A hopper scale calibration control method and system

Abstract

This invention discloses a hopper scale calibration control method and system, relating to the field of metrological calibration technology. The method includes: acquiring a target calibration load value; controlling a first loader and a second loader to synchronously apply tension; executing a multi-level speed control step, switching the loading speed from high speed to medium speed, low speed, or slow speed based on the difference between the current total tension value and the target value; executing a synchronous difference control step, calculating the tension difference between the two loaders in real time, and pausing the loader with the larger force value when the difference exceeds a preset threshold until the difference recovers. This invention also provides a hopper scale calibration system that executes the above method. This invention achieves a balance between accuracy and efficiency through multi-level speed control and solves the problem of uneven loading at two points through synchronous difference control, offering advantages such as high calibration accuracy, good loading synchronization, convenient operation, and high safety.

Description

Technical Field

[0001] This invention relates to the field of metrology and calibration technology, and more specifically, to a hopper scale calibration control method and system. Background Technology

[0002] Hopper scales are widely used weighing devices in industrial production, and their calibration accuracy directly affects product quality and production safety. Traditional hopper scale calibration methods mainly involve manually loading weights, which is labor-intensive and inefficient. Some methods use a single-speed motor for loading, but excessive loading speed can lead to overshoot and deviations, while insufficient speed affects calibration efficiency, making it difficult to balance efficiency and accuracy.

[0003] Furthermore, large hopper scales typically require simultaneous loading on both sides of the hopper. Existing solutions lack the ability to monitor and actively adjust the tension difference between the two sides in real time, relying solely on manual adjustments based on operator experience. If the loading on both sides is asynchronous, it can lead to hopper tilting and uneven force distribution, affecting calibration accuracy and potentially damaging sensors or mechanical structures. Additionally, if the equipment's soft limit switch is lost, traditional reset methods require specialized instruments or complex operations, making rapid on-site recovery difficult and complicating on-site maintenance. Summary of the Invention

[0004] The present invention aims to solve the above-mentioned problems existing in the prior art and provide a control method and system for a hopper scale calibration system that can achieve high precision, high efficiency and dual-point synchronous loading.

[0005] To achieve the above objectives, the present invention provides the following technical solution: A hopper scale calibration control method is applied to a calibration system comprising a first loader, a second loader, a controller, and a force sensor. The method includes: acquiring a target calibration load value; controlling the first loader and the second loader to operate synchronously to apply a tensile force. During the loading process, a multi-level speed control step is executed: the current total tension value collected by the force sensor is obtained; the difference between the current total tension value and the target calibration load value is calculated; based on the comparison results of the difference with multiple preset force cutoff values, the loading speed is switched from high speed to medium speed, low speed, and slow speed. During the loading process, a synchronization difference control step is performed: the first real-time tension of the first loader and the second real-time tension of the second loader are obtained; the real-time difference between the first real-time tension and the second real-time tension is calculated; if the real-time difference is greater than a preset synchronization force difference threshold, the loader with the larger tension value is controlled to pause loading until the real-time difference is less than the synchronization force difference threshold.

[0006] Furthermore, the multi-level speed control steps also include: when the difference reaches a preset high-speed acceleration cutoff, controlling the loader to switch from high-speed acceleration to medium-speed acceleration; when the difference reaches a preset medium-speed acceleration cutoff, controlling the loader to switch from medium-speed acceleration to low-speed acceleration; and when the difference reaches a preset low-speed acceleration cutoff, controlling the loader to switch from low-speed acceleration to slow-speed acceleration.

[0007] Furthermore, it also includes an unloading control step: obtaining the current total tensile force value; when the current total tensile force value is greater than the preset target unloading value, executing a multi-level speed unloading step, wherein the unloading speed is medium speed, low speed, and slow speed in sequence; wherein, when the total tensile force value is unloaded to the preset medium speed unloading cutoff amount, switching to low speed unloading; when unloading to the preset low speed unloading cutoff amount, switching to slow speed unloading.

