Belt Image Zero Tracking for Conveyor Weighing
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Solution Overview
Problem
Conventional conveyor belt weighing systems face challenges in accurately detecting an empty belt state and making zero adjustments without requiring a complete belt revolution, leading to potential errors and inefficiencies, especially in unattended operations.
Innovation Solution
A system and method that allow for the detection of an empty belt state by comparing the recorded zero image with measured belt weights, determining if the difference is constant across sections, and using this information to make zero adjustments without needing a full belt revolution, utilizing processors and memory to store and analyze weight data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional zero adjustment methods are used requiring a complete belt revolution, then the zero measurement can be accurately determined, but the system efficiency decreases and time is lost
Solution Approach 1:
The patent divides the belt into multiple sections and creates a zero image for each section. Instead of requiring a complete belt revolution to determine zero, the system segments the weighing process and uses stored zero images for individual sections to enable faster zero adjustments without compromising accuracy
Solution Approach 2:
The system performs preliminary zero measurements and stores zero images for different belt sections in advance. This preliminary action allows the system to retrieve pre-stored zero data during operation, eliminating the need to wait for a complete belt revolution and thereby improving efficiency while maintaining measurement precision
2Productivity
If automatic zero tracking is implemented without complete belt revolution, then system productivity improves, but measurement precision may deteriorate
Solution Approach 1:
The system continuously monitors belt weight measurements and compares them against stored zero images. When deviations are detected, the system provides feedback and automatically retrieves appropriate zero constants from memory to correct the measurements, ensuring precision is maintained without requiring complete belt revolutions
Solution Approach 2:
The system creates copies of zero measurements stored as zero images for different belt sections. These copied zero data can be quickly retrieved and applied during operation, enabling automatic zero tracking that maintains precision while improving productivity by avoiding complete belt revolutions
3Measurement precision
If zero image system with multiple zero constants is used, then instantaneous weight results improve in accuracy, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical zero adjustment mechanisms with a digital memory system that stores zero images. The processor automatically retrieves and applies the appropriate zero constant based on belt position, substituting mechanical complexity with electronic data storage and retrieval that achieves the same functional result with greater precision
4Ease of operation
If manual zero adjustment is performed, then operation simplicity is maintained, but time loss increases and reliability decreases in unattended operations
Solution Approach 1:
The system performs automatic zero tracking by continuously monitoring belt weight and automatically retrieving appropriate zero constants from stored zero images. This self-service capability eliminates the need for manual intervention, maintaining operational simplicity while significantly improving reliability in unattended operations
Data Source
AI summary
A belt weighing system, including a belt passing over a weigh frame able to measure the weight of conveyed material, and at least one memory to store a zero image for the belt. At least one processor able to determine differences between a measured belt weight and a stored zero image for corresponding points or sections of the belt, and to determine if the differences are constant for different sections of the belt. A condition for an empty belt state can be detected where the instantaneous difference between the stored zero image and the measured belt weight for corresponding belt points or sections is equal to an average difference for different belt points or sections.