A belt scale calibration simulation device

Abstract

The utility model provides a belt scale school scale simulation device. Including work table, work table surface is equipped with simulation subassembly, simulation subassembly includes weighing controller, frequency changer, weighing sensor, speed motor, frequency conversion motor, weighing support pole and counterweight, frequency changer links to each other with frequency conversion motor, is used for adjusting frequency conversion motor rotating speed, simulates the speed change of belt, frequency conversion motor links to each other with speed motor, frequency conversion motor drives the rotation of speed motor, and speed motor obtains the rotating speed signal in real time, and the top of weighing sensor is connected with weighing support pole, and the counterweight is detachably slidably set on the weighing support pole, is used for simulating different material load, and the weight of counterweight is converted into weight signal by weighing sensor, and weighing sensor receives weight signal and rotating speed signal. The utility model simulation subassembly reproduces the weight of belt scale through counterweight in laboratory, reproduces the speed of belt scale through frequency conversion motor and speed motor, carries out pre -calibration to new controller, avoids the on -the -spot shutdown.

Description

Technical Field

[0001] This utility model relates to the field of simulated belt scale calibration technology, and in particular to a belt scale calibration simulation device. Background Technology

[0002] In modern industrial production, belt scales are crucial equipment for precise raw material measurement in key processes such as sintering batching, coking coal blending, blast furnace coke return, and ore return metering. Their measurement accuracy directly affects production continuity, raw material proportions, and product quality. A belt scale control system typically consists of load cells, speed sensors, and a weighing controller (or integrator). The weighing controller, acting as the "brain" of the belt scale, is responsible for signal processing and measurement calculations, outputting results for display, recording, control, or participation in calculations within the upper-level production management system. The controller is the core algorithm and data processing hub that ensures measurement accuracy. If it malfunctions or is replaced, recalibration is required to ensure accuracy.

[0003] If the controller malfunctions or is damaged, it will trigger a series of serious problems: 1. Production interruption: The belt scale's metering function fails or the results are unreliable, forcing the production line to stop and causing direct production loss.

[0004] 2. Loss of control over batching accuracy: During the fault period or after replacement, the uncalibrated controller has an unpredictable deviation in its output flow or cumulative quantity, which leads to a serious imbalance in the raw material ratio and directly affects the quality of intermediate or final products (such as sinter basicity, coke strength, pig iron composition, etc.).

[0005] 3. Amplified economic losses: Defective products, rework, customer claims, and downtime resulting in lost production capacity, wasted energy, and delayed orders accumulate into incalculable economic losses.

[0006] 4. The most challenging aspect: Lack of online calibration: When controllers need to be replaced (whether for fault replacement, preventative maintenance upgrades, or spare parts replacement), the field often faces severe time pressure or production continuity requirements (i.e., "production cannot be stopped"). The biggest challenge at this time is that the new or backup controller cannot be calibrated online while the belt scale is actually running (carrying material). Traditional calibration methods (such as chain code calibration and physical material calibration) all require stopping material conveying. This results in the new controller's output measurement value lacking a reliable benchmark, and potential measurement deviations cannot be detected and corrected in a timely manner, becoming a persistent hidden production hazard that seriously threatens process stability and product quality.

[0007] Existing calibration methods have significant drawbacks: Chain code calibration, which involves laying chain codes of known mass per unit length flat on the belt to simulate material load and calibrating by running the belt, requires manual laying of chain codes, is cumbersome and time-consuming, cannot simulate real material characteristics, has large accuracy deviations, and must be shut down for operation. Operators must work near the running belt, posing safety hazards. Material calibration requires the preparation of standard materials, is complex, and involves preparing standard materials, accurate weighing, careful organization of material transportation, collection, and re-weighing verification. The entire process is extremely time-consuming, seriously affecting production. It is costly, involving material handling, storage, loss (especially for valuable materials), and a large amount of manpower. It is also limited by material characteristics (such as high temperature, toxicity), which also requires shutdown, conflicting with the need for continuous production.

