Weighing sensor intelligent detection and fault diagnosis device

Abstract

An intelligent detection and fault diagnosis device for a weighing sensor belongs to the technical field of intelligent detection and fault diagnosis of a weighing system, and comprises an improved weighing sensor, a switching device, a self-diagnosis weighing controller, a simulation junction box and a cable, the improved weighing sensor accesses an output signal to a detection channel and a weighing channel, the two channels realize electrical self-locking and interlocking, detection and weighing are carried out alternately, the output value of each weighing sensor when the scale is empty or calibrated is detected and tracked in the first time, intelligent pre-diagnosis is carried out on the fault of the weighing sensor through the variable quantity of the output value, and the detection accuracy is improved. The intelligent pre-diagnosis device has the beneficial effects that the intelligent pre-diagnosis device is simple in overall structure, convenient to install and standard in signal acquisition, can carry out intelligent pre-diagnosis on faults of each weighing sensor, accurately diagnoses critical conditions of the faults of the weighing sensors in advance, improves the initiative of maintenance, and ensures reliable, accurate and stable operation of a weighing system.

Description

Technical Field

[0001] This utility model relates to the field of intelligent detection and fault diagnosis technology of weighing systems, and in particular to an intelligent detection and fault diagnosis device for weighing sensors. Background Technology

[0002] Load cells are widely used in material weighing, product inspection, and process control. Their accuracy and stability directly affect a company's production efficiency, production costs, and product quality. Due to the inherent characteristics of load cells and their operation in complex and harsh environments, their failures are diverse, complex, and frequent. On-site diagnosis and replacement of load cells is not only time-consuming and difficult but also disrupts normal production schedules, severely impacting the company's economic benefits.

[0003] With the continuous advancement of intelligent manufacturing processes in enterprises, traditional methods for diagnosing weighing sensor faults can no longer meet the demands of modern enterprises for intelligent production. Therefore, the development of intelligent fault diagnosis devices for weighing sensors has significant theoretical and practical implications. It can improve the detection accuracy and fault diagnosis efficiency of weighing sensors, thereby enhancing enterprise production efficiency and quality. It is a crucial tool for promoting the integration of industry, academia, research, and application, and for effectively addressing the challenges facing enterprise development. Summary of the Invention

[0004] To address the aforementioned technical problems, this utility model provides an intelligent detection and fault diagnosis device for weighing sensors. This device can intelligently and proactively diagnose weighing sensor faults in advance, accurately diagnose and handle weighing sensors in critical fault conditions as early as possible, improve the predictability and initiative of maintenance, and ensure the reliable, accurate, and stable operation of the weighing system.

[0005] To achieve the above objectives, the technical solution adopted by this utility model to solve its technical problem is as follows: The intelligent detection and fault diagnosis device for the weighing sensor consists of an improved weighing sensor, a switching device, a self-diagnostic weighing controller, a lifting device, a simulated junction box, and cables. The switching device includes switching device A and switching device B. One end of switching device A is connected to the improved weighing sensor via the cable, and the other end is connected to the self-diagnostic weighing controller via a cable to detect the weighing output value of the improved weighing sensor under no-load, empty scale, and calibration conditions. One end of switching device B is connected to the improved weighing sensor via the cable, and the other end is connected to the simulated junction box via a cable. The simulated junction box aggregates the output signals of multiple improved weighing sensors and outputs them to the self-diagnostic weighing controller to complete the weighing process.

[0006] Furthermore, in the improved load cell, the signal output pins are increased from a single pair of pins connected in parallel to two pairs on the inside of the load cell output connector. This results in the load cell output connector having two pairs of signal output pins. The improved load cell output connector adds one more pair of signal pins compared to the traditional load cell output connector.

[0007] Furthermore, the improved load cell output connector is connected to the cable input connector to input the output signal of the improved load cell into two channels. One channel connects the output signal of the improved load cell via a cable, the switching device A, and the detection port of the self-diagnostic weighing controller; this channel is called the detection channel. The other channel first inputs the output signal of the improved load cell via the switching device B to the analog junction box. After the analog junction box aggregates and processes the output signal, it is then connected to the weighing port of the self-diagnostic weighing controller via a cable; this channel is called the weighing channel.

[0008] Furthermore, the switching device comprises a coil, normally open contacts, normally closed contacts, a reaction spring, a return spring, and a housing. Switching device A is located near the detection port of the detection channel, and switching device B is located before the analog junction box of the weighing channel. Switching device A and switching device B are electrically self-locking and interlocked, controlling the detection channel and the weighing channel; when one is connected, the other should be disconnected.

