Welcome to

12.04.16

Electrical Section Training

Scales
Scales are gravimetric devices.
In other words, they are devices that measure
the force that gravity exerts on mass.
Scales can be classified as two types:
Differential weighing devices
Integral weighing devices

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Differential Weighing Devices

Differential weighing devices are the most
common.
You begin at one weight on a scale and then
add or subtract weight to give you the
difference between the beginning and ending
reading.

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Electrical Section Training

Differential Weighing Devices

A truck scale starts at one reading, generally
zero, and then goes to a different weight
reading when you drive a truck onto the scale
platform.
The difference between the two readings is the
weight of the truck.
Truck scales, rail scales, platform scales,
package scales, postal scales, counting scales,
etc. all operate on this principle.

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Electrical Section Training

Differential Weighing Devices

Batching scales weigh ingredients into a weigh
hopper on a differential basis, one ingredient at a
time.
Bulk weighers weigh and dump into and out of a
bulk material weigh hopper to record the high
weight, the low weight, and the difference which is
the total weight transferred of bulk materials.
Loss-in-weight feeders use a feeding device to
empty a weigh hopper at a controlled rate using the
rate of change of weight (the differential weight
change) as the measuring element.
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Electrical Section Training

Integrating Weighing Devices

Integrating weighing devices are the second category of
scales.
Conveyor belt scales are integrating weighing devices
that use a simple integral calculus summation process
to measure a conveyed quantity of material.
Two variables are involved:
weight and speed.
A weight function measures the weight of a small section of
a conveyor.
The gross weight on the scale is the weight of the belt, the
belt conveyor idler and the material on the belt.
The net weight of material only is the gross weight less the
weight of the supported section of the belt and the scale
idler.
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Electrical Section Training

Integrating Weighing Devices

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The speed function is the second variable to be measured.

Most modern speed sensors are rotary digital pulse
generators. These can be optical, magnetic or other on/off
sensing units. They are mounted on a pulley or wheel that
rotates as the belt moves. They generate an on/off signal
as they move which is directly proportional to the distance
the belt moves and the speed of the belt.

Electrical Section Training

Integrating Weighing Devices

Formulas used for commonly displayed Data:

Total weight = Weight / unit distance x distance
Rate = Change of total weight / Time
Belt Speed = Distance / Time

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Electrical Section Training

Types of Belt Scale Weighing Technologies

Many different types of weighing technologies have
been used over the years for conveyor belt scales.
The first belt scales used mechanical integrators.
The speed of the belt drives a disk. A ball or another disk
rolls on this disk at right angles to the speed disk. The
position of the ball or second disk is controlled by the
weight on the scale. If the ball is in the center of the speed
disk, it does not rotate at all. As the ball is moved to the
outside, it rotates faster and faster. The speed of the ball
is a mechanical multiple of the speed of disk and the
position of the ball on the disk. The ball is connected to a
shaft that drives a totalizer. The speed of this shaft is the
rate.
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Electrical Section Training

Types of Belt Scale Weighing Technologies

Another method of determining the load on a
conveyor belt was to use a nuclear source on
one side of the belt and a detector on the other
side.
The more material that is on the belt, the less
radiation is detected. You get an inversely
proportional signal of absorbing mass on the
belt. Using this along with belt speed you could
make a belt scale. These were never very wide
spread in actual use.

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Electrical Section Training

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Types of Belt Scale Weighing Technologies

LVDTs (linear variable differential transformers)
are position sensing devices that have been used
in conjunction with spring mechanisms to measure
belt weight.
They are non-contacting sensors and generally have
spring mechanisms that are rugged in nature which
gives them very good overload characteristics. On
the down side, they can exhibit problems with
thermal effects on the mechanical springs. These
effects can be both on zero because of thermal
expansion and on the span due to modulus of
elasticity changes.

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Electrical Section Training

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Types of Belt Scale Weighing Technologies

Strain gage load cells are commonly used in scales
today.
Many have been adapted to mechanical lever scales
using a lever system to sum forces at a single point
where a load cell is used to read the resultant force
electronically at this point. These scales were
common for retrofit installations on truck scales for
example. Also, strain gage load cells were initially
very expensive and limited to in-line tension and
compression forces. This made mechanical hybrid
load cell mechanisms popular. Some belt scales are
made with this technology today, but their use is
declining.

