A flow monitoring system and its monitoring device based on an electric flow electronic scale

Abstract

This invention relates to the field of electronic flow scales, specifically a flow monitoring system and device based on an electric electronic flow scale. The system includes a main body, a monitoring system, a belt tension monitoring module, a recording module, and a calibration module. In this invention, solid materials are fed onto the belt scale via a feeding device. At this time, the load monitoring module and the flow velocity monitoring module within the flow monitoring module begin monitoring the load on the material and the conveyor belt's conveying speed. A load cell senses the weight of a section of belt and the material on it on the scale frame, and calculates and subtracts the tare weight. A speed sensor, installed on the driven roller or return belt of the belt conveyor, rotates with the belt and emits pulse signals. Each pulse represents a small, fixed distance traveled by the belt, thus monitoring the conveyor belt's conveying speed. The speed is then adjusted using a tension adjustment method to prevent insufficient tension from affecting the weighing results.

Description

Technical Field

[0001] This invention relates to the field of flow electronic scale technology, specifically to a flow monitoring system and monitoring device based on an electric flow electronic scale. Background Technology

[0002] The flow monitoring system and its monitoring device of the electric flow electronic scale are a crucial automation system in the field of bulk material conveying. It can perform real-time, dynamic, and high-precision weighing and flow calculation of solid bulk materials continuously conveyed on belt conveyors, and use the data for monitoring, management and control of the production process.

[0003] Traditional electric flow scales and their monitoring devices can weigh and calculate the flow rate of solid bulk materials conveyed on belts. However, after prolonged use, the tension of the belt changes, altering the pressure distribution between the belt and the idler rollers. This results in the force acting on the weighing sensor being not solely the weight of the material but also including the tension component, leading to inaccurate weighing. Summary of the Invention

[0004] To address the aforementioned problems, this invention provides a flow monitoring system for an electric flow electronic scale that can prevent inaccurate weighing caused by changes in belt tension.

[0005] To address the problems in the prior art, this invention provides a flow monitoring system and its monitoring device based on an electric flow electronic scale, comprising a main body and a detection system. The monitoring system uses a control panel as its carrier. The belt tension monitoring module is located within the detection system. The belt tension monitoring module includes a recording module and a calibration module. The recording module contains a signal transceiver module and a data storage library. The data storage library stores the tension monitoring data results. The signal transceiver module is used for data transmission. The calibration module includes a tension calculation module and a tension comparison module. The tension calculation module calculates the belt tension in real time, and the tension comparison module compares the calculated tension with the increased tension.

[0006] Tension adjustment steps: S1: After detecting insufficient tension, first design a tension that minimizes slippage and sag according to the belt manufacturer's or conveyor equipment's design specifications. Run the belt under no-load conditions at this tension to check for belt misalignment. S2: Under the current tension, perform an accurate zero-point calibration and record the zero-point value. S3: Increase the tension and allow the system to run stably for 3-4 revolutions. Record the new zero-point value and calculate the zero-point drift by subtracting the previous zero-point value from the new value. Analyze the results. S4: Find the optimal tension point where small increases or decreases in tension result in minimal zero-point drift. S5: Adjust the equipment with increased tension to the optimal tension and restart a complete zero-point calibration.

[0007] Specifically, the monitoring system is equipped with a flow detection module, which in turn is equipped with a load monitoring module and a flow velocity monitoring module. The load monitoring module is used to monitor the weight of the conveyed solid material, and the flow velocity monitoring module is used to monitor the conveying speed of the solid material.

[0008] Specifically, the load monitoring module is equipped with a weighing sensor, a weight calculation module, and a signal transceiver module. The weighing sensor is located inside the belt scale, and the weight calculation module is used to calculate the weight of the solid material located on the belt scale. The weighing sensor senses the weight of a section of belt and the material on it on the scale frame. After calculation and subtraction of the tare weight (weight of the empty belt), the linear density of the pure material is obtained.