[0008] Current calibration technologies and mainstream methods all require interrupting normal production material supply, which severely conflicts with the continuous and efficient production requirements of modern industry. The calibration process itself consumes significant time, manpower, and material resources. Therefore, there is an urgent need for a device that can rapidly calibrate controllers under simulated laboratory conditions without interrupting production. Utility Model Content

[0009] To address the aforementioned technical problems, a belt scale calibration simulation device is provided. This device enables simulation processing in a laboratory setting, avoiding the cumbersome, time-consuming, and labor-intensive methods of chain code or material calibration, thus meeting the demands for high efficiency and accuracy in industrial production. The technical means employed in this invention are as follows: A belt scale calibration simulation device includes a workbench; a simulation component is mounted on the surface of the workbench, the simulation component including a weighing controller, a frequency converter, a weighing sensor, a tachometer motor, a variable frequency motor, a weighing support rod, and weights; the frequency converter is connected to the variable frequency motor and is used to adjust the speed of the variable frequency motor to simulate belt speed changes; the variable frequency motor is connected to the tachometer motor and drives the tachometer motor to rotate, the tachometer motor acquires speed signals in real time; the top of the weighing sensor is connected to the weighing support rod, and the weights are detachably slidably mounted on the weighing support rod to simulate different material loads; the weighing sensor converts the weight of the weights into a weight signal; the weighing sensor receives both the weight signal and the speed signal.

[0010] Furthermore, the circuit control mechanism, weighing controller, and frequency converter are mounted on the upper surface of the workbench.

[0011] Furthermore, the weighing sensor and the variable frequency motor are detachably connected to the workbench by bolts, and the speed measuring motor is installed at the output end of the variable frequency motor.

[0012] Furthermore, it also includes a support plate located at the bottom of the workbench for supporting the variable frequency motor and the weighing sensor. An auxiliary component is installed on the surface of the support plate. The auxiliary component includes a connecting plate symmetrically arranged on the bottom surface of the workbench and a positioning strip symmetrically arranged on the surface of the support plate. The positioning strip is inserted into the positioning groove of the connecting plate.

[0013] Furthermore, a first nut is threaded to one end of the weighing support rod, and the first nut fits against the weight to limit the weight in the working state.

[0014] Furthermore, a storage box is installed on the bottom surface of the support plate, and the interior of the storage box is divided into multiple spaces for storing weights of different specifications.

[0015] Furthermore, a through hole is formed between the two positioning strips, penetrating the support plate. A positioning rod is slidably connected in the through hole. Both ends of the positioning rod penetrate the positioning strip and the connecting plate, and both ends are threaded with a second nut that fits against the connecting plate.

[0016] This utility model has the following advantages: 1. This utility model's simulation component can reproduce the weight of a belt scale in the laboratory using weights, and reproduce the speed of the belt scale using a variable frequency motor and a speed measuring motor. It can also pre-calibrate newly replaced controllers, avoiding on-site downtime and resolving the conflict between traditional methods and continuous production.

[0017] 2. This utility model eliminates cumbersome operations such as chain code handling and material preparation, reducing calibration process time by more than 50%; after the controller is replaced, the online approval cycle is reduced to minutes, reducing downtime by more than 100 hours per year and recovering huge production capacity losses.

[0018] 3. This utility model can simulate different material loads and belt speeds by changing different weights and adjusting the frequency converter to change the motor speed, thus ensuring the metering accuracy of the controller under various working conditions.

[0019] 4. The auxiliary components of this utility model enable quick assembly and disassembly of the support plate, and the weighing sensor, motor and other components are detachable for easy maintenance; it supports controller parameter preset and fault simulation, and also has the functions of component testing and technical training. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0021] Figure 1This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the circuit control mechanism and weighing controller of this utility model; Figure 3 This is a schematic diagram of the structure of the weighing sensor and weighing support rod of this utility model; Figure 4 This is a schematic diagram of the structure of the support plate of this utility model when it is pushed out; Figure 5 This is a schematic diagram of the positioning strip and positioning rod of this utility model.