[0008] Furthermore, it also includes a soft limit setting step: obtaining a zero-point setting command input by the user, wherein the zero-point setting command corresponds to the position where the annular mark on the loader telescopic rod coincides with the loader extension opening; the annular mark is a pre-made annular groove or marking line on the loader telescopic rod, used to physically indicate the reference position of the telescopic rod; recording the position value of the loader at the coincident position as the zero point; and setting the soft limit range for the extension and retraction of the loader based on the zero point.

[0009] The present invention also provides a hopper scale calibration system, comprising: The first loader and the second loader are respectively disposed on both sides of the hopper to be calibrated and are used to apply tension; the force sensor is respectively disposed on the first loader and the second loader and is used to collect the tension value; the controller is electrically connected to the first loader, the second loader and the force sensor respectively. The controller includes an input module, a storage module, and a processing module; The input module is used to set the target calibration load value; The storage module is used to store preset multi-level speed control parameters and synchronization control parameters; The processing module is used to execute the aforementioned hopper scale calibration control method.

[0010] Furthermore, the hopper scale calibration system also includes: A connecting steel plate is welded to both sides of the hopper to be calibrated, and the connecting steel plate is provided with hook holes; The connector, including an arc-shaped lifting buckle and a stainless steel bar, is used to connect the lifting ring at the top of the loader to the connecting steel plate; A fixed steel plate is fixed to the ground or base by expansion bolts, and the loader is fixed inside the fixed steel plate by pins.

[0011] Furthermore, the loader is a servo electric cylinder, and the controller controls the loading speed of the servo electric cylinder through pulse frequency.

[0012] Furthermore, the controller also includes a self-calibration module; the self-calibration module is used to receive a no-load confirmation command to determine the no-load zero point in the no-load state; when an external weight is suspended below the sensor, it receives the input weight value of the weight; and calibrates the force sensor based on the no-load zero point and the weight value of the weight.

[0013] Furthermore, the controller also includes a prompting module for displaying at least one of the following status information in the device prompt bar: emergency stop status, manual status, automatic reset status, automatic standby status, automatic power-up operation status, servo alarm status, and over-limit alarm status.

[0014] Furthermore, the stainless steel strip in the connector has a preset service life threshold, and the stainless steel strip is replaced according to the service life threshold.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention employs multi-stage speed closed-loop control, employing high-speed loading when far from the target value to improve calibration efficiency, and low-speed approximation when approaching the target value to avoid overshoot, thus achieving a balance between calibration accuracy and efficiency. Simultaneously, through synchronous differential control, it monitors and actively corrects the tension difference between the two loaders in real time, ensuring coordinated operation of the two loaders, effectively solving the problem of uneven loading at two points, and preventing hopper tilting and sensor damage.

[0016] Furthermore, this invention allows operators to remotely control the equipment from a safe distance, avoiding close proximity to the equipment under heavy loads and significantly improving operational safety. When the equipment's soft limit is lost, the zero point can be quickly restored without specialized instruments using the ring-shaped imprint reference and soft limit setting method, facilitating on-site maintenance. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the structural composition of the hopper scale calibration system of the present invention; Figure 2 This is a schematic diagram of the user interface of the controller of the present invention; Figure 3 This is a schematic diagram of the soft limit parameter setting interface of the present invention.

[0018] The reference numerals in the attached drawings are as follows: 1. Loader; 2. Hopper; 3. Connecting steel plate; 4. Fixing steel plate; 5. Steel rope. Detailed Implementation

[0019] The specific embodiments of the present invention will be described in further detail below with reference to the accompanying drawings and examples.

[0020] Reference Figure 1 This invention provides a hopper scale calibration control method, which is applied to a calibration system including a first loader 1, a second loader 1, a controller and a force sensor. The fixed steel plate 4 provides a basic positioning for the loader 1. The loader 1 applies tension or support force to the hopper 2 through the steel rope 5. The connecting steel plate 3 realizes the force transmission and installation transition between the steel rope 5 and the hopper 2.