[0009] Specifically, the flow rate monitoring module includes a speed sensor and a signal transceiver module. The speed sensor is installed on the driven roller or return belt of the conveyor belt, and rotates with the belt, emitting pulse signals. Each pulse represents a small fixed distance traveled by the belt.

[0010] Specifically, the tension monitoring method is as follows: S1: First, ensure the weighing frame is clean, the belt is unloaded, and record the current position of the belt tensioning device (such as the counterweight) or the hydraulic tensioning pressure value; S2: Then perform a "zero point calibration" and record the zero point value A1; S3: Significantly increase the belt tension, and then let the system run normally for 1-3 revolutions. After supplementing the calibration, record the new zero point value A2, and calculate the zero point change value: A = A2 - A1. If the change in A is very significant (e.g., exceeding 0.1% of the full scale or even higher), then it indicates insufficient tension.

[0011] Specifically, a smoothing assembly is installed on the conveyor belt inside the main body of the equipment. The smoothing assembly includes a mounting frame, a rotating shaft, a snap-fit ​​plate, and smoothing blocks. The mounting frame is fixedly installed on the main body of the equipment. A set of rotating shafts is fixedly installed inside the mounting frame. A set of snap-fit ​​plates is rotatably connected to the rotating shafts. A set of smoothing blocks is fixedly installed at the lower end of the snap-fit ​​plates. The smoothing blocks are installed on the side wall of the main body of the equipment, and the lower end of the smoothing blocks is attached to the upper end of the belt scale. Multiple sets of support legs are fixedly installed inside the main body of the equipment, and belt scales are installed on the support legs.

[0012] The beneficial effects of this invention are:

[0013] 1. The calibration module in this invention can calculate and compare tension, thereby alerting staff in advance to avoid tension changes affecting weighing operations.

[0014] 2. In this invention, after insufficient tension is detected, the staff can quickly restore the normal operation of the system according to the tension adjustment method, thereby improving work efficiency.

[0015] 3. In this invention, the snap-fit ​​plate and the smoothing block can smooth the material and prevent it from piling up and affecting the weighing process. Attached Figure Description

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention;

[0018] Figure 2 This is a flowchart illustrating the internal flow monitoring system of the present invention.

[0019] Figure 3 This is a flowchart of the internal tension adjustment method of the present invention;

[0020] Figure 4 This is a schematic diagram of the internal component connection structure of the weighing assembly in this invention;

[0021] Figure 5 This is a schematic diagram of the connection structure of the mounting frame, belt scale, and support legs in this invention.

[0022] Figure 6 In this invention Figure 5 Enlarged view of point A inside.

[0023] In the diagram: 1. Main body of the equipment; 2. Smoothing component; 210. Mounting frame; 211. Rotating shaft; 212. Snap-fit ​​plate; 213. Smoothing block; 3. Weighing component; 310. Support leg; 311. Belt scale. Detailed Implementation

[0024] 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.

[0025] In the description of this application, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more features. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0026] In the description of this application, it should also be noted that, unless otherwise expressly specified and limited, the terms "set up," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this technology based on the specific circumstances.

[0027] In the description of this application, spatial relation terms such as "below," "under," "below," "below," "above," "over," etc., are used herein to describe the relationship between one element or feature shown in the figures and other elements or features. It should be understood that, in addition to the orientation shown in the figures, spatial relation terms also include different orientations of the device in use and operation. For example, if the device in the figures is flipped, an element or feature described as "below" or "under" or "below" of other elements or features will be oriented "above" other elements or features. Therefore, the exemplary terms "below" and "under" can include both upper and lower orientations. Furthermore, the device may also include other orientations (e.g., rotated 90 degrees or other orientations), and the spatial descriptive terms used herein are interpreted accordingly.