[0022] Figure 6 This is a physical image of the present utility model.

[0023] Figure 7 This is a schematic diagram of the overall circuit of this utility model.

[0024] In the diagram: 1. Workbench; 2. Simulation component; 21. Circuit control mechanism; 22. Weighing controller; 23. Frequency converter; 24. Support plate; 25. Weighing sensor; 26. Tachometer motor; 27. Variable frequency motor; 28. Weighing support rod; 29. ​​Weight; 210. First nut; 211. Storage box; 3. Auxiliary component; 31. Connecting plate; 32. Positioning strip; 33. Positioning rod; 34. Second nut. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model.

[0026] like Figure 1 As shown, this utility model embodiment discloses a belt scale calibration simulation device, including a workbench; a simulation component 2 is mounted on the surface of the workbench 1, the simulation component including a weighing controller 22, a frequency converter 23, a weighing sensor 25, a speed measuring motor 26, a frequency converter 27, a weighing support rod 28, and weights 29; as shown Figures 3-5As shown, the frequency converter 23 is connected to the frequency converter motor 27 to adjust the speed of the frequency converter motor 27 and simulate the belt speed change. The frequency converter motor 27 is connected to the speed measuring motor 26, and the frequency converter motor 27 drives the speed measuring motor 26 to rotate. The speed measuring motor 26 acquires the speed signal in real time. The top of the weighing sensor 25 is connected to the weighing support rod 28. The weight 29 is detachably slidably sleeved on the weighing support rod 28 to simulate different material loads. The weighing sensor 25 converts the weight of the weight 29 into a weight signal. The weighing sensor 22 receives the weight signal and the speed signal.

[0027] like Figure 6 As shown, after actual use, this utility model can simulate the weighing operation of a belt scale in the laboratory by calibrating with weights, avoiding the cumbersome, time-consuming and labor-intensive operation caused by using chain codes or material calibration, thus meeting the needs of efficient and accurate industrial production.

[0028] Furthermore, such as Figure 2 As shown, the circuit control mechanism 21, the weighing controller, and the frequency converter are mounted on the upper surface of the workbench. The circuit control mechanism is used to control the circuit switching and signal transmission of the entire device.

[0029] Furthermore, the weighing sensor and the variable frequency motor are detachably connected to the workbench by bolts, and the speed measuring motor is installed at the output end of the variable frequency motor.

[0030] Furthermore, it also includes a support plate 24, located at the bottom of the workbench, for supporting the variable frequency motor and the load cell. An auxiliary component 3 is mounted on the surface of the support plate. This auxiliary component includes a connecting plate 31 symmetrically arranged on the bottom surface of the workbench and positioning strips 32 symmetrically arranged on the surface of the support plate. The positioning strips engage with the positioning grooves of the connecting plate. This configuration allows the entire support plate 24 to be disassembled, and then the load cell 25 and variable frequency motor 27, among other components, can be disassembled according to actual needs, facilitating inspection and maintenance of the device.

[0031] Furthermore, a first nut 210 is threadedly connected to one end of the weighing rod. The first nut fits against the weight to limit the position of the weight in the working state.

[0032] Furthermore, a storage box 211 is installed on the bottom surface of the support plate. The storage box is divided into multiple spaces for storing weights of different specifications.

[0033] Furthermore, a through hole is formed between the two positioning strips, penetrating the support plate. A positioning rod 33 is slidably connected within the through hole. Both ends of the positioning rod pass through the positioning strips and the connecting plate, and both ends are threadedly connected to second nuts 34 that fit against the connecting plate. In normal use, the positioning strips fixed to the surface of the support plate are inserted into the positioning grooves of the connecting plate, then the positioning rod is inserted, and the second nuts 34 are tightened. This allows the position of the positioning rod 33 to be fixed, greatly improving the stability of the device.

