A weighing and anti-toppling integrated device and a control method thereof

Abstract

This application discloses an integrated weighing and anti-tipping device and its control method, relating to the field of storage equipment safety technology. The device includes: an anti-tipping actuator, a main control unit, a displacement sensor, multiple tilt sensors, and multiple weighing modules. The anti-tipping actuator includes: multiple supports and multiple jacks. Multiple supports are fixed between a ring beam seat and a support seat, and are arranged alternately with multiple triangular supports. Each support is an interlocking structure for lateral and longitudinal limiting, composed of limiting bolts and steel plates. Each triangular support has a weighing module and a jack. The displacement sensor is fixed to the top of the steel silo. Multiple tilt sensors are fixed at different positions on the outer wall of the steel silo. The displacement sensor, multiple tilt sensors, and multiple weighing modules are connected to the main control unit. This application solves the problems of separation of weighing and anti-tipping, delayed early warning, and passive protection in the prior art.

Description

Technical Field

[0001] This application relates to the field of storage equipment safety technology, and in particular to an integrated weighing and anti-tipping device and its control method. Background Technology

[0002] In modern industrial production, especially in fields such as building materials, metallurgy, grain processing, and chemicals, large quantities of powdery, granular, or lumpy bulk materials (such as cement, clinker, ore, grain, and plastic particles) need to be stored, transferred, and metered. Industrial steel silos, as a common storage device, are widely used in various production lines due to their advantages such as high structural strength, short construction period, small footprint, and good sealing performance, becoming a key link connecting upstream and downstream processes and ensuring continuous production.

[0003] To achieve precise material control, inventory management, and production statistics, real-time and accurate weight measurement of materials within the warehouse is crucial. Currently, the mainstream weighing method is "static continuous weighing" of steel silos. For elevated steel silos, a common design involves installing load cells at the top of the supporting frame and below the silo supports. To ensure clear force on the sensors and accurate measurement, the design typically follows a three-point support principle. However, this weighing method has limited safety redundancy. Its anti-tipping mechanism relies heavily on purely mechanical structures such as reinforcing ribs and diagonal braces. These two components are designed independently and lack interlocking protection. Furthermore, it cannot provide real-time monitoring and early warning of silo tilting. Summary of the Invention

[0004] The purpose of this application is to provide an integrated weighing and anti-tipping device and its control method, which solves the problems of separation of weighing and anti-tipping, delayed early warning, and passive protection.

[0005] To achieve the above objectives, this application provides the following solution.

[0006] Firstly, this application provides an integrated weighing and anti-tipping device for use in storage equipment. The storage equipment includes a support base and a steel silo placed on the support base. A ring beam seat is provided on the steel silo, located above the support base. Multiple triangular supports are evenly arranged around the ring beam seat. The integrated weighing and anti-tipping device includes an anti-tipping actuator, a main control unit, a displacement sensor, multiple tilt sensors, and multiple weighing modules. The anti-tipping actuator includes multiple brackets and multiple jack devices. The multiple brackets are fixed between the ring beam seat and the support base, and the multiple brackets and multiple triangular supports are arranged alternately. The brackets are interlocked structures for lateral and longitudinal limiting, composed of limiting bolts and steel plates. Each triangular support is provided with a weighing module and a jack device. The displacement sensor is fixed to the top of the steel silo. The multiple tilt sensors are fixed at different positions on the outer wall of the steel silo. Multiple weighing modules are connected to the main control unit. The main control unit is used to: read the weighing results of all weighing modules and superimpose all weighing results to obtain a weighing value; read the displacement measurement value of the displacement sensor and calculate the theoretical value of the tilt angle based on the displacement measurement value and the height of the steel silo; read the tilt angle measurement value of all tilt angle sensors, compare the theoretical value of the tilt angle with all tilt angle measurement values, and take the maximum value of the theoretical value of the tilt angle and the tilt angle measurement value as the center of gravity offset; when the center of gravity offset is greater than 0 and less than a first threshold, generate an alarm signal; when the center of gravity offset is greater than or equal to the first threshold and less than or equal to a second threshold, generate an alarm signal and adjust the jack device to cut off the feeding device of the steel silo; the second threshold is greater than the first threshold; when the center of gravity offset is greater than the second threshold, generate an alarm signal and adjust the jack device to cut off the feeding device of the steel silo and start the emergency unloading device of the steel silo.