[0028] In the description of this application, the term "for example" is used to mean "used as an example, illustration, or description." Any embodiment described as "for example" in this application is not necessarily to be construed as being more preferred or advantageous than other embodiments. The following description is provided to enable any person skilled in the art to make and use the invention. Details are set forth in the following description for purposes of explanation. It should be understood that those skilled in the art will recognize that the invention can be made without using these specific details. In other instances, well-known structures and processes will not be described in detail to avoid obscuring the description of the invention with unnecessary detail. Therefore, the invention is not intended to be limited to the embodiments shown, but is consistent with the broadest scope of the principles and features disclosed in this application.

[0029] Example 1:

[0030] like Figure 1 , Figure 2 as well as Figure 3 The diagram illustrates a flow monitoring system and its monitoring device based on an electric flow electronic scale. The system includes a main body 1 and a detection system. The monitoring system uses a control panel as its carrier. A belt tension monitoring module is located within the detection system. This belt tension monitoring module includes a recording module and a calibration module. The recording module contains a signal transceiver module and a data storage library. The data storage library stores the tension monitoring data results. The signal transceiver module transmits the data. The calibration module includes a tension calculation module and a tension comparison module. The tension calculation module calculates the belt tension in real time, and the tension comparison module compares the calculated tension with the increased tension.

[0031] Tension Adjustment Method Steps: S1: After detecting insufficient tension, first design a tension that minimizes slippage and sag according to the belt manufacturer's or conveyor equipment's design specifications. Run the belt under no-load conditions at this tension to check for belt misalignment. S2: Under the current tension, perform an accurate zero-point calibration and record the zero-point value. S3: Increase the tension, allow the system to run stably for 3-4 revolutions, and record the new zero-point value. Calculate the zero-point drift by subtracting the previous zero-point value from the new zero-point value and analyze the results. S4: Find the optimal tension point where small increases or decreases in tension result in minimal zero-point drift. S5: Adjust the equipment with increased tension to the optimal tension and restart a complete zero-point calibration.

[0032] The monitoring system is internally equipped with a flow detection module, which in turn includes a load monitoring module and a flow velocity monitoring module. The load monitoring module monitors the weight of the conveyed solid material, and the flow velocity monitoring module monitors the conveying speed of the solid material. The load monitoring module contains a weighing sensor, a weight calculation module, and a signal transceiver module. The weighing sensor is located inside the belt scale 311. The weight calculation module calculates the weight of the solid material located on the belt scale 311. The weighing sensor senses the weight of a section of belt and the material on it on the scale frame. After calculation and subtraction of the tare weight (weight of the empty belt), the linear density of the pure material is obtained. The flow velocity monitoring module contains a speed sensor and a signal transceiver module. The speed sensor is installed on the driven roller or return belt of the belt conveyor, rotates with the belt, and emits pulse signals. Each pulse represents the belt traveling a small fixed distance.

[0033] Tension monitoring procedure: S1: First, ensure the weighing frame is clean, the belt is unloaded, and record the current position of the belt tensioning device (such as the counterweight) or the hydraulic tensioning pressure value; S2: Then perform a "zero point calibration" and record the zero point value A1; S3: Significantly increase the belt tension, and then let the system run normally for 1-3 revolutions. Supplement the calibration and record the new zero point value A2. Calculate the zero point change value: A = A2 - A1. If the change in A is very significant (e.g., exceeding 0.1% of the full scale or even higher), then it indicates insufficient tension.

[0034] like Figure 1 , Figure 2 as well as Figure 3 As shown, in this invention, solid materials are conveyed to the belt scale 311 via a feeding device. At this time, the load monitoring module and flow rate monitoring module inside the flow monitoring module will start monitoring the load of the material and the conveying speed of the conveyor belt. The weighing sensor senses the weight of a section of belt and the material on it on the scale frame. After calculation, the tare weight (weight of the empty belt) is subtracted to obtain the linear density of the pure material, which is in kilograms per meter (kg / m). The speed sensor is installed on the driven roller or return belt of the belt conveyor and rotates with the belt, emitting pulse signals. Each pulse represents the belt traveling a small fixed distance, thereby monitoring the conveying speed of the conveyor belt.