[0021] First, obtain the target calibration load value; then control the first loader 1 and the second loader 1 to operate synchronously to apply tension; During the loading process, a multi-level speed control step is executed: the current total tension value collected by the force sensor is obtained; the difference between the current total tension value and the target calibration load value is calculated; based on the comparison results of the difference with multiple preset force cutoff values, the loading speed is switched from high speed to medium speed, low speed, and slow speed. During the loading process, a synchronization difference control step is performed: the first real-time tension of the first loader and the second real-time tension of the second loader are obtained; the real-time difference between the first real-time tension and the second real-time tension is calculated; if the real-time difference is greater than a preset synchronization force difference threshold, the loader with the larger tension value is controlled to pause loading until the real-time difference is less than the synchronization force difference threshold.

[0022] Furthermore, the multi-level speed control steps also include: when the difference reaches a preset high-speed acceleration cutoff, controlling the loader to switch from high-speed acceleration to medium-speed acceleration; when the difference reaches a preset medium-speed acceleration cutoff, controlling the loader to switch from medium-speed acceleration to low-speed acceleration; and when the difference reaches a preset low-speed acceleration cutoff, controlling the loader to switch from low-speed acceleration to slow-speed acceleration.

[0023] Furthermore, it also includes an unloading control step: obtaining the current total tensile force value; when the current total tensile force value is greater than the preset target unloading value, executing a multi-level speed unloading step, wherein the unloading speed is medium speed, low speed, and slow speed in sequence; wherein, when the total tensile force value is unloaded to the preset medium speed unloading cutoff amount, switching to low speed unloading; when unloading to the preset low speed unloading cutoff amount, switching to slow speed unloading.

[0024] Furthermore, it also includes a soft limit setting step: obtaining a zero-point setting instruction input by the user, wherein the zero-point setting instruction corresponds to the position where the annular mark on the telescopic rod of the loader 1 coincides with the extension opening of the loader 1; recording the position value of the loader 1 at the coincident position as the zero point; and setting the soft limit range for the extension and retraction of the loader 1 based on the zero point.

[0025] Example 1: Multi-stage speed control Specifically, this embodiment uses a 3000kg full-scale calibration as an example for illustration.

[0026] The operator enters the target calibration load value in the "Calibration Total Tension Setting" box on the controller's main interface. In this embodiment, the target calibration load value is 2000 kg. After clicking the "Force Activation" button, the controller activates the first loader 1 and the second loader 2 to begin synchronous loading.

[0027] The controller reads the current total tension value collected by the force sensor in real time. In the initial stage of loading, the current total tension value is much smaller than the target value. The controller controls the loader to run at a high-speed pulse frequency (100kHz) to quickly approach the target value.

[0028] The preset high-speed loading cutoff is 90kg. When the difference between the current total tensile force and the target calibration load reaches the preset "high-speed loading cutoff" (90kg), that is, when the current tensile force is 2000-90=1910kg, the controller will automatically switch the loading speed to the medium-speed pulse frequency.

[0029] The preset medium-speed force application cutoff is 20kg. When the current tension value of the loader continues to increase, and the difference between the current total tension value and the target calibration load value reaches the "medium-speed force application cutoff" (20kg), that is, when it reaches 2000-20=1980kg, the controller switches to a low-speed pulse frequency.

[0030] The preset low-speed force application cutoff is 5kg. When the difference between the current total tension value and the target calibration load value reaches the "medium-speed force application cutoff" of 5kg (i.e., the current total tension value reaches 1995kg), and it approaches the target value, it switches to a slow pulse frequency to approach the target value of 2000kg with the highest accuracy, and finally stabilizes within the range of ±1kg of the target value.

[0031] Through the above multi-level speed control, both loading efficiency (rapid advancement in the high-speed segment) and calibration accuracy (fine approximation in the low-speed segment) are ensured, avoiding the overshoot problem common in single-speed loading.

[0032] Example 2: Dual-loader Synchronization Differential Control During the simultaneous loading process of the two loaders 1, the uneven force on the two loaders may occur due to factors such as the asymmetrical structure of the hopper 2 and the installation deviation of the connecting parts.

[0033] Reference Figure 2 In this embodiment, the operator presets the "loader synchronous force difference" to 30 kg. The controller acquires the real-time tension of the first loader 1 and the real-time tension of the second loader 1 in real time, and calculates the real-time difference.

