Weigh Feeder Training Module

Manufacturing Workforce Training
HGRS MASTER - MAINTENANCE

Training Module:
Weigh Feeders
Presentation:
Weigh Feeder Training Module.ppt
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
Holcim Group Support
Weigh Feeder
7.3.2003
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
Taring and Zero Setting

Weight Check Calibration (Test Weights)
Material test
Maintenance
Maintenance
Training of Belt
Changing of Belt
Belt Splicing
Troubleshooting
Overview
Tracing Back the Defect
Set Point Increase System Reaction
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Function of a Weigh Feeder

Weigh feeders are designed to deliver a designated rate of material
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
spillages, leakages, and dust emissions
Back to Main menu
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Operating Principle of a Weigh Feeder
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.
The weighbridge is limited by two carrying idlers. By means of a centrally

positioned weigher idler and a lever system, the load on the platform exerts a
force, platform LOAD, on a load cell. The output voltage of the load cell is
proportional to the platform load and is transformed into digital information
though an AD converter.
The speed and load of the belt

and material determines the flow.
Basic Formula:
SPEED
LOAD
FLOW
In all cases: This is the first control

function of the flow.
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Operating Principle of a Weigh Feeder

In short:
The material flows from the hopper onto the moving belt, and over
the weigh bridge

The material on the belt exerts a load on the weigh bridge (limited
by two idlers)
The output signals of the weigh bridge and the belt speed is
converted into a flow and compared to a preset value

Through a feedback loop to the motor drive of the belt, the speed is
adjusted to achieve the desired flow

Changes in its thickness and shape may reveal the presence of
problems in the material flow up-line from the belt
Back to Main menu
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Applications in the Plant

Raw Mill Feed
Cement Mill Feed
Coal Mill Feed

Coal Feed
AFR Dosing
Kiln Feed (seldom)
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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
storage and the proportional feeder. It absorbs large flow

fluctuations from preceding equipment.
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Manual Control Gate

Function:
It defines the initial setting of the bed height to be in the operating
range of the load cell.

This is simply a thick steel plate positioned and fixed with bolts. By
adjusting the gate position, changes to the height of the material
bed on the belt is possible. The gate is set during the initial
calibration of the weighing device and is fixed once the optimum
height has been determined. The height of material bed determines
also the operating speed range of the weigh feeder Some weigh
feeders do not have a control gate!
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Side Skirts
Function:
Side skirts contain the material within the belt width, avoiding
spillages to the sides
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
the correct functioning of the load cell.
They must be removed after calibration !!!!!!!!
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Idlers and Idler Support

Function:
The weigh feeder belt moves on a series of idlers. The idlers
around the load cell must be fixed with precision supports

Some idlers are mounted on a frame supported by the weighing
mechanism on the load cell
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Mechanical Drive Parts

Function:
The drive is the mechanical link between the variable speed motor
and the driving pulley

It consists of a:
Coupling and a
Reducer or Chain Drive
Any mechanical problem will obviously disturb the operation of the

weighing device
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Driving Pulley
Function:
The drive pulley provides the force to move the belt. It is driven by a
variable speed motor via a reducer or a chain
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Belt Cleaning Device

Function:
The belt cleaners ensure that material does not build up on the belt
and alter the calibration

The cleanliness of the area is highly depended of the proper
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
the load cell

It forces the belt to remain centered on the pulleys (sometimes
guiding idlers or limit idlers are additionally fitted on the sides)
The device normally consists

of a tensioning screw on
each side of the tail pulley
Back to Main menu
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Electrical Components of a Weigh Feeder

DRIVING MOTOR
CIRCUIT
WEIGH MEASURING CIRCUIT

(LOAD MEASURE & AMPLIFIER)
FLOW CONTROL CIRCUIT

(FLOW MEASURING CIRCUIT)
SPEED MEASURING CIRCUIT

(SPEED MEASURE)
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Weight Measuring Circuit

Some idlers are supported by a weighing mechanism on a load
cell. The latter transforms the load pressure into an electric signal.
The small signal of the load cell must be amplified before it can be
used for the speed control and accordingly for flow control.
The circuit consists of:

Load Cell Power Supply
Load Cell
Belt Load Indicator
Weight Amplifier
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Electrical Feed of the Load Cell Power Supply

Function:
It supplies the appropriate power to the d.c. load cell. It transforms
the network voltage (220Vac) into a 30V d.c. or a.c. depending on

the rectifier cell of the load cell
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DC supply of the Load Cell

Function:
It stabilizes the voltage feed to the load cell. When the power
supply is an alternating voltage (30vac), the signal goes through a

rectifier cell before being stabilized
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Load Cell
Function:
The load cell converts the weight measurement from the belt into a
proportional electric current

