Page 1

Managing your Belt Weigher Fleet

„ Establishing that your Belt Weighing
equipment is fit for purpose.
„ Common Belt Weigher accuracy
problems. (& The special problem
represented by Stockpile figures
figures.))
„ Effective Belt Weigher Maintenance.
„ Testing and Auditing Belt Weighers
 Page 2

Is the equipment Fit for Purpose ?

„ Process Control,, 1% or 5% might
g be OK,,
but the equipment should be stable.
„ Unstable Equipment is a maintenance and
downtime cost.
„ Product Reconciliation,
Reconciliation 00.25%
25% or better,
better
only the best will do.
„ Stockpile Figures are a constant accuracy issue.
 Page 3

Is the equipment Fit for Purpose ?

„ When performance
Wh f does
d not meet
expectation, the reasons can be;
„ Weigh Frames that are unstable and affected by
belt tension.
„ Poor Choice of Location, High belt tensions,
Long Conveyors.
„ Tachometer Systems that are unstable.
„ Zero Error, which can turn a 0.25% belt weigher
into a 5% weigher.
„ Shoddy Calibration References and poor
calibration/maintenance
lib i / i practices.
i
 Page 4

Weigh Frame Considerations

„ Fully
ll Suspended
d d type are usually
ll the
h better
b
performer. Fully Suspended designs are
sensitive only to loads perpendicular to the
conveyor belt and are insensitive to roll
turning
g moment.
 Page 5

Fully Suspended Weigh Frame

• Some Examples of Fully Suspended Designs

CST PFS4-4

Ramsey
10-14

Schenck BMP

CST PCS2-2
 Page 6

Weigh Frame Performance

„ Factors Affecting
ff Accuracy
 Page 7

Weigh Frame Error Sources

„ Belt Tension, the Higher and More variable, the worse is
the performance.
„ Longer Weigh Lengths support more of the material we
wantt tto weigh
i h and
d see lless b
belt
lt tension.
t i
„ Good idler Alignment is important to stable weigh frame
performance.
f
„ Weigh Frames which are rugged and do not deflect
much do not go out of alignment under load.
load Conveyor
Stringers should also be robust and well supported
„ Longer idler spacing works better than narrow idler
spacing. Artificially reduced spacing should not be used
and negates the advantage of multiple idlers.
 Page 8

Conveyor Requirements
„ To perform correctly a belt weigher requires:
„ A straight length of conveyor typically 10 times longer
than the weigh length, and 10 sets from skirts,
samplers, magnets and the like.
„ Belt tension control, usually achieved with a gravity
take up device.
„ The material should stay fixed on the conveyor. Sliding
or rolling
lli material
i l cannot be
b weighed
i h d accurately.
l
„ Accurate alignment of weigh idlers and two fixed idler
sets
t each h side
id off the
th weigh
i h frame.
f A gradual
d l ramp
down from the weigh zone over at least 5 idler sets is
desirable.
desirable
 Page 9

W i h Frame
Weigh F Accuracy
A Estimates
E ti t
Weigh Frame Accuracy Four Idl
F Idler F
Fully
ll T Idler
Two Idl Si l Idl
Single Idler
Estimates.
Suspended

Extreme Belt tension 5 0%

5.0% 10 0%
10.0% 20 0%
20.0%
Length > 1000m
Location Near Head
Multiple or moving feed
High Belt Tension 2.0% 5.0% 10.0%
Length > 300m High Lift,
location mid conveyor

Medium Belt Tension 0.5% 1.0% 5.0%

Length>200m
Location mid conveyor

Low Belt Tension 0.25% 0.5% 2.0%

Length<100m
Tail Location
 Page 10

Weigh Frame Calibration

„ Static Masses simulate a conveyor
loading,
g, units kg/m
g/
 Page 11

Weigh Frame Calibration Systems

SIP Masses

Hand Masses

Calibration Chain
 Page 12

Static Weight Calibration

„ Best to apply 100% of full scale mass to Weigh
Frame
„ Using a small percentage of full scale static mass can
lead to extrapolation error.
„ Factors which affect the precision of the result are;
„ Is the System
y a Single
g Point or can it be applied
pp in steps
p to
check linearity?
„ Can the mass be easily applied several times to check
repeatability?
 Page 13

C lib ti Chain
Calibration Ch i
„ S u a es a fixed
Simulates ed kg/m
g/ oof be
belt loading,
oad g, usually
usua y
around 70% of full capacity
„ Must extend beyond the weight sensitive zone
„ Are used with the belt running
„ Are used over complete belt revolutions as are
static masses
„ Are a single point load, represent maintenance
and OHS issues.
 Page 14

Calibration with <100% Mass

Best
Accuracy Loss of
Calibration Calibration
Ca b at o
Precision

Low
Accuracy
Calibration

20% 100%
 Page 15

The value of a Linearity test

1. Single 100%
Calibrtaion point
Response can be
Non-Linear due to
2. Any Calibration
2 jambing of weigh
Error is obvious at f
frame or possible
ibl
50% of full scale electronics range
issues.