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Electrical Section Training

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Types of Belt Scale Weighing Technologies

Today, most scales are full strain gage suspension
types. They use little or no mechanical mechanisms
and the load platform is directly supported by the
load cell system.
Most new conveyor belt scales use this technology.
Overload stops are built into the load cell mounting
systems to make them rugged and reliable. Also, they
are simple in their overall design. Single point
suspension load cell designs allow for off-center
loading. This also compensates for any extraneous
side loading that could effect the true weight
component of the belt load forces that we are
measuring.
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Electrical Section Training

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Types of Belt Scale Weighing Technologies

There are advantages and disadvantages when
considering conveyor belt scales.
As an integrating device, a conveyor belt scale is a
very compact device that fits into a conveying
system. The scale handles large quantities of raw
materials on a continuous basis. It does not require
large batch hoppers, truck scales or rail scales. It
can handle rates that make the application of
differential scales almost impractical. Loading and
unloading ships is one example.

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Electrical Section Training

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Types of Belt Scale Weighing Technologies

Belt scales have their weak points.
First, belt scales can run for extended periods of time without
returning to zero.
This means that any buildup on the scale that affects the zero
will not be detected until the scale is run empty.
A zero error is not a one-time error. This error is continuously
added along with the weight of actual material.
Also, extraneous forces such as wind loading, changing belt
tension, excessive vibration, and mechanical interference with
the scale can cause errors in the weighing system.
The scale does not know the difference between the forces from
actual material we are trying to weigh and the forces from
external noise.
Although this is true of all scales, the ratio of signal to noise is
much better on differential weighing devices than on integrating
devices. Integrating belt scales are weighing a small portion of
weight on a continuous basis and external noise can be
significant. Care must be taken to correctly install a belt scale
and to protect it from external influences
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Electrical Section Training

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Free Fall Bulk Flow Meter

During "free fall", a non-contacting mass flow
measurement can be performed at the delivery end
of conveyor systems such as vibrating conveyors,
screw conveyors, rotary dischargers, chain
conveyors and conveyor belts. The material is
irradiated during its "free fall" to determine the
weight per area.
The material flow in tons / hour is calculated from
the product of weight per area and material speed.

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Electrical Section Training

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Loss-in-Weight Feeder for highly precise, continuous processes

Loss-in-Weight Feeders are continuously weight

controlled hopper combined with a volumetric feeder.
They generate a controlled, absolutely constant mass
flow, as required in mixing processes, for example.
For the refill of the weigh feeders - co-ordinated
systems feeder such as pneumatic conveyors or
volumetric feeders.

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Electrical Section Training

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Basic Operating Principle of weighing

Weighing instrument
A measuring instrument
that serves to determine
the mass of a load by
using the action of
gravity.
According to its method
of operation, a weighing
instrument is classified
as automatic or nonautomatic.

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Electrical Section Training

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Basic Operating Principle of weighing

Automatic weighing instrument
An instrument that weighs without the intervention of
an operator and follows a predetermined program of
automatic processes characteristic of the instrument.

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Electrical Section Training

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Basic Operating Principle of weighing

Control method
The method used to determine the mass of the
product used as the test load during material
tests. This will generally involve the use of a
weighing instrument, referred to as the control
instrument.

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Electrical Section Training

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Basic Operating Principle of weighing

Control method
The method used to determine the mass of the
product used as the test load during material
tests. This will generally involve the use of a
weighing instrument, referred to as the control
instrument.

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Electrical Section Training

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Basic Operating Principle of weighing

Control method

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Electrical Section Training

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Weigh Feeder?

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Electrical Section Training

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Types of weighing system

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Electrical Section Training

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Types of weighing control system

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Electrical Section Training

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Overview Feeding

1. Volumetric Feeders

2. Gravimetric Feeders

1. Volumetric Feeders
High accuracy feeder
Screw
Belt feeder
Rotary value

Increasing
accuracy

Bin Discharger
Gravity feeder

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Electrical Section Training

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Base for efficient and accurate feeding

A carefully designed volumetric feeder
with agitator, homogeniser and large
entry section to ensure:

a continuous product flow

and
a constant bulk density
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Electrical Section Training

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Selection criteria for feeding mode