Principle:
The stabilized voltage 15V is applied to a Wheatstone bridge. The
resistance varies linearly with the load applied on the load cell. If no
load is applied, the voltage difference between the middle points of
the two branches fed in parallel is zero. If load is applied, a voltage
proportional to the load is generated.
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Swing chord load cells (new development)

Almost no deflection under load (<0.05mm)
High resolution
Fast stabilizing
No hysteresis
Insensitive towards vibration
This system is not recommended by Holcim
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Belt Load Indicator

Function:
It indicates the weight measured (conversion of the 0-6 V signal to
a scale expressed from 0 100%; could be kg/m)
Often not available

in older systems
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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
Back to Main menu
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In order to control the belt speed it must first be measured. A
tachometer is connected to the driven pulley. The former produces
an electric signal. The tachometer signal must be transformed and
amplified for use.
Tachometer (Revolution Counter)

Speed Signal Amplifier
Belt Speed Indicator
Belt Index Indicator (Optional)
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Tachometer (Revolution Counter)

Function
Remark: In latest developments the speed is

directly taken from the VSD (Variable Speed Drive)
The tachometer is a motor-coupled device that generates a voltage
between its terminals proportional to the rotation of the motor
Two systems are generally used:

1st case the tachometer generator which generates a direct voltage
2nd case the rotation controller generates pulse signals, proportional to
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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Speed Signal Amplifier

Function:
It converts the speed measuring signal to the input range of the
multiplier used for calculating the flow

Generally, this is an attenuator since the speed measuring signal
can reach 40 V while the input signal of the multiplier cannot
exceed 6 V
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Belt Speed Indicator

Function:
It displays the belt speed by converting the input signal 06V to a
0100% scale (could be m/s)

Two standard signals are available, Belt Load & Belt Speed, their product
gives the FLOW. This multiplication is carried out in the flow measuring
circuit
Often not available

in older systems
Back to Main menu
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Belt Index Indicator (Optional)

Function
A mark (belt index) is attached to the belt in one position. The belt
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 Speed Calibration

Slip Warning for belt
Segmental taring of belt
Belt Index
Indicator
Belt
Index
Tachometer
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Flow Control Circuit

Two signals are available, BELT LOAD and BELT SPEED. Their product
gives the FLOW and is displayed as the effective flow. This multiplication is
carried out in the flow measuring circuit. The effective flow is compared to
the set point. If the former is lower than the set point, the flow measuring
circuit sends a signal to increase the belt speed and vice versa.
Integrator
Flow Totalizer
Multiplier
Instantaneous Flow Indicator
Set Point Indicator
Controller Comparator
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Integrator
Function
The integrator converts the voltage signal from the weigh amplifier
into a pulse signal with a frequency proportional to it

The integration function is done by the totalizer !!!
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Flow Totalizer
Function:
The flow totalizer counts the pulse coming from the frequency
converter (integrator) to give a total weight indication of material

supplied by the weighing device since resetting
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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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Instantaneous Flow Indicator

Function:
It allows the visualization of instantaneous flow by converting the
output signal of the multiplier (0-6 V) to a scale of 0-100% (could be

kg/s)
Often not available

in older systems
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Set Point Indicator

Function
Adjusting a set point in the controller-comparator will change the
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
Back to Main menu
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Driving Motor Circuit

The signal coming from the flow measuring circuit is
used to modulate the belt speed according to the set
flow. The driving motor circuit transforms the electric
signal coming from the flow measuring circuit into
mechanical action.
Belt Driving Motor
Ampere Meter
Power Supply
Command Module of the Motor
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Belt Driving Motor

Function
It is the driving force for the belt
It is either a VSD (Variable Speed Drive) or in older applications a

DC (Direct Current) Motor.
The direct current motor was especially adapted as variable speed
motor by acting on the induced voltage.
Example of characteristics
of a DC Motor
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Ampere Meter (Intensity):

DC Motor example!
Function
The ampere meter is a digital or dial-type indicating instrument for
displaying the current drawn by the induced coil of the direct

current motor that drives the belt
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Power Supply
Function
It supplies the motor command module with alternating current
DC Motor example! In case of a VSD it is integrated in the motor

command module
Depending upon the DC motor power, the alternating voltage that
will be rectified by the thyristor control module to supply the variable
induced voltage, will be greater than or equal to the voltage that will
be rectified by the diode bridge to supply the induced voltage
(constant)
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Command Module of the Motor

Function
The command module supplies an adequate electric feed to the
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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Weigh Feeder Control with PCS

There is a tendency within Holcim to integrate the
controlling functions of a weigh feeder into the plant
control system (PCS)
Main reason to use own PCS system
Known technology
No spare parts available from original supplier
No local service from supplier
Better visualization
Better alarming
Plant PCS concept can be applied
Most plants using PCS integrated weigh feeder control

have either good own PCS knowledge or a good local
engineer.
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Weigh Feeder Control with PCS