[0009] Furthermore, when the switching device A is turned on, the detection channel is self-locked and performs detection work, collecting the output signals of each improved weighing sensor. At this time, the interlock of the switching device B is disengaged, the weighing channel is disconnected, and the weighing work cannot be performed. Conversely, when the switching device B is turned on, the weighing channel is self-locked and performs weighing work. At this time, the interlock of the switching device A is disengaged, the detection channel is disconnected, and the detection work cannot be performed.

[0010] Furthermore, when switching device A and switching device B are self-locked, they each consist of two identical normally open contacts connected in parallel; when the interlock between switching device A and switching device B is disengaged, they each consist of two identical normally closed contacts connected in series. This backup design can greatly improve the reliability of the system operation.

[0011] Furthermore, the self-diagnostic weighing controller includes a self-diagnostic detection module, a weighing module, a setting input module, a display module, and an alarm module. The self-diagnostic weighing controller is connected to the display module via the self-diagnostic detection module to display the weighing output values ​​of each improved weighing sensor under no-load, empty scale, and calibration conditions. The self-diagnostic weighing controller is also connected to the alarm module via the self-diagnostic detection module to indicate that each improved weighing sensor or the weighing channel is in a critical fault state. Finally, the self-diagnostic weighing controller is connected to the lifting device via the alarm module to collect the no-load output values ​​of each improved weighing sensor.

[0012] Furthermore, the self-diagnostic weighing controller is equipped with several detection ports and one weighing port. Each detection port is equipped with several "detection display windows" and one "detection summary display window". The weighing port is equipped with one "weighing display window". The detection channel is connected to the detection port and the weighing channel is connected to the weighing port.

[0013] Furthermore, the "detection display window" displays the weighing value of each corresponding improved weighing sensor, the "detection summary display window" displays the theoretical weighing value, which is obtained by connecting the weighing values ​​displayed in the "detection display window" in parallel, and the "weighing display window" displays the actual weighing value.

[0014] Furthermore, the self-diagnostic weighing controller panel is equipped with "Setting," "Detection," "Weighing," and "Intelligent Detection Weighing" buttons. The "Setting" button includes numeric keys and some function keys to complete the input and selection of technical indicators and parameters of the weighing system, so that the self-diagnostic weighing controller can perform calculations and self-learning.

[0015] Furthermore, when the "Detect" button is pressed, switching device A is activated, the detection process begins, and weighing cannot proceed. The detection process is a self-diagnostic procedure performed on each improved weighing sensor. When the "Weigh" button is pressed, switching device B is activated, the weighing process begins, and the detection process cannot proceed. The weighing process is the basic operation of the weighing system. When the "Intelligent Detection and Weighing" button is pressed, the weighing system intelligently cycles through detection and weighing.

[0016] Furthermore, the initial no-load value is established. At the initial no-load state, the lifting device is activated, lifting the weighing platform (or weighing frame) to separate it from the improved load cells. At this point, with no other external force acting on the improved load cells, only the excitation voltage, pressing the "Detect" button displays the initial no-load value for each corresponding improved load cell in the "Detection Display Window." The self-diagnostic weighing controller intelligently collects and stores the initial no-load values. Establishing the initial no-load values ​​allows for further confirmation of improved load cells with pre-diagnostic faults.

[0017] Furthermore, the initial empty scale value is established. Initially, there is no object loaded on the weighing platform (or weighing frame). Pressing the "Detect" button displays the initial empty scale value for each corresponding improved weighing sensor in the "Detection Display Window," and the "Detection Summary Display Window" displays the initial theoretical measurement value of the empty scale. Pressing the "Weigh" button displays the initial actual measurement value of the empty scale in the "Weighing Display Window." The difference between the initial theoretical measurement value and the initial actual measurement value is the empty scale compensation value. The self-diagnostic weighing controller intelligently collects and stores the initial empty scale value, the initial actual empty scale value, and the empty scale compensation value.

[0018] Further, initial calibration values ​​are established. During initial calibration, a calibration object is loaded onto the weighing platform (or weighing frame), and the "Detect" button is pressed. The "Detection Display Window" displays the initial calibration value for each corresponding improved weighing sensor, and the "Detection Summary Display Window" displays the initial theoretical measurement value. Pressing the "Weigh" button displays the initial actual measurement value. The difference between the initial theoretical measurement value and the initial actual measurement value is the calibration compensation value. The self-diagnostic weighing controller intelligently collects and stores the initial calibration value, the initial theoretical measurement value, and the calibration compensation value.