[0007] Secondly, this application also provides a control method for an integrated weighing and anti-tipping device, applied to the integrated weighing and anti-tipping device described in the first aspect. The control method includes: reading the weighing results of all weighing modules and superimposing all weighing results to obtain a weighing value; reading the displacement measurement value of the displacement sensor and calculating the theoretical tilt angle value based on the displacement measurement value and the height of the steel silo; reading the tilt angle measurement values ​​of all tilt angle sensors, comparing the theoretical tilt angle value with all tilt angle measurement values, and taking the maximum value of the theoretical tilt angle value and the tilt angle measurement value as the center of gravity offset; generating an alarm signal when the center of gravity offset is greater than 0 and less than a first threshold; generating an alarm signal and adjusting the jack device when the center of gravity offset is greater than or equal to the first threshold and less than or equal to a second threshold, cutting off the feeding device of the steel silo; the second threshold is greater than the first threshold; generating an alarm signal and adjusting the jack device when the center of gravity offset is greater than the second threshold, cutting off the feeding device of the steel silo, and activating the emergency unloading device of the steel silo.

[0008] Based on the specific embodiments provided in this application, the following technical effects are disclosed.

[0009] This application, through the coordinated setup of an anti-tipping actuator and multiple weighing modules, enables dual tilt protection for the steel silo while it is being weighed. First, multiple supports are added to the ring beam seat of the steel silo and fixed between the ring beam seat and the support base. The interlocking structure composed of limiting bolts and steel plates effectively limits the silo's lateral (left-right) and longitudinal (up-down) movement. These supports provide reverse support when the silo tilts, serving as the first line of defense. Second, in addition to the weighing module under each triangular support, a jack device is added below it. This jack can promptly lift the triangular supports in case of silo overturning, serving as the second line of defense. Finally, the application uses a main control unit to analyze data collected by displacement and tilt sensors in real time and compares the calculated center of gravity offset with a corresponding threshold, thereby achieving early warning and protection against silo tilt. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of this application or related technologies, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0011] Figure 1 This is a schematic diagram of the installation of the integrated weighing and anti-tipping device in one embodiment of this application.

[0012] Figure 2This is a schematic diagram of the support structure in one embodiment of this application.

[0013] Figure 3 This is a flowchart of a control method for an integrated weighing and anti-tipping device according to another embodiment of this application.

[0014] Reference numerals: Support base-1, Steel silo-2, Ring beam base-3, Triangular support-4, Displacement sensor-5, Inclination sensor-6, Weighing module-7, Support base-8, Jack device-9, Top plate-10, Intermediate plate-11, Bottom plate-12, First support plate-13, Second support plate-14, First side plate-15, Second side plate-16, First limit bolt-17, Second limit bolt-18, Audible and visual alarm-19. Detailed Implementation

[0015] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0016] Currently, steel silos with cones sit on frames, and weighing is mostly done by installing load cells on three supports. This method has the following main drawbacks.

[0017] (1) When the load is off-center, the weighing data is not synchronized with the tilt state, and the early warning is delayed.

[0018] (2) The mechanical anti-tipping structure provides passive protection and has no active early warning capability.

[0019] (3) The tilting of the steel silo caused by foundation settlement and material eccentricity is difficult to monitor accurately.

[0020] (4) Traditional devices are not reliable enough in extreme conditions such as earthquakes and strong winds.

[0021] Therefore, it is urgent to solve the above-mentioned problems in the existing technology and provide a steel silo safety assurance system with accurate weighing, real-time tilt monitoring, active early warning and multi-level protection.

[0022] To make the above-mentioned objectives, features and advantages of this application more apparent and understandable, the application will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0023] In one exemplary embodiment, an integrated weighing and anti-tipping device is provided, which is applied to storage equipment. The storage equipment includes: a support base 1 and a steel silo 2 placed on the support base 1. A ring beam seat 3 is provided on the steel silo 2, located above the support base 1. Multiple triangular supports 4 are evenly arranged around the circumference of the ring beam seat 3. Figure 1 As shown, the integrated weighing and anti-tipping device includes: an anti-tipping actuator, a main control unit, a displacement sensor 5, multiple tilt sensors 6, and multiple weighing modules 7; the anti-tipping actuator includes: multiple supports 8 and multiple jack devices 9.

[0024] Multiple supports 8 are fixed between the ring beam seat 3 and the support seat 1, and the multiple supports 8 and multiple triangular supports 4 are arranged alternately; the supports 8 are interlocking structures with lateral and longitudinal limiting composed of limiting bolts and steel plates; each triangular support 4 is provided with a weighing module 7 and a jack device 9; the displacement sensor 5 is fixed on the top of the steel silo; multiple tilt sensors 6 are fixed at different positions on the outer wall of the steel silo; the displacement sensor 5, multiple tilt sensors 6 and multiple weighing modules 7 are respectively connected to the main control unit.