Weigh Feeder - a Variable Speed Drive Belt Conveyor with
Weight Measurement
Belt index
Weight
Setpoint,
Speed
PCS
Process Control
System
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Requirements for the PCS

Any modern PCS can perform a weigh feeder control.
30 years ago the suppliers used the PI controller of the DC drive

the multiplication was performed using the load cell signal
instead of the speed feedback - supplier measurement
guarantee: 1% accuracy
Standard Software can be used for PID, VSD, integration, alarming
and visualization.
Special Software is required for calibration
In most applications the calibration can be performed from the

central control panel (no local panel required). Calibration
generally is no longer an issue (performed every 6 month).
Further information in Holspace under Engineering Services / CoP Process

Control & Electrical
Back to Main menu
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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
Preparation for Calibration:

The mechanical installation must be free of vibration
Proper dedusting has to be assured
If a bypass device is installed it needs to be free of leaks
A calibration task is a measurement of the respective parameters; Only if

the difference to the last measurement is too large the new parameters
should be used for further operation (change calibration parameters)
Stability is therefore the most important factor

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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
The documentation can

be a page including all the
necessary details and
stored in a respective folder
or
it can be a data base (for several feeders)
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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
Static test weights

Test chains
Material test (if weigh out method is applied)
On-line calibration is:

Material test (if loss of weight method is applied)
Material test with loss of weight method is the most accurate calibration
method because it uses known standards under actual operating conditions
Back to Main menu
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Calibration Taring (recommended for weigh feeder)

With taring the dynamic reference is set. It is carried out with an
empty but turning belt.
If a belt index indicator is used (as in modern equipments), the
taring can be conditional to the belt position. With this it allows for
differences in the belt segment weight due to:
Initial discrepancies in the belt weight

Uneven wear of the belt
Splices
Other influences
All this can be then electronically compensated. The same

calibration run might also be used for the belt speed calibration.
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The following procedure is a typical example for a commonly used
weigh feeder type:
The acquired value is stored as tare N and deducted from gross value in
normal mode. Program run time is set with Parameter P 02.01
Start-up and Operating Conditions:

Weigher ON (local mode),
Volumetric Mode
No Material on belt.
Program End:
Value tare N is stored as Parameter P 03.03
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Program Sequence
FUNCTION
Display in sub-function distributor
TW: TARE
Start program.
Running display showing residual run time of program
TW: xx.x%
Tara: x.xx%
Abw: x.xx%
Tara: x.xx%
[% total time] and deviation from zero point [%qNENN]

End display showing tare correction N [%qNENN] and
the deviation from previous value [%qNENN].
Store value
Abort program.
Automatic Weigh Check

If automatic weigh check has been selected, additional messages are displayed
TW:
Program start is acknowledged after approximately 7 sec
E-prog. Aktiv.
Check weigh is positioned on feeder. Program is not started.
TW:
Remove check weigh.
Remove PRG
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Calibration Zero Set (recommended for belt weigher)

The following procedure is a typical example for a
commonly used belt weigher type:
The acquired value is stored as Zero Set and deducted from gross value in
normal mode. Program run time is set with Parameter P 02.01

Volumetric Mode
No Material on belt.
Program End:
Value of Zero Set is stored as Parameter P 03.03
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Calibration Zero Set (recommended for belt weigher)

Program Sequence
FUNCTION
TW: ZERO SET
Start program.
Running display showing residual run time of program
TW: xx.x%
Tara: x.xx%
Abw: x.xx%
Tara: x.xx%
[% total time] and deviation from zero point [%qNENN]

End display showing Zero Set correction N [%qNENN]
and the deviation from previous value [%qNENN].
Store/accept correction value
Abort program.

TW:
E-prog. Aktiv.
Check weigh is positioned on feeder. Program is not started.
TW:
Remove check weigh.
Remove PRG
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Calibration Belt Speed (optional)

With belt speed calibration the drive and control circuit are tested. It
is carried out with an empty but turning belt
Belt Index
Indicator
Belt Index
Tachometer
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Belt Speed Calibration - Steps

Calculate travel distance of belt for one tachometer impulse using
the mechanical parameters

Count number of tachometer impulses for one complete turn of belt
(one impulse of belt index indicator)

Calculate the belt speed (distance/time)
Calculate the difference between theoretical, actual, and measured
length (should not exceed 10%)
A belt speed calibration can also be carried out by using a stop

watch. Mark the belt and record the time for several turns (divide it
afterwards by the number of turns). This method is less accurate.
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Calibration Weight Check

In the weight check procedure the span of the load cell is tested
and calibrated for. It is carried out with the belt stopped.
Steps using Static Test Weights
Position different known weights on the central weigh bridge
Verify that the weight indicated corresponds to the actual weight
Read values into program
Remark: The weigh bridge

has to be properly aligned
The dynamic of the moving belt

is not taken into consideration
with this method
Scale Range
Cal. Weight
max. points of converter
Delta Weight
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The following procedure is a typical example for a commonly used
weigh feeder type:
Program CW acquires mean value of platform load for the check
weigh applied. The weight should not exceed the range of 2/3 to
4/3 of the nominal platform load.