[0019] Furthermore, regarding the determination of critical thresholds, the self-diagnostic detection module collects the unloaded initial value, empty scale initial value, and calibration initial value of each improved weighing sensor as their respective standard initial values ​​and stores them. Simultaneously, combining the weighing system's technical indicators and parameters (such as weighing range, actual scale division value, and number of scale divisions), and based on the verification standards, it determines the fault critical threshold for each improved weighing sensor in different weighing ranges (taking a medium accuracy class scale as an example). These standard initial values ​​serve as the primary reference values ​​for the self-diagnostic weighing controller's calculations and self-learning.

[0020] Taking a scale with a medium accuracy class as an example:

[0021] Furthermore, the actual scale division value is denoted by d. National standards stipulate that the actual scale division value in the design and manufacture of scales must meet the requirement of 1x10⁻⁶. k kg, 2x10 k kg, 5 x 10 kThe value is in the form of kg, where k is a positive integer, a negative integer, or zero. ① For analog displays, the actual scale division refers to the difference between corresponding values ​​of two adjacent scale lines. ② For digital displays, the actual scale division refers to the difference between two adjacent displays.

[0022] Furthermore, during the testing process, when the scale is empty or in calibration mode, pressing the "Test" button will cause the self-diagnostic weighing controller to collect the current empty scale value or calibration value of each improved weighing sensor. The current empty scale value or calibration value is compared with the initial empty scale value or calibration value. When the critical threshold corresponding to the fault is reached, the alarm module will display a flashing number or issue an audible and visual alarm in the corresponding "Test Display Window".

[0023] Furthermore, the lifting device lifts the weighing platform (or weighing frame) to separate it from the improved weighing sensor, so that the improved weighing sensor is in an unloaded state free from external forces.

[0024] Furthermore, when an alarm is triggered, the self-diagnostic weighing controller will activate the corresponding lifting device to collect the no-load value of the improved weighing sensor for the problematic sensor, and compare it with the initial no-load value of the improved weighing sensor for further confirmation.

[0025] Furthermore, during weighing operations, pressing the "Weigh" button allows the improved weighing sensor to directly enter the weighing module through the weighing port of the weighing channel, displaying the actual measured value in the "Weighing Display Window," and the system performs routine weighing.

[0026] Furthermore, during channel diagnosis, if the channel is detected as normal during empty weighing or calibration, and a load is applied, pressing the "Detect" button will display the theoretical measurement value of the weighing load in the "Detection Summary Display Window." When the "Weigh" button is pressed, the actual measurement value of the weighing load displayed in the "Weighing Display Window" will be compared with the theoretical measurement value of the weighing load. If the difference is ≥ (compensation value + critical threshold), the self-diagnostic weighing controller will issue a prompt alarm, indicating that the analog junction box or line of the weighing channel is in a critical fault state, thus pointing out the fault area for quick diagnosis of the weighing system fault.

[0027] Furthermore, when the "Intelligent Detection and Weighing" button is pressed, the weighing system enters an intelligent cycle state of intelligent detection, fault diagnosis, and weighing operation. During this cycle, the frequency of weighing and detection is intelligently selected based on the detection results; as alarms increase, the detection frequency increases, and vice versa. The weighing system intelligently performs real-time self-diagnosis on each improved weighing sensor and weighing channel while simultaneously completing the weighing operation, promptly alerting the system to any abnormalities.

[0028] Furthermore, the analog junction box comprises a housing, terminals, wiring terminals, and a precision potentiometer. It is a device that aggregates and processes signals from multiple load cells, enabling the output of a single voltage signal after parallel connection of multiple load cell signals. The analog junction box adjusts the output signal magnitude of the load cells by adjusting the resistance of the potentiometer, ensuring consistency in the output signals of each load cell. The analog junction box is installed on the weighing channel.

[0029] Furthermore, the cable is a copper core cable with several strands and a shielding layer.

[0030] The beneficial effects of this utility model are:

[0031] 1. This utility model changes the traditional detection and fault diagnosis methods. By setting up an improved weighing sensor, switching device, self-diagnostic weighing controller, lifting device, simulated junction box and cables, two independent detection channels and weighing channels are formed. These two channels achieve electrical self-locking and interlocking. During detection or weighing, only the corresponding channel is connected, while the other channel is disconnected. Detection and weighing are carried out alternately. The system detects and tracks the weighing output value of each weighing sensor in no-load, empty scale, or calibration conditions in real time. By measuring the change in the weighing output value, intelligent pre-diagnosis of weighing sensor faults is performed, making detection more convenient and faster, and reducing detection costs. It can accurately diagnose the weighing sensor in a critical fault state in advance, improve the initiative of maintenance, and ensure the reliable, accurate and stable operation of the weighing system. It effectively solves the problem that traditional weighing systems cannot detect the output status of each weighing sensor during weighing operations.

