Weigh Feeder Training Module
Weigh Feeder Training Module
Weigh Feeder Training Module
Weigh Feeders
Presentation:
Version:
Last Update:
1.0
23-03-03
Objective
Weigh Feeder is intended to be a comprehensive
training material for all technical staff within Holcim
Group companies
It will familiarize you with the general knowledge as
well as with the maintenance requirements
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Content of Presentation
Weighfeeder
Function
Operating Principle
Material Flow
Mechanical components
Mechanical Components
Electrical components
Weigh Measuring Circuit
Speed Measuring Circuit
Flow Control Circuit
Driving Motor Circuit
Calibration Function
Calibration
Maintenance
Maintenance
Training of Belt
Changing of Belt
Belt Splicing
Troubleshooting
Overview
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in a process. They are used to convey, weigh, and control the flow
rate of bulk materials by varying the speed of the belt.
They transform a variable material flow into a constant and
controllable flow
A sub-function of a weigh feeder is to reduce the possibility of
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Weigh feeder continuously weighs and feeds bulk solids. The belt load is
measured through a weighbridge located under the conveyor belt. A control
loop adjusts feed rate FLOW to a preset set point via belt SPEED.
LOAD
FLOW
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by two idlers)
The output signals of the weigh bridge and the belt speed is
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Mechanical Components
Feeding Hopper
Manual Control Gate
Side Skirts
Calibration Weight
Idlers and Idler Support
Driving Pulley
Belt Cleaning Device
Tensioning Device
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Feeding Hopper
Function:
The feeding hopper forms a small buffer stock between the material
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Side Skirts
Function:
Side skirts contain the material within the belt width, avoiding
They are generally made of rubber. Care has to be taken that they
do not exert force on the load cell, thus influencing the reading.
In other designs the skirting rubber is an integral part of the belt,
avoiding the above risk.
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Calibration Weight
Function:
Calibrated weights are hooked to the weighing mechanism to check
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Driving Pulley
Function:
The drive pulley provides the force to move the belt. It is driven by a
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functioning
All conveyors are to be equipped with a
suitable belt cleaning system for removing
the maximum amount of carry-back material
from the belts surface prior to exiting the
discharge chute enclosure.
In all applications, the minimum requirement
is a dual belt cleaning system, consisting
of a pre-cleaner / primary cleaner and a
multi-bladed secondary cleaner.
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Tensioning Device
Functions:
The TD stretches the belt, in order to have a defined zero load on
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Load Cell
Function:
The load cell converts the weight measurement from the belt into a
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Weigh Amplifier
Functions:
To amplify the output signal of the load cell from between 0 and 30
mV and,
To convert it into a 0-6 V or a 0-10 V signal depending upon the
equipment
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the rotation speed. These signals are transformed into an analogue signal
proportional to the speed through a frequency to voltage converter
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index indicator is giving a signal each time the belt has made a
complete turn.
This device is included in some newer application. It is used for:
Belt Index
Indicator
Belt
Index
Tachometer
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Integrator
Function
The integrator converts the voltage signal from the weigh amplifier
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Flow Totalizer
Function:
The flow totalizer counts the pulse coming from the frequency
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Multiplier
Function
The multiplier produces a voltage (Q) proportional to the product of
the voltages of the belt speed (V) and of the material weight on the
belt (P). Q = V x P
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belt speed after a comparison between the actual and the set point
flows
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Controller Comparator
Function
To compare the actual measured flow with the set point and act upon the
belt drive to bring the actual flow to the level of the set flow
The comparator calculates the difference between the set point and the
actual flow. The resulting error signal is sent to the control module of the
motor
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Example of characteristics
of a DC Motor
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Power Supply
Function
It supplies the motor command module with alternating current
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motor
DC Motor example! In case of a VSD it is integrated in the motor
command module
The inductor circuit is fed from 220 V network via a diode rectifier
while the induced circuit is fed from the high voltage (500 V)
through the thyristor card. The thyristor triggers are fed through a
pulse generator transforming the 0-10 V DC signal received from
the controller-comparator
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Known technology
No spare parts available from original supplier
No local service from supplier
Better visualization
Better alarming
Plant PCS concept can be applied
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Belt index
Weight
Setpoint,
Speed
PCS
Process Control
System
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Calibration
It is important to understand that a weigh feeder is only
as reliable as the standard to which it is calibrated
The need for calibration can come from different sources:
An interval given by the planned maintenance routine (PMR's)
When readings are suspicious (mainly from process side)
After each intervention (repair) to a component of the feeder
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Calibration Documentation
Every Calibration has to be properly documented
There are three reasons:
Requirements from standards (ISO 900x)
Internal follow up for maintenance planning (drift trends, etc.)
Base for correction of plant reports
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Calibration Methods
Weigh feeders can be calibrated off- or on-line.
