sensors are determined by the locations of the sensors and the relative positions of the sensors.

7. A tower weight calculation method according to claim 1, characterized in that: Based on the map data of the current layer and the layer above it, the weight value that the damage state sensor should have output is reconstructed using the interpolation method.

8. A material tower weighing system, characterized in that: It includes a plurality of sensors arranged on a material tower support, and a weighing meter connected to the sensors, and is characterized in that the weighing meter includes at least one processor and at least one memory, and the memory stores a computer program, and when the program is executed by the processor, the processor is able to execute the material tower weight calculation method according to any one of claims 1 to 7.

9. A material tower weighing system according to claim 8, characterized in that: The material tower is placed on the material tower support, and all sensors are in the same horizontal plane.

10. A material tower weighing system according to claim 8, characterized in that: The signal output by each sensor is independently transmitted to the weighing instrument. When the weighing instrument does not receive the signal from any sensor, it is determined that the corresponding sensor is in a damaged state.

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