[0032] 2. The self-diagnostic weighing controller of this utility model includes a self-diagnostic detection module, a weighing module, a setting input module, a display module, and an alarm module. The self-diagnostic weighing controller is connected to the display module via the self-diagnostic detection module to display the weighing output values ​​of each improved weighing sensor under no-load, empty scale, and calibration conditions. When the weighing output value approaches or reaches the fault threshold of each weighing sensor, the performance of the weighing sensor begins to deteriorate. The self-diagnostic weighing controller then controls the alarm module to alert the weighing sensor that it is approaching or in a fault-critical state, making pre-diagnosis more convenient, further improving the predictability and proactivity of maintenance, and ensuring the reliable, accurate, and stable operation of the weighing system.

[0033] 3. This utility model improves upon traditional weighing sensors by adding a pair of signal pins at the output end, making signal acquisition more convenient and standardized, reducing interference factors. The detection channel added to the traditional weighing channel facilitates real-time detection of each weighing sensor and also enables self-diagnosis of the weighing channel, improving the reliability of detection, comparison, and analysis, and further ensuring the accuracy and reliability of the weighing system.

[0034] In summary, this utility model has a simple overall structure, is easy to install, and collects signals in a standardized manner. It can perform intelligent pre-diagnosis of faults in each weighing sensor, and the diagnosis of channels is more convenient. It can accurately diagnose weighing sensors or weighing channels that are in a critical fault state in advance, improve the initiative of maintenance, and ensure the reliable, accurate and stable operation of the weighing system. Attached Figure Description

[0035] The following is a brief explanation of the contents of each of the accompanying drawings and the markings in the drawings:

[0036] Figure 1 This is a schematic diagram illustrating the composition principle of this utility model;

[0037] Figure 2 This is a control diagram of the detection channel and weighing channel of this utility model;

[0038] Figure 3 for Figure 1 A schematic diagram of the panel settings for the self-diagnostic weighing controller;

[0039] The markings in the above diagrams are as follows: 1. Switching device A coil, 11. Normally open contact of switching device A, 12. Normally open contact of switching device A, 13. Normally open contact of switching device A, 14. Normally open contact of switching device A, 15. Normally closed contact of switching device A, 16. Normally closed contact of switching device A, 2. Switching device B coil, 21. Normally open contact of switching device B, 22. Normally open contact of switching device B, 23. Normally open contact of switching device B, 24. Normally open contact of switching device B, 25. Normally closed contact of switching device B, 26. Normally closed contact of switching device B, 3. Normally open detection button, 4. Normally open weighing button. Detailed Implementation

[0040] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions in the embodiments will be clearly and completely described below with reference to the accompanying drawings. The following embodiments are used to illustrate this utility model, but are not intended to limit the scope of this utility model.

[0041] In the description of this utility model, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0042] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" 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. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0043] The specific implementation scheme of this utility model is as follows: Figure 1 As shown, a smart detection and fault diagnosis device for weighing sensors includes an improved weighing sensor, a switching device, a self-diagnostic weighing controller, a lifting device, a simulated junction box, and cables. One end of the switching device A is connected to the improved weighing sensor via a cable, and the other end is connected to the self-diagnostic weighing controller via a cable to detect the weighing output values ​​of each improved weighing sensor under no-load, empty scale, and calibration conditions. One end of the switching device B is connected to the improved weighing sensor via a cable, and the other end is connected to the simulated junction box via a cable. The simulated junction box aggregates the output signals of multiple improved weighing sensors and outputs them to the self-diagnostic weighing controller to complete the weighing process. Two independent, self-locking, and interlocking detection and weighing channels operate alternately, tracking the weighing output value of each load cell in both empty and calibrated states. By analyzing changes in the weighing output value, intelligent pre-diagnosis of load cell faults is performed, making detection more convenient, faster, and less costly. This allows for the accurate early diagnosis of load cells or weighing channels in critical fault conditions, improving proactive maintenance and ensuring the reliable, accurate, and stable operation of the weighing system.

[0044] Specifically, such as Figure 1 As shown, the improved load cell has two pairs of signal output pins inside the load cell output port, instead of the original one pair connected in parallel. These two pairs are connected to the inside of the load cell output connector, thus providing two pairs of signal output pins within the connector. The improved load cell output connector adds one more pair of signal pins compared to the traditional load cell output connector.

[0045] Specifically, such as Figure 1 As shown, the improved load cell output plug connector and the cable input plug connector are connected to each other to connect the output signal of the improved load cell to the detection channel and the weighing channel. The detection channel connects the output signal of the improved load cell to the detection port of the self-diagnostic weighing controller via cable and switching device A. The weighing channel first inputs the output signal of the improved load cell to the analog junction box via switching device B. The analog junction box collects and processes the output signal and then connects it to the weighing port of the self-diagnostic weighing controller via cable.

