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Weightometers in industry

Weightometers in industry

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Very often, there are disputes between two departments, or between two business associates/units, where weights of product(s)is/are concerned. THESE NOTES ARE AIMED AT HELPING TO RESOLVE SUCH ACRIMONIOUS DISPUTES, WITHOUT THE NEED FOR CALLING IN AN INDEPENDENT REFEREE. The author has used them successfully in the past 35 years in the mining industry, with good mine to mill tonnage reconciliation. The efficacy of the effectiveness of these notes was tested at Suhar in Oman in 2007 where two neighbouring mining properties had a 5-year dispute on tonnages and were on the verge of protracted litigation. Having studied the points mentioned here, an amicable compromise was arrived at by both parties. The author is available to carry out a full audit of your industrial application(s) and make recommendations to improve upon the accuracy of the weighing devices. The knowledge garnered from there notes is cherished by plant operators, their boost in their self esteem is always palpable. T

Very often, there are disputes between two departments, or between two business associates/units, where weights of product(s)is/are concerned. THESE NOTES ARE AIMED AT HELPING TO RESOLVE SUCH ACRIMONIOUS DISPUTES, WITHOUT THE NEED FOR CALLING IN AN INDEPENDENT REFEREE. The author has used them successfully in the past 35 years in the mining industry, with good mine to mill tonnage reconciliation. The efficacy of the effectiveness of these notes was tested at Suhar in Oman in 2007 where two neighbouring mining properties had a 5-year dispute on tonnages and were on the verge of protracted litigation. Having studied the points mentioned here, an amicable compromise was arrived at by both parties. The author is available to carry out a full audit of your industrial application(s) and make recommendations to improve upon the accuracy of the weighing devices. The knowledge garnered from there notes is cherished by plant operators, their boost in their self esteem is always palpable. T

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Published by: Ramoutar (Ken) Seecharran on Aug 05, 2010
Copyright:Attribution Non-commercial

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09/17/2013

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 1
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Weightometer errors occur in two forms, namely; Random Errors and SystematicErrors.
1.
 
RANDOM ERRORS
 Also called “Non Repeatability” errors, is the name for the errors which areseen when the same measurement is repeated, over and over.SOURCES OF RANDOM ERRORSIn belt weighing, random errors come from “Influence Errors”, such as belttension, idler roll alignment and out of roundness, the general sensitivity of the belt scale’s weigh frame to alignment, temperature and belt tension.These factors move slowly around in circles so that over a year, a typicalhighly random belt scale may move around inside a few percentage range.Here is a list of a few fundamental sources of variability:a)
 
Weigh frame deflection and belt stiffnessb)
 
Weigh frame sensitivity to the position at which the calibration masses areappliedc)
 
Weigh frame friction, stiction and hysteresisd)
 
Belt tension, variability of belt tension caused by sticking gravity take up,or angle of wrap around the pickup pulleye)
 
Weigh frame initial alignment qualityf)
 
Uncontrolled spillage which is not zeroed off g)
 
Connection of the tachometer to the belt, skip, slip and bounceh)
 
Stability of pulley and idler diameters in the face of process material build-up.
2.
 
SYSTEMATIC ERRORS
This is the error that is always there. This error comes from:a.
 
The inherent randomness of the belt weigher itself, andb.
 
The difficulty of simulating a live load of material on the belt.The solution to this can only come from an appropriate combination of;
 
 Always taking multiple measurements to overcome the effect of randomness, or to verify repeatability
 
Going to greater extremes in simulating live loads of material forcalibration purposes.
 
 2 An “absolute” test of vertical alignment is to vary the belt tension andobserve the system zero. A PERFECT ALIGNMENT WILL RESULT IN NO APPRECIABLE CHANGE IN THE ZERO POINT.SOURCES OF SYSTEMATIC ERRORSConcave or convex curves near the weigh frame will cause belt lift or pulldown which will vary with load and belt tension.Installation too close to a feed point will have the material settling as ittransits the weightometer and causing errors due to material movement inthe vertical plane.Steering/tracking idlers within sometimes considerable distances (up to 20frames) can cause substantial error. They must be located a minimum of 11idler spaces either side of the scale-mounted idlers.Installation near the head end of a simple inclined conveyor will producemuch less accurate results than those nearer the tail end.
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1.
 
BELT TENSION: The scale must be installed in an area where the belttension and tensioning variations are minimal. For this reason, the scaleshould be installed near the tail section of the conveyor, but far enoughforward so as not to be influenced by the infeed skirt boards and verticalcomponent caused by feed segregation in the vertical plane.2.
 
BELT LOADING: It is desired that the belt loading be as uniform aspossible.3.
 
LOADING POINTS: On high accuracy installations, the conveyor should beloaded at one and the same point.4.
 
MATERIAL SLIPPAGE: Product speed must equal belt speed at the scale.The conveyor speed and slope should not exceed that at which materialslippage occurs.5.
 
CONVEX CURVES: Straight conveyors are preferred to curved conveyors.Corves are not recommended between loading point and the scale.Convex curves are permissible at a distance of 7 metres, or a minimum of 5 idler spaces, beyond the scale area idlers.6.
 
CONCAVE CURVES: The point of tangency on a concave curve must be atleast 13 metres beyond the scale. The scale must be installed on astraight line and the belt must be in contact with 8 idlers either side of thescale.7.
 
WIND LOADING: To minimise the effect of wind loading, a minimum of 7metres must be enclosed on either side of the scale.

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