[0035] During the operation of the belt scale 311 and the flow monitoring module, the belt tension monitoring module also detects the tension of the belt on the belt scale 311. The tension calculation module inside the calibration module will accurately calculate the tension of the belt at this time. First, ensure that the scale frame is clean and the belt is unloaded, and record the current position of the belt tensioning device (such as the counterweight) or the hydraulic tensioning pressure value; then perform a "zero point calibration" and record the zero point value A1; then significantly increase the belt tension and let the system run normally for 1-3 revolutions. After supplementing the calibration, record the new zero point value A2 and calculate the zero point change value: A = A2 - A1. If the change of A is very significant (for example, exceeding 0.1% or even higher than the full scale), then it means that the tension is insufficient.

[0036] After detecting insufficient tension, the signal transceiver module inside the calibration module will transmit the signal to the display screen on the device control panel and issue a warning.

[0037] Next, design a tension that meets the requirements of no slippage and minimal sag according to the design specifications of the belt manufacturer or conveyor equipment. Run the belt under no-load at this tension to see if it will run off-center.

[0038] S2: Under the current tension, perform an accurate zero-point calibration and record this zero-point value;

[0039] S3: Increase the tension, allow the system to run stably for 3-4 revolutions, record the new zero point value, and calculate the zero point drift by subtracting the previous zero point value from the new zero point value. Analyze the results.

[0040] S4: Find the optimal tension point. At this point, a small increase or decrease in tension will cause the minimum zero-point drift.

[0041] S5: Adjust the tensioning device to the optimal tension, restart a complete zero-point calibration, and after finding the optimal tension, use the counterweight to lift it a certain distance. This distance needs to be adjusted multiple times to adjust the current belt tension to the optimal tension, so as to avoid insufficient tension affecting the accuracy of the monitoring results.

[0042] Example 2:

[0043] like Figure 1 , Figure 4 as well as Figure 5As shown, a smoothing component 2 is installed on the conveyor belt inside the main body 1 of the equipment. The smoothing component 2 includes a mounting frame 210, a rotating shaft 211, a snap-fit ​​plate 212, smoothing blocks 213 and 214. The mounting frame 210 is fixedly installed on the main body 1 of the equipment. A set of rotating shafts 211 is fixedly installed inside the mounting frame 210. A set of snap-fit ​​plates 212 are rotatably connected to the rotating shafts 211. A set of smoothing blocks 213 are fixedly installed at the lower end of the snap-fit ​​plates 212. The 214 is installed on the side wall of the main body 1 of the equipment, and its lower end is attached to the upper end of the belt scale 311. Multiple sets of support feet 310 are fixedly installed inside the main body 1 of the equipment. A belt scale (311) is installed on the support feet 310.

[0044] like Figure 1 , Figure 4 as well as Figure 5 As shown, before the feeding equipment conveys solid materials to the belt scale 311, the operator first rotates the clamping plate 212 to clamp one end of the clamping plate 212 into the interior of another set of mounting brackets 210. At this time, a set of interlayer gaps will be formed between the smoothing block 213 and the upper surface of the belt scale 311. Then the feeding equipment is started, and the feeding equipment will convey the material to the belt scale 311. At this time, some of the material will be blocked by the smoothing block 213, and some of the material will be driven forward by the belt scale 311 through the interlayer gap, so that the material is evenly distributed on the belt scale 311, avoiding the material from piling up together and sliding down during the conveying process, which would cause the weighing result to deviate.

[0045] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of protection claimed by the present invention.