[0034] In this embodiment, the circuit control mechanism 21 and similar structures are existing technologies, and their working principles are well-known technologies. The appropriate model is selected according to the actual use, and the control method and wiring layout will not be explained in detail.

[0035] Or, as attached Figure 7 As shown, perform the circuit wiring. For the load cell and feeder controller: connect the excitation +, excitation -, signal +, and signal - wires accordingly. The excitation line provides a stable operating voltage to the sensor, and the signal line transmits the analog / digital signal for weight detection, used to measure the feed weight. For the feeder controller power supply: connect E (ground), L (phase line), and N (neutral line). For the frequency converter and feeder controller: associate the given input (terminal 2, etc.), control output (terminals 5, 6, etc.), and flow output; for the frequency converter and motor: connect U, V, and W wires. In actual use, the shielding layer grounding method can be single-ended or double-ended grounding.

[0036] In this embodiment, the Y80M2-6 three-phase asynchronous motor from Shanghai Lichao is used.

[0037] The working principle and process of this utility model are as follows: First, the support plate 24 is placed between the two connecting plates 31 at the bottom of the workbench 1, so that the positioning strip 32 is inserted into the positioning groove on the surface of the connecting plate 31. The positioning rod 33 passes through the through hole of the positioning strip 32 and the connecting plate 31, and the two ends are tightened with the second nut 34 to ensure that the support plate 24 is stably installed and to avoid shaking during operation. A circuit control mechanism 21, a weighing controller 22, and a frequency converter 23 are fixedly installed on the surface of the workbench 1. The weighing sensor 25 and the frequency converter motor 27 are detachably connected to the workbench 1 by bolts. A speed measuring motor 26 is installed at the output end of the frequency converter motor 27 for real-time monitoring of the motor speed. The circuit control mechanism 21 can control the circuit of the entire device. This is existing technology. The specific model can be selected according to the actual situation. Its working process is based on existing technology. The components such as the circuit control mechanism 21, the weighing controller 22, the frequency converter 23, the weighing sensor 25, and the frequency conversion motor 27 are connected by electrical signals, which is the prior art. For specific operation, please refer to the prior art. The weighing support rod 28 is installed on the surface of the weighing sensor 25. The required weight 29 is taken out from the storage box 211 on the bottom of the support plate 24. The storage box 211 has a partitioned space inside that can store weights 29 of different weights for easy access. Then the weight 29 is slidably sleeved on the weighing support rod 28, and the end is tightened with the first nut 210 to prevent the weight 29 from shifting. According to the calibration requirements, the weight 29 is slid to the designated position of the weighing support rod 28 and fixed by the first nut 210 to simulate the weight load of the material on the belt. The load cell 25 senses the weight pressure of the weight 29, converts the mechanical signal into an electrical signal, and transmits it to the weighing controller 22; The frequency converter 23 receives signals and adjusts the speed of the frequency converter motor 27, driving the tachometer motor 26 to rotate. The tachometer motor 26 feeds back speed signals to the weighing controller 22 in real time, simulating the actual linear speed of the belt. Specifically, the speed of the frequency converter motor 27 is controlled by the frequency converter 23; by changing the power supply frequency input to the motor, the motor's rotational speed can be precisely adjusted. Since the belt speed of the belt scale is directly related to the speed of the drive motor, the change in the speed of the frequency converter motor can equivalently simulate the change in the belt's running speed. The tachometer motor 26 is installed at the output end of the frequency converter motor 27 and rotates synchronously with the motor, converting the speed signal into an electrical signal and transmitting it to the weighing controller 22. This signal is consistent with the output signal of the speed sensor in a real belt scale, enabling the controller to calculate the flow rate based on the simulated speed. By setting different frequencies through the frequency converter 23, the speed of the belt under various operating conditions such as start-up, constant speed, and variable speed can be simulated, covering the speed range that may occur in actual production.