Off-line calibration methods include:
Taring (weigh feeders) or Zero Set (belt weighers)
Belt Speed Calibration (optional)
Weight Check
Material test with loss of weight method is the most accurate calibration
method because it uses known standards under actual operating conditions
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Program End:
Value tare N is stored as Parameter P 03.03
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Program End:
Value of Zero Set is stored as Parameter P 03.03
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Belt Index
Tachometer
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Scale Range
Cal. Weight
max. points of converter
Delta Weight
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weigh applied. The weight should not exceed the range of 2/3 to
4/3 of the nominal platform load.
Program End:
Span correction KOR is stored as Parameter P 03.06
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CW: xx.x%
Upon program end running message stops at 0%, the lower line
SOLL/IST: x.xx
shows the span correction KOR. If deviations exceeds 3%
CW: 0%
(KOR>1.03 or KOR<0.97), check set parameters and
KOR: x.xxxx
mechanical equipment.
Store value
Abort program.
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chain
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Load Cell
Material &
Belt Weight
Belt speed
Loss of Weight
Control
Module
Motor
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Control
Module
Calculation of Deviation
Bin = Reference
vs. Totalizer
Man. or autom. corr.
Correction if required
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Maintenance
The production person in the plant is the first line of defense against
breakdowns, since he is around the equipment all day and therefore knows it
best. He reports deficiencies using the proper channel and tools
(notifications). A check sheet with the important points to look at and the
description of the correct state is making his work easier.
To assure reliability of the weigh feeder regular planed maintenance tasks
(PMRs) are to be carried out. These routines are described in the
maintenance schedule. There are different sources for the elaboration:
Manufacturers recommendation
Experience from the plant personnel
Failure Mode and Effect Analysis (FMEA) study
The best structured approach is using the FMEA method
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Verify daily that the belt is tracking properly and that appropriate belt tension is
maintained
This interval can be lengthened if, over time, there is little deviation between
routine span calibrations.
and motor
environmental conditions
Check daily for material lodged between the skirting and belt
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Adjustment of Idlers
+ 1 mm
Adjusting
Bolts
Idlers around weigh bridge are to be aligned properly:
About 1 mm above the rest of the idlers/pulley
Forming a straight line within themselves
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0.9
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0
-0.1
-0.2
-0.3
10
20
30
40
50
60
Alignment Mistake 0 mm
Alignment Mistake +0.5mm
Alignment Mistake +1mm
70
80
90
100
110
Throughput
t/h
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tension is low.
Mechanical fastener are to be strictly avoided
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Method Description
Cold Vulcanisation is a gluing method, with liquid cold vulcanisers, or cold
glues
It is jointing the vulcanised or gelatinised rubber or PVC, with the belt material
Cold vulcanising fluids contain solvents which must be well vented prior to
The splicing must be of high quality, with no change of the belt thickness in
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Troubleshooting
Possible ways of identifying the reason for a
breakdown:
By Conjecture
By Systematic Testing of all the Components
By Tracing Back the Defect
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Conjecture
This is the strategy of TRIAL and ERROR.
In some cases, conjecture may rapidly reveal the cause
of a problem.
But generally this is a relatively unreliable approach to
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However this strategy is not easy as it requires a knowledge of the way each
component operates and the interactions between the different components.
Tracing Back is the recommended strategy for this type of problem solving.
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The weight or
The speed
- an incorrect WEIGHT or
- an incorrect SPEED.
What exactly do we mean by incorrect?
WEIGHT
SPEED
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Troubleshooting
In the case of the flow of a weigh feeder, there are two possible
cause of an incorrect signal:
Actual
flow of
material
FLOW
Output
signal at
the flow
indicator
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Troubleshooting
This can be formulated in rule no.3
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Troubleshooting
Where could the cause of breakdown be located if the SPEED indication
gives an incorrect value?
1. At the origin: motor speed incorrect, or
2. In the connections: the difference between the actual motor speed and the
speed indicated results from a problem in:
- the speed measuring circuit, or
FLOW = OK
WEIGHT
SPEED
Material Flow
Motor Speed
Mechanical Construction
Mechanical Connection
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Troubleshooting
With the tree-diagram of causes in mind, you can rapidly locate the circuit were the
problem lies.
The tree-diagram of causes
FLOW = OK
WEIGHT
SPEED
Material Flow
Motor Speed
Mechanical Construction
Mechanical Connection
To identify the defective component, all you have to do is apply the three rules in
the respective circuit.
Back to Main menu
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begins to accelerate.
The increase of motor speed makes the belt rotates faster,
extracting more material from the hopper thus increasing the flow.
The increase of motor speed also corresponds to an increase of
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As soon as the belt speed has stabilized to the new flow, the
displayed flow and the set point are identical. This marks the end of
an adjustment cycle which has permitted a flow increase.
Any new modification of the set point by the operator will start the
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