[0034] The real-time tensile force of the first loader 1 is 1020 kg, and the real-time tensile force of the second loader 1 is 980 kg. The real-time difference between the two is 40 kg, which exceeds the preset threshold of 30 kg. At this time, the controller immediately pauses the loading action of the first loader 1 and allows only the second loader 1 to continue loading. When the second loader 1 loads to a point where the difference with the first loader 1 is less than 30 kg, the controller resumes the loading of the first loader 1, and both continue to load synchronously.

[0035] This mechanism effectively prevents hopper 2 from tilting, sensor damage, or calibration data distortion caused by off-center loading, and is especially suitable for calibrating hopper scales with large spans and high capacities.

[0036] Example 3: Soft Limit Setting Method Reference Figure 3 When the device prompts "Extend the ultra-soft limit" or "Retract the ultra-soft limit", you can quickly restore it by following these steps: Switch to manual mode on the controller interface, and use the "Extend Loader" or "Retract Loader" button to control the movement of the loader 1 telescopic rod until the ring mark on the telescopic rod coincides with the loader extension opening.

[0037] Then, click the "Zero Point Confirmation" button on the corresponding loader on the controller interface. At this time, the controller records the position as 0mm and automatically sets the extension limit value and retraction limit value based on the zero point.

[0038] Obtain the zero-point setting instruction input by the user, wherein the zero-point setting instruction corresponds to the position where the annular mark on the telescopic rod of loader 1 coincides with the extension opening of loader 1; record the position value of loader 1 at the coincident position as the zero point; and set the soft limit range for the extension and retraction of loader 1 based on the zero point.

[0039] If the over-limit warning persists after the above steps, the physical limit switch on the side of loader 1 needs to be checked. The specific method is as follows: Loosen the fixing bolts of the physical limit switch, move the limit switch up and down, observe whether the indicator light illuminates, fix the limit switch in the position where the indicator light is on, then finely adjust it 3-5mm in the opposite direction and tighten it. This completes the recalibration of the physical limit. This method requires no special instruments, is easy to operate, and effectively solves on-site equipment maintenance problems.

[0040] The present invention also provides a hopper scale calibration system, including a first loader 1 and a second loader 1, which are respectively disposed on both sides of the hopper 2 to be calibrated for applying a pulling force; a force sensor, which is respectively disposed on the first loader 1 and the second loader 1 for collecting the pulling force value; and a controller electrically connected to the first loader 1, the second loader 1 and the force sensor respectively. The controller includes an input module, a storage module, and a processing module; The input module is used to set the target calibration load value; The storage module is used to store preset multi-level speed control parameters and synchronization control parameters; The processing module is used to execute the control method of the hopper scale calibration system.

[0041] Furthermore, the hopper scale calibration system also includes: A connecting steel plate 3 is welded to both sides of the hopper 2 to be calibrated, and hook holes are provided on the connecting steel plate 3; The connector, including an arc-shaped lifting buckle and a stainless steel bar, is used to connect the lifting ring at the top of the loader 1 to the connecting steel plate 3; The fixed steel plate 4 is fixed to the ground or base by expansion bolts, and the loader 1 is fixed inside the fixed steel plate 4 by pins.

[0042] Furthermore, the loader 1 is a servo electric cylinder, and the controller controls the loading speed of the servo electric cylinder through pulse frequency.

[0043] Furthermore, the controller also includes a self-calibration module; the self-calibration module is used to receive a no-load confirmation command to determine the no-load zero point in the no-load state; when an external weight is suspended below the sensor, it receives the input weight value of the weight; and calibrates the force sensor based on the no-load zero point and the weight value of the weight.

[0044] Furthermore, the controller also includes a prompting module for displaying at least one of the following status information in the device prompt bar: emergency stop status, manual status, automatic reset status, automatic standby status, automatic power-up operation status, servo alarm status, and over-limit alarm status.

[0045] Furthermore, the stainless steel strip in the connector has a preset service life threshold, and the stainless steel strip is replaced according to the service life threshold.