[0025] The main control unit is used to: read the weighing results of all weighing modules 7, superimpose all weighing results to obtain the weighing value; read the displacement measurement value of displacement sensor 5, and calculate the theoretical value of the tilt angle based on the displacement measurement value and the height of the steel silo; read the tilt measurement value of all tilt angle sensors 6, compare the theoretical value of the tilt angle with all tilt measurement values, and take the maximum value of the theoretical value of the tilt angle and the tilt measurement value as the center of gravity offset; when the center of gravity offset is greater than 0 and less than the first threshold, generate an alarm signal; when the center of gravity offset is greater than or equal to the first threshold and less than or equal to the second threshold, generate an alarm signal and adjust the jack device 9 to cut off the feeding device of the steel silo 2; when the second threshold is greater than the first threshold; when the center of gravity offset is greater than the second threshold, generate an alarm signal and adjust the jack device 9 to cut off the feeding device of the steel silo 2 and start the emergency unloading device of the steel silo 2.

[0026] Furthermore, such as Figure 2 As shown, the support 8 includes: a top plate 10, a middle plate 11, a bottom plate 12, a first support plate 13, a second support plate 14, a first side plate 15, a second side plate 16, a plurality of first limiting bolts 17 and a plurality of second limiting bolts 18.

[0027] The intermediate plate 11 and the bottom plate 12 are fixed together by the first support plate 13 and the second support plate 14; the bottom plate 12 is fixed to the support seat 1 by full welding; one end of the first side plate 15 and one end of the second side plate 16 are fixed to the top plate 10, and the other end of the first side plate 15 and the other end of the second side plate 16 are suspended; the top plate 10 is fixed to the ring beam seat 3 by full welding; the top plate 10 and the intermediate plate 11 are connected by multiple first limiting bolts 17; the first limiting bolts 17 are used to limit the steel silo 2 longitudinally; second limiting bolts 18 are provided between the first side plate 15 and the intermediate plate 11, and between the second side plate 16 and the intermediate plate 11; the second limiting bolts 18 are used to limit the steel silo 2 laterally.

[0028] In a preferred embodiment, the top plate 10, intermediate plate 11, bottom plate 12, first support plate 13, second support plate 14, first side plate 15, and second side plate 16 are all made of steel. Specifically, the top plate 10 and bottom plate 12 are made of Q355B steel. The top plate 10 has dimensions of 400×200×16mm, the bottom plate 12 has dimensions of 200×240×16mm, and the first side plate 15 and second side plate 16 have dimensions of 120×200×16mm. Four M24X145 first limiting bolts 17 are installed between the top plate 10 and the intermediate plate 11, leaving a 100mm gap between them. One M16X70 second limiting bolt 18 is installed between the first side plate 15 and the intermediate plate 11, and between the second side plate 16 and the intermediate plate 11, respectively.

[0029] Furthermore, the integrated weighing and anti-tipping device includes two tilt sensors 6 and one displacement sensor 5. The number of weighing modules 7, the number of jack devices 9, and the number of support seats 8 are all the same as the number of triangular supports 4.

[0030] In one preferred embodiment, the weighing module 7 is a column-type load cell, the displacement sensor 5 is a rope displacement sensor, and the jack device 9 is an electro-hydraulic rod. A rope displacement sensor is installed circumferentially on the top of the steel silo, and two tilt sensors 6 are respectively fixed on the silo wall corresponding to the x-axis and y-axis directions of the steel silo.

[0031] Furthermore, the integrated weighing and anti-tipping device also includes: an audible and visual alarm 19; the audible and visual alarm 19 is fixed to the top of the steel silo; the audible and visual alarm 19 is connected to the main control unit; the audible and visual alarm 19 is used to trigger an audible and visual alarm based on the alarm signal.

[0032] In addition, this embodiment also provides a practical application scenario for the integrated weighing and anti-tipping device, as detailed below.

[0033] Industrial steel silo: 6m in diameter and 6m in height.

[0034] Weighing module installation: Three column load cells are evenly distributed under the three triangular supports of the steel silo. The rated load of each column load cell is 100t, and an anti-overload protection device is equipped.

[0035] Inclination monitoring arrangement: Fix one pull rope displacement sensor and one acoustic-optic alarm at the top of the steel silo. The measuring range of the pull rope displacement sensor is 500mm, and its accuracy is ±0.5mm. Install two inclination sensors in the middle of the silo wall, and cross-verify the measurement data.