[0046] Specifically, such as Figure 1 As shown, switching device A is located near the detection port of the detection channel, and switching device B is located before the simulation junction box of the weighing channel. Switching device A and switching device B have an interlocking and self-locking function, controlling the connection and disconnection of the detection channel and the weighing channel respectively.

[0047] Specifically, such as Figure 2 As shown, when the normally open button 3 of the "Detection" button is pressed, the coil 1 of the switching device A is energized, the normally open contacts 11 and 12 connected in parallel close, the detection channel is connected, the normally open contacts 13 and 14 connected in parallel close, the detection channel achieves self-locking, at the same time, the normally closed contacts 15 and 16 connected in series open, at this time, the coil 2 of the switching device B cannot be energized, achieving interlocking, the normally open contacts 21 and 22 connected in parallel open, the weighing channel is also disconnected, and the weighing cannot work.

[0048] Specifically, such as Figure 2 As shown, when the normally open button 4 of the "Weighing" button is pressed, the coil 2 of the switching device B is energized, the normally open contacts 21 and 22 connected in parallel close, the weighing channel is connected, the normally open contacts 23 and 24 connected in parallel close, the weighing channel achieves self-locking, at the same time, the normally closed contacts 25 and 26 connected in series open, at this time, the coil 1 of the switching device A cannot be energized, achieving interlocking, the normally open contacts 11 and 12 connected in parallel open, the detection channel is also disconnected, and the detection cannot work.

[0049] Specifically, such as Figure 2 As shown, when switching device A and switching device B are self-locked, they each have two identical normally open contacts connected in parallel; when the interlock between switching device A and switching device B is disengaged, they each have two identical normally closed contacts connected in series. This backup design can greatly improve the reliability of the system.

[0050] Specifically, such as Figure 1 As shown, the self-diagnostic weighing controller includes a self-diagnostic detection module, a weighing module, a setting input module, a display module, and an alarm module. The self-diagnostic weighing controller is connected to the display module via the self-diagnostic detection module to display the weighing output values ​​of each improved weighing sensor under no-load, empty scale, and calibration conditions. The self-diagnostic weighing controller is also connected to the alarm module via the self-diagnostic detection module to indicate that each improved weighing sensor or weighing channel is in a critical fault state.

[0051] Specifically, such as Figure 1 He Ru Figure 3As shown, the self-diagnostic weighing controller is equipped with several detection ports and one weighing port. The detection ports are equipped with several "detection display windows" and one "detection summary display window", and the weighing port is equipped with one "weighing display window". The detection channels are connected to the detection ports, and the weighing channels are connected to the weighing port.

[0052] The “Detection Display Window” displays the weighing value of each corresponding improved weighing sensor, the “Detection Summary Display Window” displays the theoretical weighing value, which is obtained by connecting the weighing values ​​displayed in the “Detection Display Window” in parallel, and the “Weighing Display Window” displays the actual weighing value.

[0053] Specifically, such as Figure 1 He Ru Figure 3 As shown, the self-diagnostic weighing controller panel has "Set", "Detect", "Weighing" and "Intelligent Detection Weighing" buttons.

[0054] The "Settings" section includes numeric keys and some function keys, allowing users to input and select the technical specifications and parameters of the weighing system so that the self-diagnostic weighing controller can perform calculations and self-learning.

[0055] When the "Detect" button is pressed, the detection process begins, performing a self-diagnostic check on each improved load cell. When the "Weigh" button is pressed, the weighing process begins; this is the basic operation of the weighing system. When the "Intelligent Detection and Weighing" button is pressed, the weighing system intelligently cycles through detection and weighing. The frequency of the weighing and detection cycles is intelligently selected based on the detection results; as alarms increase, the detection frequency increases, and vice versa.

[0056] Specifically, such as Figure 1 As shown, the lifting device raises the weighing platform (or weighing frame) to separate it from the improved load cell, placing the improved load cell in an unloaded state free from external forces. When an alarm is triggered and further confirmation is required, the self-diagnostic weighing controller will activate the lifting device to collect the unloaded value of the problematic improved load cell and compare it with the initial value of the improved load cell for confirmation.

[0057] Specifically, such as Figure 1 As shown, the analog junction box consists of a housing, terminals, wiring terminals, precision potentiometers, etc. It is a device that aggregates and processes signals from multiple load cells. It can output a voltage signal after connecting the signals of multiple load cells in parallel. The analog junction box adjusts the output signal of the load cells by adjusting the resistance of the potentiometer to ensure that the output signals of each load cell are consistent. The analog junction box is installed on the weighing channel.