(m m soll )
100%
Relative feeding error S D [%]
(m setpoint )
m soll
soll

Recommended values:
Sample interval
Sample number
Sampling time

t = 1 min
n = 30
ttotal= 30 min

(Definition by NAMUR NA 40)

feeding accuracy achievable

volumetric feeding > 1%
gravimetric < 1%

depending on the

product characteristics
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Electrical Section Training

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Limits of the volumetric feeding

LH

3
1 > 2 > 3

2
1

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Bulk density
changes in function
of the product level
(head effect)
( = f (h))

LL

Other influences:
Variation of the bulk density
Non-constant filling degree of
the screw
Electrical Section Training

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Robust, precise volumetric feeder layout is mandatory

for an advanced volumetric feeder
Agitator-Drive*
Inlet
Vent Spigot
Hopper
Agitator

*Geared AC motors

Feeder GLD 87
Screw-Drive*
Intromitter-Drive*
Intromitter
Feeding Tube
Screw/Helix
Outlet Tube

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Electrical Section Training

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2. Gravimetric Feeder

High precision, robust,

reliable and durable construction
were the main objectives for the
development of the Gericke
gravimetric Feeders DIW-KE, 50,
200 and DIW-E

Principle of continuous gravimetric feeders

refilling valve

m
t

const.

80%

feed rate

20%

load cell
rpm

control
value

frequency
inverter

Refilling capacity
approx. 10 x feeding capacity

external setpoint
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Electrical Section Training

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Tare-compensated mechanic allows the use of heavy duty

AC-Drives and gearboxes in a weight feeder (no Tara weight)

= Only the bulk material

inside the feeder & hopper is
measured by the load cell

Force transmission
spring

Volumetric
feeder

Mechanical
overload
protection

Oil damper

Parallelogram
weighing frame

Vibrations and disturbances

are MECHANICALLY damped
BEFORE they reach the load cell
or the EASYDOS controller input

Load cell
Tare-compensatingspring
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Electrical Section Training

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EASYDOS Plug & Dose

Pre-wired and ready to start!

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Motor
Frequency converter
Load cell
Regulator
Contractors
Terminal strips
Input/Output
terminal
Electrical Section Training

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EASYDOS Controller Highlights

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Only one standard load cell, which is mechanically protected

against destruction (overload) and vibration (oil damper)
Stand alone system. Operation and display on the scale as
standard equipment. No additional service panel or control
system required
High accuracy achieved by TrendTech feedrate calculation
algorithm.
Automatic calculation of bulk density and head effect
compensation. No additional actions or inputs necessary.
Self optimising feeding by permanently updated profiles, 50
different products with separate profiles
Easy operating. EASYDOS-Controller menus available in
English, French, German, Spanish, Italian, Dutch
Easy linked to common field busses such as:
ModBus, ProfiBus DP, Device Net, Ethernet etc.
Executions for ATEX Zone 1, 2, 21, 22 available
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Belt weigher
Belt weighers permit a continuous weighing of bulk
materials. The bulk material running over the belt is
weighed on a defined measuring section. In the
controller the feed rate is then calculated and
regulated. In feeding mode the belt speed regulated
to provide consistent feed rate. In measuring mode
the belt speed is constant and the mass flow is
measured. The accuracy particularly depends on the
calm tape operation and on as consistent material
allocation as possible.

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Electrical Section Training

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Belt weigher

FrequencyInverter

M
Measuring section

Motor speed
Actualvalue

EASYDOS EB-1

CPU

Setpoint

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Electrical Section Training

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Differences between Batch and loss-in-weight

EB-1 Batch controller
Small quantities can be dosed
e.g. 100 g from 20 kg balance
If there is not enough product
in the hopper it is refilled first
-> no continuous mass flow
Volumetric mass flow (fast and
trickle speed)
Up to 16 ingredients, 99
recipes, two sequences
Fast and trickle speed
Interruption and continuation
of the batches possible.

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EL-1 loss-in-weight controller

Batch size min. 20 % of the
max. scale weight,
recommended proportion max.
scale weight/min. feedrate
max. 1:10
Feeding during the refill - > nobreak 1000 kg batches with a
20 kg balance possible
Controlled mass flow
One ingredient
No trickle speed
Only abort of the Batches
possible

Electrical Section Training

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Accuracy of continuous feeding

Weight m

How is the regularity of a continuous mass flow

to be determined?
m

m have to be the same

t

All
t

m
t
Feeding time

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Electrical Section Training

t
40

THE END

THANK YOU