[0036] Parameters of the anti-tipping actuator: The ring beam seat is made of Q355B steel, with a cross-sectional dimension of 400×200mm and a gap of 100mm from the column. The maximum buffer force of the jacking device is 50t, the stroke is 100mm, and the response time ≤ 0.05 seconds.

[0037] Control process: Data acquisition (weighing + inclination + displacement) → Inclination calculation (center of gravity offset a) → Threshold judgment → Normal (a = 0): Display data (weighing value, displacement measurement value, inclination measurement value, etc.); Mild inclination (0 < a < 0.5°): Early warning; Inclination (0.5° ≤ a ≤ 2°): Early warning + Adjustment of the electro-hydraulic rod, cut off the feeding device; Severe inclination (a ≥ 2°): Early warning + Adjustment of the electro-hydraulic rod, start the emergency discharging device.

[0038] In another exemplary embodiment, a control method for the integrated weighing and anti-tipping device is provided, which is applied to the above integrated weighing and anti-tipping device, as Figure 3 shown. The control method for the integrated weighing and anti-tipping device includes the following steps.

[0039] Step S1: Read the weighing results of all weighing modules, superimpose all weighing results, and obtain the weighing value.

[0040] Step S2: Read the displacement measurement value of the displacement sensor, and calculate the theoretical inclination value based on the displacement measurement value and the height of the steel silo.

[0041] In this embodiment, the calculation formula for the theoretical inclination value is as follows.

[0042] .

[0043] In the formula, is the theoretical inclination value; is the displacement measurement value; H is the height of the steel silo.

[0044] Step S3: Read the inclination measurement values of all inclination sensors, compare the theoretical inclination value with all inclination measurement values, and take the maximum value of the theoretical inclination value and the inclination measurement value as the center of gravity offset.

[0045] In this embodiment, the comparison between theoretical and measured values ​​mainly makes full use of cross-validation of the data.

[0046] Step S4: When the center of gravity offset is greater than 0 and less than the first threshold, an alarm signal is generated.

[0047] In this embodiment, the first threshold is set to 0.5°.

[0048] Step S5: When the center of gravity offset is greater than or equal to the first threshold and less than or equal to the second threshold, an alarm signal is generated and the jack device is adjusted to cut off the feeding device of the steel silo.

[0049] In this embodiment, the second threshold is greater than the first threshold, and the second threshold is set to 2°. The jack device is mainly adjusted manually until the steel silo is restored to a horizontal position.

[0050] Step S6: When the center of gravity offset is greater than the second threshold, an alarm signal is generated and the jack device is adjusted to cut off the feeding device of the steel silo and start the emergency unloading device of the steel silo.

[0051] In this embodiment, the jack device is mainly adjusted manually until the steel silo is restored to a horizontal position.

[0052] In summary, this application has the following main effects.

[0053] Safety redundancy: dual monitoring of weighing and tilting, dual protection of mechanical and hydraulic systems, triple safety guarantee.

[0054] Active protection: When the tilt exceeds the threshold (0.5°~2°), an early warning is automatically triggered and an electric hydraulic rod is adjusted to prevent overturning.

[0055] Precise measurement: Multi-sensor data fusion ensures weighing accuracy of ±0.5% FS even under off-center load conditions.

[0056] Intelligent control: Supports remote monitoring and data uploading, and is compatible with IoT platforms.

[0057] Cost optimization: The integrated design reduces equipment redundancy and facilitates installation and maintenance.

[0058] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on the differences from other embodiments. The same or similar parts between the various embodiments can be referred to each other.

[0059] This document uses specific examples to illustrate the principles and implementation methods of this application. The descriptions of the above embodiments are only for the purpose of helping to understand the methods and core ideas of this application. Furthermore, those skilled in the art will recognize that, based on the ideas of this application, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of this application.