[0058] The cable is a copper core cable with a shielding layer.

[0059] The diagnostic steps of the above-mentioned intelligent detection and fault diagnosis device for weighing sensors are as follows:

[0060] I. Preparatory Work

[0061] 1. Improvement of traditional load cells. The signal output pins on the inside of the traditional load cell output port are increased from a single pair of pins connected in parallel to two pairs of pins. These are then connected to the inside of the load cell output connector, giving the load cell output connector two pairs of signal output pins.

[0062] 2. After the improved weighing sensor has been properly adjusted, it will replace the traditional weighing sensor.

[0063] 3. Complete the connection of the testing channel and the weighing channel.

[0064] ①Detection channel: One end of the normally open contact 11 and normally open contact 12 connected in parallel by the switching device A is connected to the improved weighing sensor through a cable, and the other end is connected to the detection port of the self-diagnostic weighing controller through a cable.

[0065] ② Weighing channel: One end of the normally open contact 21 and normally open contact 22 connected in parallel by the switching device B is connected to the improved weighing sensor through a cable, and the other end is connected to the analog junction box through a cable. The analog junction box is then connected to the weighing port of the self-diagnostic weighing controller through a cable.

[0066] 4. Complete the connection of the self-locking interlocking control of the detection channel and the weighing channel.

[0067] ①For example Figure 2 As shown, the normally open button 3 of the "Detection" button is connected in parallel with the two self-locking normally open contacts 13 and 14 of the switching device A, and then connected in series with the two interlocking normally closed contacts 25 and 26 of the switching device B and the coil 1 of the switching device A to complete the connection of the detection channel control.

[0068] ② Similarly, such as Figure 2 As shown, the normally open button 4 of the "weighing" button is connected in parallel with the two self-locking normally open contacts 23 and 24 of the switching device B. Then, it is connected in series with the two interlocking normally closed contacts 15 and 16 of the switching device A and the coil 2 of the switching device B to complete the connection of the weighing channel control.

[0069] 5. Complete the settings for the self-diagnostic weighing controller. Enter or select the accuracy class, maximum weighing capacity, minimum weighing capacity, actual graduation value, and number of graduations.

[0070] 6. The power supply, shielding wire, and ground wire should be connected according to standard technical requirements.

[0071] II. Intelligent detection and fault diagnosis

[0072] 1. No-load testing: The no-load state refers to the state of the weighing system (or scale) when no other external force is applied. Testing the output of each load cell in the weighing system (or scale) under no-load conditions, with only the excitation voltage applied, is called no-load detection.

[0073] Establishing the initial no-load value. Under actual weighing conditions, place each improved weighing sensor in a no-load state. At the initial no-load state, press the "Detect" button. The "Detection Display Window" will display the initial no-load value of each corresponding improved weighing sensor. When the output signal stabilizes, the self-diagnostic weighing controller will intelligently collect and confirm the data, and input the corresponding information (position information, time information, etc.) to complete the detection.

[0074] 2. Empty Scale Test: An empty scale state refers to the state of the weighing system (or scale) when only the weighing platform (or frame) is in operation and no other external forces are applied. The test of the output of each load cell in the weighing system (or scale) under empty scale conditions, with only the weighing platform (or frame) and excitation voltage in operation, is called an empty scale test.

[0075] Under actual weighing conditions, the weighing platform (or weighing frame) and all mechanical components are correctly positioned. In the event of a power outage, further confirm the connection of each improved weighing sensor, the connection of the two channels, the connection of the switching device's self-locking interlock, and the self-diagnostic weighing controller starts working when powered on.

[0076] Initial setup of the empty scale. During the initial empty scale setup, press the "Detect" button. The "Detection Display Window" shows the initial empty scale value for each corresponding improved load cell, and the "Detection Summary Display Window" shows the initial theoretical measurement value of the empty scale. Press the "Weigh" button, and the "Weighing Display Window" shows the initial actual measurement value of the empty scale. The difference between the initial theoretical measurement value and the initial actual measurement value of the empty scale is the empty scale compensation value. Once the output signal stabilizes, the self-diagnostic weighing controller will collect and store the initial empty scale value, the initial actual empty scale value, and the empty scale compensation value. Input the corresponding information (location information, time information, etc.), and the detection is complete.

[0077] 3. Calibration test: Under actual weighing conditions, the weighing platform (or weighing frame) and all mechanical parts are correctly positioned and calibrated by loading with standard weight.