50% 100%
 Page 16

Errors from Weigh Frame Calibration

Weigh Frame Single Application of Multiple hand weights Multiple Stored In
Calibration Methods Single Point Load or Place, Conveniently
Calibration Chain Applied Calibration
M
Masses
30% of Full Scale 0.5% 0.4% 0.3%

70% of Full Scale 0.3% 0.2% 0.15%

100% of Full Scale 0 2%

0.2% 0 1%
0.1% 0 1%
0.1%
 Page 17

Tachometer
„ Tachometer – A Length measuring device
„ The length
g measurement device,, commonlyy called
the tachometer, is attached to a relatively large
diameter pulley in contact with the clean side of
the conveyor belt
belt.
„ The tachometer produces a digital electronic
pulse, each pulse represents a calibrated length of
conveyor belt which has passed over the weigh
frame.
„ The tachometer is usually calibrated in meters per
pulse (m/pulse).
 Page 18

Tachometer Calibration
 Page 19

S
Some E
Examples
l off Tachometers
T h t

Ramsey, Prox Type Schenck Standard

CST Spiral Pulley

Shaft Driven on CST
 Page 20

Tachometer Accuracy Estimates

Tachometer Good Tachometer Medium Poor tachometer
tachometer,
Diameter >= 600mm tachometer Diameter <=100mm
Accuracy 180 Degree Angle of Tangential contact
Dia 200-300mm
Estimates Wrap Contact 5Deg to
tangential
i l

Calibrate by 0.5% 1.0% 2.0%

Pulley
Measurement
alone

Calibrate by 0.1% 0.2% 0.5%

Measuring the belt
l
length
h andd
capturing the pulses
in one belt
revolution
 Page 21

Belt Weigher System Schematic

Electronics
WIM (Weigher Interface Module)
LCD and
Keypad

CPU
Electrical (Central Processor Unit)
Junction Box

AI1 Tachometer
AIO2
AIO3
Analogue
AO4
and Digital
Load

Load

WEIGH In/Outputs DIO1

dcells

dcells

FRAME DIO2
DIO3
DIO4
Proximity Sensor

DIO5
 Page 22

Zero Concepts
„ Manual / Auto Zero process
Old zero set point (too high)
Exactly one belt revolution
+ + + + +

- - -
Error - New zero set point -
(Sum of + and – weights) (avg. of + and – weights)

„ Auto Zero Tracking

g If outside of limit
alarm is raised and
Zero Tracking timer One Revolution new zero is not set.
MATERIAL Zero tracking window
+
+%
ZT limit

Zero set point of -

last zero process
New Zero constant
-∞
if inside limits
 Page 23

The Accuracy Sum, ‘0.5%’ System

Error Source Best Case Worst
Case?
Zero Error -0.1%
0.1% 3.0%
Dead Weight Repeatability, manifesting as 0.1% 0.5%
systematic error
Live load to Dead Load Error, systematic 0.5% 4.0%
error
Live Load repeatability, random error -0.1% 1.0%
Tachometry Error, systematic error 0.1% 0.3%
Idler Roll Buildup and alignment Error 0.0% 1.0%

Total Error 0.5% 9.8%

 Page 24

D to D
Day Day A
Accuracy Issues
I
„ Large errors of consistent size
size, 5%
to 10% (Alignment)
„ Smaller errors, spoiling 0.25%
performance (Calibration system)
„ Zero Stability Error
„ Idler roll problems
„ PLC Connection
 Page 25

Large Errors, Alignment Problem

„ When everything else has
been checked and
verified, its always
alignment that causes the
large errors.
„ A 3mm alignment error
can be 6% error.
error
 Page 26

S ll Errors,
Small E Check
Ch k Clearances
Cl

„ SIP Calibration
Masses, check the
chain supports,
they need to be
fully off when off
and fully on when
on.
 Page 27

Zero Stability and buildup

„ 'Normal'
Normal buildup can be
taken care of by Zero
Tracking, but there must
be an opportunity.
„ Water sitting over the
weigh frame will give a
false zero adjustment
adjustment.
„ Buildup on rolls affects
zero andd geometry with h
large errors as a result.
 Page 28

PLC Connection Errors

„ Mismatch, belt weigher display to Citect

(DCS) screen can rob performance.
„ Use built in test routines
routines. Stretch pulses so
PLC scan matches, test PLC ability to count
pulses.
l PLC Scan 70ms

Pulse would need to be 100mS

 Page 29

Stockpile Accuracy
„ Errors in and out of stockpiles add and
accumulate,, Error will include belt weigher
g
error and moisture content changes.
„ All the error on all the incoming material
adds to stockpile error
„ All the error on all the outgoing material
adds to stockpile error
„ Stockpiles contain the sum of the errors
 Page 30