Claims

1. A weighing and anti-toppling integrated device applied to a warehousing equipment, the warehousing equipment comprising: The device comprises a support base and a steel silo placed on the support base. A ring beam seat is provided on the steel silo and is located above the support base. Multiple triangular supports are evenly arranged around the ring beam seat. The integrated weighing and anti-tipping device includes: an anti-tipping actuator, a main control unit, a displacement sensor, multiple tilt sensors, and multiple weighing modules; the anti-tipping actuator includes: multiple support seats and multiple jack devices. Multiple supports are fixed between the ring beam seat and the support seat, and the multiple supports and multiple triangular supports are arranged alternately; the supports are interlocking structures with lateral and longitudinal limiting functions, composed of limiting bolts and steel plates; each triangular support is provided with a weighing module and a jack device; the displacement sensor is fixed to the top of the steel silo; multiple tilt sensors are fixed at different positions on the outer wall of the steel silo; the displacement sensor, multiple tilt sensors and multiple weighing modules are respectively connected to the main control unit; The main control unit is used for: reading the weighing results of all weighing modules, superimposing all weighing results to obtain a weighing value; reading the displacement measurement value of the displacement sensor, and calculating the theoretical value of the tilt angle based on the displacement measurement value and the height of the steel silo; reading the tilt angle measurement values ​​of all tilt angle sensors, comparing the theoretical value of the tilt angle with all tilt angle measurement values, and taking the maximum value of the theoretical value of the tilt angle and the tilt angle measurement value as the center of gravity offset; generating an alarm signal when the center of gravity offset is greater than 0 and less than a first threshold; generating an alarm signal and adjusting the jack device when the center of gravity offset is greater than or equal to the first threshold and less than or equal to a second threshold, cutting off the feeding device of the steel silo; the second threshold is greater than the first threshold; generating an alarm signal and adjusting the jack device when the center of gravity offset is greater than the second threshold, cutting off the feeding device of the steel silo, and activating the emergency unloading device of the steel silo.

2. The integrated weighing and anti-tipping device according to claim 1, characterized in that, The support includes: a top plate, a middle plate, a bottom plate, a first support plate, a second support plate, a first side plate, a second side plate, a plurality of first limiting bolts, and a plurality of second limiting bolts; The intermediate plate and the bottom plate are fixed together by the first support plate and the second support plate; one end of the first side plate and one end of the second side plate are fixed to the top plate, and the other end of the first side plate and the other end of the second side plate are suspended; the top plate and the intermediate plate are connected by a plurality of first limiting bolts; second limiting bolts are provided between the first side plate and the intermediate plate, and between the second side plate and the intermediate plate.

3. The integrated weighing and anti-tipping device according to claim 2, characterized in that, The top plate, the middle plate, the bottom plate, the first support plate, the second support plate, the first side plate, and the second side plate are all made of steel; the top plate is fully welded to the ring beam seat; the bottom plate is fully welded to the support seat.

4. The integrated weighing and anti-tipping device according to claim 2, characterized in that, The first limiting bolt is used to limit the steel silo longitudinally; the second limiting bolt is used to limit the steel silo laterally.

5. The integrated weighing and anti-tipping device according to claim 1, characterized in that, The number of tilt sensors is two; the two tilt sensors are respectively fixed on the silo wall corresponding to the x-axis and y-axis directions of the steel silo.

6. The integrated weighing and anti-tipping device according to claim 1, characterized in that, The number of weighing modules, the number of jack devices, and the number of support bases are all the same as the number of triangular supports.

7. The integrated weighing and anti-tipping device according to claim 1, characterized in that, The integrated weighing and anti-tipping device also includes: an audible and visual alarm; The audible and visual alarm is fixed to the top of the steel silo; the audible and visual alarm is connected to the main control unit; the audible and visual alarm is used to trigger an audible and visual alarm based on the alarm signal.

8. The integrated weighing and anti-tipping device according to claim 1, characterized in that, The weighing module is a column-type load cell; the displacement sensor is a rope displacement sensor; and the jack device is an electric hydraulic rod.

9. A control method for an integrated weighing and anti-tipping device, characterized in that, The weighing anti-tipping integrated device according to any one of claims 1-8, wherein the control method of the weighing anti-tipping integrated device includes: Read the weighing results from all weighing modules and sum them up to obtain the weighing value; Read the displacement measurement value from the displacement sensor, and calculate the theoretical value of the tilt angle based on the displacement measurement value and the height of the steel silo; Read the tilt angle measurement values ​​of all tilt angle sensors, compare the theoretical tilt angle value with all tilt angle measurement values, and take the maximum value of the theoretical tilt angle value and the tilt angle measurement value as the center of gravity offset; An alarm signal is generated when the center of gravity offset is greater than 0 and less than the first threshold. When the center of gravity offset is greater than or equal to the first threshold and less than or equal to the second threshold, an alarm signal is generated and the jack device is adjusted to cut off the feeding device of the steel silo; the second threshold is greater than the first threshold. When the center of gravity offset is greater than the second threshold, an alarm signal is generated and the jack device is adjusted to cut off the feeding device of the steel silo and start the emergency unloading device of the steel silo.

10. The control method for the integrated weighing and anti-tipping device according to claim 9, characterized in that, The formula for calculating the theoretical value of the tilt angle is: ； In the formula, This is the theoretical value of the tilt angle; These are displacement measurements; H This refers to the height of the steel silo.

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