[0046] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the patent application. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A calibrating control method for a hopper scale, characterized in that, A calibration system comprising a first loader, a second loader, a controller, and a force sensor, the method comprising: acquiring a target calibration load value; controlling the first loader and the second loader to operate synchronously to apply a tensile force; During the loading process, a multi-level speed control step is executed: the current total tension value collected by the force sensor is obtained; the difference between the current total tension value and the target calibration load value is calculated; based on the comparison results of the difference with multiple preset force cutoff values, the loading speed is switched from high speed to medium speed, low speed, and slow speed. During the loading process, a synchronization difference control step is performed: the first real-time tension of the first loader and the second real-time tension of the second loader are obtained; the real-time difference between the first real-time tension and the second real-time tension is calculated; if the real-time difference is greater than a preset synchronization force difference threshold, the loader with the larger tension value is controlled to pause loading until the real-time difference is less than the synchronization force difference threshold.

2. The calibrating control method for a hopper scale according to claim 1, characterized in that, The multi-level speed control steps further include: when the difference reaches a preset high-speed acceleration cutoff value, controlling the loader to switch from high-speed acceleration to medium-speed acceleration; when the difference reaches a preset medium-speed acceleration cutoff value, controlling the loader to switch from medium-speed acceleration to low-speed acceleration; and when the difference reaches a preset low-speed acceleration cutoff value, controlling the loader to switch from low-speed acceleration to slow-speed acceleration.

3. The calibrating control method for a hopper scale according to claim 1, characterized in that, It also includes an unloading control step: obtaining the current total tensile force value; when the current total tensile force value is greater than the preset target unloading value, executing a multi-level speed unloading step, wherein the unloading speed is medium speed, low speed, and slow speed in sequence; wherein, when the total tensile force value is unloaded to the preset medium speed unloading cutoff amount, switching to low speed unloading; when unloading to the preset low speed unloading cutoff amount, switching to slow speed unloading.

4. The calibrating control method for a hopper scale according to claim 1, characterized in that, It also includes a soft limit setting step: obtaining a zero-point setting command input by the user, wherein the zero-point setting command corresponds to the position where the annular mark on the loader telescopic rod coincides with the loader extension opening; recording the position value of the loader at the coincident position as the zero point; and setting the soft limit range for the extension and retraction of the loader based on the zero point.

5. A hopper scale calibration control system, used to execute the hopper scale calibration control method according to any one of claims 1 to 4, characterized in that, include: The first loader and the second loader are respectively located on both sides of the hopper to be calibrated, and are used to apply tension; Force sensors are respectively installed on the first loader and the second loader to collect tensile force values; the controller is electrically connected to the first loader, the second loader, and the force sensors respectively. The controller includes an input module, a storage module, and a processing module; The input module is used to set the target calibration load value; The storage module is used to store preset multi-level speed control parameters and synchronization control parameters; The processing module is used to execute the aforementioned hopper scale calibration control method.

6. The hopper scale calibration control system according to claim 5, characterized in that, Also includes: A connecting steel plate is welded to both sides of the hopper to be calibrated, and the connecting steel plate is provided with hook holes; The connector, including an arc-shaped lifting buckle and a stainless steel bar, is used to connect the lifting ring at the top of the loader to the connecting steel plate; A fixed steel plate is fixed to the ground or base by expansion bolts, and the loader is fixed inside the fixed steel plate by pins.

7. A hopper scale calibration control system according to claim 5, characterized in that, The loader is a servo electric cylinder, and the controller controls the loading speed of the servo electric cylinder through pulse frequency.

8. A hopper scale calibration control system according to claim 5, characterized in that, The controller also includes a self-calibration module; the self-calibration module is used to receive a no-load confirmation command to determine the no-load zero point in the no-load state; and to receive the input weight value of the external weight when an external weight is suspended below the sensor. The force sensor is calibrated based on the no-load zero point and the weight value of the weight.

9. A hopper scale calibration control system according to claim 5, characterized in that, The controller also includes a prompting module for displaying at least one of the following status information in the device prompt bar: emergency stop status, manual status, automatic reset status, automatic standby status, automatic power-up operation status, servo alarm status, and over-limit alarm status.

10. A hopper scale calibration control system according to claim 6, characterized in that, The stainless steel strip in the connector has a preset service life threshold, and the connector is replaced according to the service life threshold.

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