Claims

1. A flow monitoring system based on an electric flow electronic scale, characterized in that: It includes the main body of the equipment (1) and a monitoring system, wherein the monitoring system is carried out on a control panel; A belt tension monitoring module is located within the detection system, and the belt tension monitoring module includes a recording module and a calibration module. The recording module includes a signal transceiver module and a data storage library. The data storage library is used to store the data results of tension monitoring, and the signal transceiver module is used for data transmission. The calibration module includes a tension calculation module and a tension comparison module. The tension calculation module is used to calculate the tension of the belt in real time, and the tension comparison module is used to compare the calculated tension with the increased tension. Tension adjustment method steps: S1: After detecting insufficient tension, first design a tension that meets the minimum requirements for non-slippage and sagging according to the design specifications of the belt manufacturer or conveyor equipment. Run the belt under no-load at this tension to see if it will run off-center. S2: Under the current tension, perform an accurate zero-point calibration and record this zero-point value; S3: Increase the tension, allow the system to run stably for 3-4 revolutions, record the new zero point value, and calculate the zero point drift by subtracting the previous zero point value from the new zero point value. Analyze the results. S4: Find the optimal tension point (the point where small increases or decreases in tension result in the smallest zero-point drift). S5: Adjust the tensioning equipment to the optimal tension and restart a complete zero-point calibration.

2. The flow monitoring system based on an electric flow electronic scale according to claim 1, characterized in that: The monitoring system is equipped with a flow detection module, which in turn is equipped with a load monitoring module and a flow velocity monitoring module. The load monitoring module is used to monitor the weight of the conveyed solid material, and the flow velocity monitoring module is used to monitor the speed at which the solid material is conveyed.

3. The flow monitoring system based on an electric flow electronic scale according to claim 2, characterized in that: The load monitoring module is equipped with a weighing sensor, a weight calculation module and a signal transceiver module. The weighing sensor is located inside the belt scale (311). The weight calculation module is used to calculate the weight of the solid material on the belt scale (311). The weighing sensor senses the weight of a section of belt and the material on it on the scale frame. After calculation, the tare weight (weight of the empty belt) is subtracted to obtain the linear density of the pure material.

4. A flow monitoring system based on an electric flow electronic scale according to claim 3, characterized in that: The flow rate monitoring module includes a speed sensor and a signal transceiver module. The speed sensor is installed on the driven roller or return belt of the belt conveyor, and rotates with the belt, emitting pulse signals. Each pulse represents a small fixed distance traveled by the belt.

5. A flow monitoring system based on an electric flow electronic scale according to claim 1, characterized in that: Tension monitoring method procedure: S1: First, ensure that the weighing frame is clean, the belt is unloaded, and record the current position of the belt tensioning device (such as the counterweight) or the hydraulic tensioning pressure value; S2: Then perform a "zero point calibration" once and record the zero point value A1; S3: Significantly increase the belt tension, then run the system normally for 1-3 revolutions. After supplementing the calibration, record the new zero point value A2 and calculate the zero point change value: A = A2 - A1. If the change of A is very significant (e.g., exceeding 0.1% or even higher of the full scale), then it indicates insufficient tension.

6. A flow monitoring device based on an electric flow electronic scale according to claim 1, characterized in that: A smoothing component (2) is installed on the conveyor belt inside the main body (1) of the equipment. The smoothing component (2) includes a mounting frame (210), a rotating shaft (211), a snap-fit ​​plate (212), a smoothing block (213), and a 214. The mounting frame (210) is fixedly installed on the main body (1). A set of rotating shafts (211) is fixedly installed inside the mounting frame (210). A set of snap-fit ​​plates (212) is rotatably connected to the rotating shafts (211). A set of smoothing blocks (213) is fixedly installed at the lower end of the snap-fit ​​plates (212). The 214 is installed on the side wall of the main body (1) and its lower end is attached to the upper end of the belt scale (311).

7. A flow monitoring system and monitoring device based on an electric flow electronic scale according to claim 6, characterized in that: Multiple sets of support legs (310) are fixedly installed inside the main body (1) of the equipment, and belt scales (311) are installed on the support legs (310).

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