[0078] Initial calibration setup. During initial calibration, press the "Detect" button. The "Detection Display Window" shows the initial calibration value for each corresponding improved weighing sensor, and the "Detection Summary Display Window" shows the initial theoretical measurement value. Press the "Weigh" button, and the "Weighing Display Window" shows the initial actual measurement value. The difference between the initial theoretical measurement value and the initial actual measurement value is the calibration compensation value. The self-diagnostic weighing controller intelligently collects and stores the initial calibration value, the initial theoretical measurement value, and the calibration compensation value. Input the corresponding information (location information, time information, etc.) and indicate the standard weight value.

[0079] 4. Critical Threshold Determination: The self-diagnostic testing module collects the no-load initial value, empty scale initial value, and calibration initial value of each improved weighing sensor as their respective standard initial values ​​and stores them. Simultaneously, combining the weighing system's technical specifications and parameters (such as range, actual scale division, and number of scale divisions), and according to the verification procedures, using the maximum permissible error of the initial verification as the standard, it determines the critical threshold value at which each improved weighing sensor reaches the fault threshold in different weighing ranges. The standard initial value is the main reference value for the self-diagnostic weighing controller's calculations and self-learning.

[0080] Taking a scale with a medium accuracy class as an example:

[0081] 5. Testing process: ① When the scale is empty, press the "Test" button. The self-diagnostic weighing controller will collect the current value of each improved weighing sensor. The current value of the empty scale will be compared with the initial value of the empty scale. When the critical threshold of the corresponding weighing range is reached, the alarm module will flash numbers or issue an audible and visual alarm in the corresponding "Test Display Window".

[0082] ② In the calibration state, press the "Detect" button. The self-diagnostic weighing controller collects the current calibration value of each improved weighing sensor. The current calibration value is compared with the initial calibration value. When the critical threshold of the corresponding weighing range is reached, the alarm module will flash numbers in the corresponding "Detection Display Window" or issue an audible and visual alarm.

[0083] ③ When an alarm is triggered, the self-diagnostic weighing controller will activate the lifting device to collect the no-load value of the improved weighing sensor at that time, and compare it with the initial no-load value of the improved weighing sensor for further confirmation.

[0084] 6. Channel Diagnosis. The empty scale detection channel is detected to be normal. When the same weighing load is applied and the "Detection" button is pressed, the theoretical measured value of the weighing load is displayed in the "Detection Summary Display Window". When compared with the actual measured value of the weighing load displayed in the "Weighing Display Window" after pressing the "Weighing" button, when the difference ≥ (compensation value + critical threshold), the self-diagnosing weighing controller will issue a prompt alarm, indicating that the analog junction box or circuit of the weighing channel is in a fault critical state, quickly diagnosing and confirming the location of the weighing system fault.

[0085] III. Weighing Work

[0086] During weighing work, when the "Weighing" button is pressed, the weighing signals of each improved weighing sensor directly enter the weighing module through the weighing ports of the weighing channel, and the actual measured value is displayed in the "Weighing Display Window", and the system conducts conventional weighing.

[0087] IV. Intelligent Detection Weighing

[0088] For intelligent detection weighing, when the "Intelligent Detection Weighing" button is pressed, the weighing system enters an intelligent loop state of intelligent detection, fault diagnosis, and weighing work. The cycle frequency of weighing and detection is intelligently selected according to the detection results. When the alarm prompts increase, the detection frequency also increases; conversely, the weighing frequency increases. The weighing system intelligently conducts self-diagnosis on each improved weighing sensor and weighing channel in real time, and at the same time completes the weighing work, and promptly gives a prompt alarm and confirmation when abnormalities occur.

[0089] V. Working Process

[0090] ① Non-intelligent mode: All preparatory work is completed. In the empty scale state, when the "Detection" button is pressed, the detection channel is connected, the weighing channel is disconnected, and the self-diagnosing weighing controller collects the current empty scale values of each improved weighing sensor and compares them with the initial empty scale values. When reaching the critical threshold (±0.5d) of the corresponding weighing range (0 < M ≤ 500d), the alarm module will display digital flashing or emit an audible and visual alarm and confirmation in the corresponding "Detection Display Window"; when not exceeding the critical threshold, when the "Weighing" button is pressed, the weighing channel is connected, the detection channel is disconnected, and it enters the weighing state. After the load weighing is completed; at this time, when the "Detection" button is pressed again, the detection channel is connected, the weighing channel is disconnected, and it enters the channel diagnosis state. The theoretical measured value of the weighing load is displayed in the "Detection Summary Display Window" and compared with the actual measured value of the load weighing displayed in the "Weighing Display Window". When the difference ≥ (compensation value + critical threshold of the corresponding weighing range), the self-diagnosing weighing controller will issue a prompt alarm, indicating that the analog junction box or circuit of the weighing channel is in a fault critical state; when the difference does not exceed (compensation value + critical threshold of the corresponding weighing range), it completes one frequency cycle of detection → weighing.