Stockpile contains Sum of Errors

 Page 31

Effective Belt Weigher Maintenance

„ Weigh Frame
„ Maintenance of Idler Alignment (annual)
„ Idler Roll condition and significance (bi-annual
changeout)
„ Calibration checks,
checks frequency and need
„ Maintenance of a good working zero
„ Tachometer
„ Reasonable Maintenance, good and bad practice
„ Electronics System
y
„ Checking frequency and reliability of Load Cells
and Electronic weighing systems.
 Page 32

Maintenance of
Weigh Frame Calibration
„ Maintenance of a good working zero
„ Significant zero errors of almost any size
can easily occur and can make a 0.25%
b l weigher
belt i h into
i a 5%% system.
„ Most belt weighers use Automatic Zero
Tracking
k to adjust
d the
h zero iff and
d when
h theh
belt runs empty, however, these systems
need to be carefully set up to avoid being
tricked by trickle flow of material or water.
 Page 33

Tachometer Maintenance
„ In most cases, checks at three month or six
month intervals will adequately account for
pulley wear.
„ If a conveyor belt is changed
changed, tachometer re-
calibration is advisable, but may not be as
significant as first thought because the pulley
is the ‘calibrated’ part.
„ If a pulley
ll used d as a tachometer
t h t isi changed,
h d
the tachometer must be re-calibrated.
 Page 34

Electronics System Maintenance

„ Checking frequency and reliability of Load
C ll and
Cells d Electronic
El t i weighing
i hi systems.
t
„ Modern electronic weighing systems do not show
appreciable
i bl drift
d if and
d do
d not need d regular
l re-
calibration. (We have seen 0.1% repeatability over
5 years – but weigh frame must be good)
„ Mounting electronics sets inside MCCs rather than
in harsh outdoor conditions can significantly
extend their life.
 Page 35

Maintenance Regimes
„ Day to Day Maintenance
„ There is a need for a specialist on most
large sites to keep a regular check on the
b l weighers.
belt i h
„ The Zero of the system should be checked
d l at the
daily h electronics
l display.
d l
„ Any alarms generated on the electronics
screen must be acknowledged and acted
upon.
 Page 36

Maintenance Regimes
„ Three Monthly Calibration Check
„ All setup data as found should be recorded.
„ The tachometer sub-system should be checked at
least by observing that the correct belt speed is
displayed.
„ Aft zero checking,
After h ki the
th span off the
th system
t should
h ld
be checked by applying at least 50% and 100%
calibration mass.
mass Re
Re-span
span only if there is a
credible reason, otherwise declare faulty.
„ Record all setup data as left.
 Page 37

Maintenance Regimes
„ Annual Belt Weigher Maintenance Check
„ Lift belt, check and remedy idler alignment
if required. Replace Rolls as appropriate.
Record d alignment
li observations.
b i
„ Measure the conveyor belt length and the
weigh h length.
l h Carry out full
f ll tachometer
h
calibration procedure.
„ Carry out three monthly calibration
procedure.
 Page 38

M i t i i Knowledge
Maintaining K l d Resouces
R
„ Installation and Replacement
„ At engineering level, the manufacturer can
provide expert assistance.
„ Repair and Regular Maintenance
„ Avoid 'Knowledge Dropout', Use factory
trained specialists for maintenance
maintenance.
„ Day to Day maintenance
„ Training of site electricians or instrument
specialists by factory specialists will save
un-necessary down time.
 Page 39

Testing and Auditing

„ An outside
A t id perspective
ti is
i necessary to
t avoidid
operational and maintenance blind spots or in-
appropriate
i t maintenance
i t culture.
lt
„ Live Load testing is sometimes the only way to
establish confidence. (CST has a portable truck
weigh bridge for this purpose.)
„ It is necessary to bring a belt weigher up to its
full potential before addressing deeper problems
such as live load/dead load discrepancy. This is
part of a belt weigher audit
audit.
 Page 40

Ian Burrell
Managing Director
Control Systems Technology Pty Ltd
37 Stanley St
Peakhurst, NSW, 2210
Mobile: 0419 292 604
Work Direct: 02 9584 4507
iburrell@controlsystems.com.au
www controlsystems com au
www.controlsystems.com.au

Ian Burrell has worked in the design, installation, maintenance and

troubleshooting of belt scales for more than 30 years.
years Ian started Control
Systems Technology Pty Ltd in 1984, the companies products are now
popular in Australia and are exported to many overseas economies. CST
equipment is trade certified to 0.25% in Australia, to 0.1% in Canada, to
0.25% in the USA and has an OIML Class 0.5 Certificate for Europe –
0.25%. Control Systems Technology Pty Ltd supplies and maintains belt
weighers throughout Australia. They have offices in Sydney, Mackay and
Perth.