[0038] The weighing controller 22 synchronously receives the weight signal from the weighing sensor 25 and the speed signal from the tachometer motor 26, and calculates the instantaneous flow rate or cumulative weight of the simulated material. The formula is usually: Flow rate = weight × speed. By changing the weight of the weight 29 and adjusting the speed of the variable frequency motor 27 via the frequency converter 23, the operating conditions of the belt scale under different material loads and operating speeds are simulated, ensuring the measurement accuracy of the device in various scenarios. The load cell 25 converts the gravity of the weight 29 into an electrical signal, which is transmitted to the weighing controller 22. This signal is equivalent to the force signal of the material weight acting on the load cell in a real belt scale, enabling the controller to obtain simulated material weight parameters. By adjusting the position of the weight on the weighing support 28, different distribution states of materials on the belt can be simulated, further approximating the actual material distribution in production.

[0039] The speed signal simulated by the variable frequency motor 27 and the weight signal simulated by the weighing support 28 are synchronously transmitted to the weighing controller 22. The controller calculates the instantaneous flow rate and cumulative amount according to the formula flow rate = weight × speed, realizing a complete simulation of the belt scale's metering process. This linkage can reproduce the working state of the belt scale under different loads and speeds, providing a comprehensive simulation environment for the controller's calibration and performance verification.

[0040] When maintenance and repair of the load cell 25, variable frequency motor 27, etc. are required, first unscrew the second nut 34, then pull the support plate 24 so that the support plate 24 drives the positioning strip 32 to disengage from the positioning groove opened on the surface of the connecting plate 31, thereby disassembling the entire support plate 24. Since the load cell 25 and variable frequency motor 27 are detachably connected to the workbench 1 by bolts, the load cell 25 and variable frequency motor 27 and other components can be disassembled according to the actual situation, which facilitates the inspection and maintenance of the device.

[0041] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and are not intended to limit it. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A belt scale calibration simulation device, characterized in that, The system includes a workbench; a simulation component is mounted on the surface of the workbench, comprising a weighing controller, a frequency converter, a weighing sensor, a tachometer motor, a variable frequency motor, a weighing support rod, and weights; the frequency converter is connected to the variable frequency motor and is used to adjust the speed of the variable frequency motor to simulate belt speed changes; the variable frequency motor is connected to the tachometer motor and drives the tachometer motor to rotate, and the tachometer motor acquires speed signals in real time; the top of the weighing sensor is connected to the weighing support rod, and the weights are detachably slidably mounted on the weighing support rod to simulate different material loads; the weighing sensor converts the weight of the weights into a weight signal; and the weighing sensor receives both the weight signal and the speed signal.

2. The belt scale calibration simulation device according to claim 1, characterized in that, The circuit control mechanism, weighing controller, and frequency converter are mounted on the upper surface of the workbench.

3. The belt scale calibration simulation device according to claim 1, characterized in that, The weighing sensor and the variable frequency motor are detachably connected to the workbench by bolts.

4. The belt scale calibration simulation device according to claim 1, characterized in that, It also includes a support plate located at the bottom of the workbench for supporting the variable frequency motor and the weighing sensor. An auxiliary component is installed on the surface of the support plate. The auxiliary component includes positioning strips symmetrically arranged on the surface of the support plate. A connecting plate is symmetrically arranged on the bottom surface of the workbench. The positioning strips are inserted into the positioning slots opened in the connecting plate.

5. The belt scale calibration simulation device according to claim 1, characterized in that, One end of the weighing support rod is threaded with a first nut, which fits against the weight to limit the weight's position during operation.

6. The belt scale calibration simulation device according to claim 4, characterized in that, A storage box is installed on the bottom surface of the support plate. The storage box is divided into multiple spaces for storing weights of different specifications.

7. The belt scale calibration simulation device according to claim 4, characterized in that, A through hole is formed between the two positioning strips, penetrating the support plate. A positioning rod is slidably connected in the through hole. Both ends of the positioning rod pass through the positioning strip and the connecting plate, and both ends are threaded with a second nut that fits against the connecting plate.

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