[0091] The calibration status detection and weighing cycle are the same as the empty scale status detection and weighing cycle.

[0092] ② Intelligent Mode: After all preparations are complete, when the scale is empty, pressing the "Intelligent Detection and Weighing" button will activate the weighing system, which will then enter an intelligent cycle of detection, fault diagnosis, and weighing operations. It is not necessary to press the "Detection" or "Weighing" buttons again. The frequency of weighing and detection is intelligently selected based on the detection results.

[0093] The aforementioned device can comprehensively monitor all online-operating improved load cells, effectively and promptly grasp the life cycle of the improved load cells under specific operating conditions, making fault handling more targeted and predictive, and enabling rapid and accurate fault location identification, thus shortening fault handling time. Simultaneously, it embodies the "zero-failure" maintenance philosophy.

[0094] This device adopts a switching working mode, which can perform detection and weighing online simultaneously, making the switching between weighing and detection in daily weighing systems more convenient and faster, and making the detection work more time-saving, labor-saving, and easy to promote.

[0095] The above description is merely an illustration of some principles of this utility model. This specification is not intended to limit this utility model to the specific structure and applicable scope shown. Therefore, all possible modifications and equivalents that may be used fall within the scope of the patent application of this utility model.

Claims

1. A smart detection and fault diagnosis device for a weighing sensor, characterized in that, The system includes an improved load cell, a switching device, a self-diagnostic weighing controller, a lifting device, a simulated junction box, and cables. The switching device includes switching device A and switching device B. One end of switching device A is connected to the improved load cell via the cable, and the other end is connected to the self-diagnostic weighing controller via the cable to detect the weighing output value of the improved load cell under no-load, empty scale, and calibration conditions. One end of switching device B is connected to the improved load cell via the cable, and the other end is connected to the simulated junction box via the cable. The simulated junction box aggregates the output signals of multiple improved load cells and outputs them to the self-diagnostic weighing controller to complete the weighing process.

2. The intelligent detection and fault diagnosis device for weighing sensors according to claim 1, characterized in that: The improved load cell has two pairs of signal output pins inside the load cell output port, instead of the original one pair connected in parallel. These two pairs of pins are connected to the inside of the load cell output connector, thus providing two pairs of signal output pins inside the load cell output connector.

3. The intelligent detection and fault diagnosis device for weighing sensors according to claim 1 or 2, characterized in that: The improved weighing sensor output plug connector is connected to the cable input plug connector to connect the output signal of the improved weighing sensor to the detection channel and the weighing channel. The detection channel connects the output signal of the improved weighing sensor to the detection port of the self-diagnostic weighing controller via a cable and switching device A. The weighing channel first inputs the output signal of the improved weighing sensor to the analog junction box via switching device B. The analog junction box collects and processes the output signal and then connects it to the weighing port of the self-diagnostic weighing controller via a cable.

4. The intelligent detection and fault diagnosis device for weighing sensors according to claim 3, characterized in that: The switching device A is located near the detection port of the detection channel, and the switching device B is located before the analog junction box of the weighing channel. Switching device A and switching device B are electrically self-locking and interlocked, controlling the detection channel and the weighing channel. When the normally open detection button 3 is pressed, the coil 1 of switching device A is energized, and the parallel normally open contacts 11 and 12 close, connecting the detection channel. The parallel normally open contacts 13 and 14 close, achieving self-locking of the detection channel. Simultaneously, the series normally closed contacts 15 and 16 open, preventing the coil 2 of switching device B from being energized, thus achieving interlocking. The parallel normally open contacts 21 and 22 also open, connecting the weighing channel. When the switch is disconnected, the weighing function cannot operate. Pressing the normally open weighing button 4 energizes the coil 2 of the switching device B, closing the parallel normally open contacts 21 and 22, thus connecting the weighing channel. Simultaneously, the parallel normally open contacts 23 and 24 close, achieving self-locking of the weighing channel. At the same time, the series normally closed contacts 25 and 26 open, preventing the switching device A coil 1 from being energized and achieving interlocking. The parallel normally open contacts 11 and 12 also open, disconnecting the detection channel and preventing detection from operating. When the switching device A and switching device B are self-locked, they each consist of two identical normally open contacts connected in parallel. When the interlocking between the switching device A and switching device B is disengaged, they each consist of two identical normally closed contacts connected in series.

Images