Volumetric Mode,
No Material on belt,
Check Weight (P 02.09) in position.
Program End:
Span correction KOR is stored as Parameter P 03.06
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Program Sequence:
FUNCTION
CHECK Q

Start program.
Running display showing residual run time of program [% total
time] and indicating the relation of set point to measured value
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.

CW:
E-prog. Aktiv.
Check weigh is not in position. Program is not started.
CW:
Remove check weigh.
Position PRG
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Using Test Chains
The very same procedure as with the test weights applies.
The difference is that:
Chains are used instead of the test weights

It is carried out with a running and empty belt, therefore the
dynamic of the moving belt is not taken into consideration
with this method
Accuracy is lower than with test weights
This method is old fashioned

and should no longer be applied
Back to Main menu
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Calibration by Material Tests

Material test is the most accurate calibration method because
it uses known standards under actual operating conditions
In the material test calibration methods, a known weight of material

is transferred through the machine and compared to the total
measured by the integrator. The calibration parameters in the
integrator are then adjusted to compensate for any difference.
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Consideration to be made
Before any calibration by material tests is to be carried out, the belt
has to be tarred properly (see Unit before), or it has to be assumed

that the tarring did not change since the last time this check was
performed!!!!
It is important to note that all of the known weight of material
should pass through the weigh feeder. Sometimes the test

materials can fall from the weigh feeder or become stuck in the bin
or in-feed section.
This will alter the calibration !!!
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The known weight of material can be obtained by two methods:
Weigh out method
Off-line calibration
Material can be weighed before or after the test
Loss of weight method
On-line calibration
Test load in a bin supported by load cells
It is critical that the weighing device used for the test

load be accurate and calibrated to a reliable standard
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Weigh out method

The material is diverted to a place where it can be
weight or a specific amount of material is fed to the
weigh feeder. The amount of material is then compared
to the flow totalizer of the weigh feeder
Most of the time it is taken out of the circuit by either a
diverter chute or a reversible belt and then loaded onto

trucks that are weight on a nearby scale
The disadvantage is the additional effort for material
handling and weighing

A critical point in the procedure is the start and stop
sequence of the calibration
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Loss of Weight Method

The amount of material flowing out of a bin (without
further feed) is compared to the flow totalizer of the
weigh feeder during the same period
This is the only on-line calibration method
It includes all possible errors throughout the measuring
chain
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Following parts of the weigh feeder will be used
Shut off gate
Load Cell
Material &
Belt Weight
Belt speed
Loss of Weight
Control
Module
Motor
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Step by step procedure
The longer the calibration runs,
the more accurate it will be
Weigh Feeder running

Material
quantity in
Silo O.K.
Close shut off gate
Shut off gate close
Time to Stabilize
Stable
Get Bin Weight
Set point reached
Control
Module
Calculation of Deviation
Bin = Reference
vs. Totalizer
Man. or autom. corr.
Back to Main menu
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
Finally there is the corrective maintenance carried out by the respective

specialists
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PMRs - Minimum Guidelines

Check the weighbridge weekly and remove any material buildup that could
influence the deflection of the scale
Verify daily that the belt is tracking properly and that appropriate belt tension is
maintained
Perform a zero calibration weekly (important weigh feeders), or at least monthly

Conduct a span calibration check once each month during initial operations.
This interval can be lengthened if, over time, there is little deviation between
routine span calibrations.
Inspect, clean, and apply lubricants as needed to the chain, sprockets,
bearings, and drive assemblies
Follow the manufacturer's recommendations for maintaining the gear reducer
and motor
Perform extra or specific maintenance required by extraordinary climatic or
environmental conditions
Check daily for material lodged between the skirting and belt
Back to Main menu
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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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Example of Chart of Alignment Mistakes

Differences in straight alignment of idlers lead to mistakes
in the weight measured (Example from a specific weigh feeder model)
Diff. in Weight
(%) 1
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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Training of the belt

Weight feeder belt training consist firstly of eliminating the root
cause of the problem
The second step is a proper adjustment of the weight feeder
components to ensure the correct tracking
Possible root causes are:
Splice is not square to the belt

Structure is not accurately aligned
Idlers and pulleys are not aligned in all three axes
Material build-up alters the profile of idlers or pulleys
Friction forces are not symmetric to centre
Improper working condition of aligning idlers
Deflection of pulleys
Load is not centered (root cause is then related to chute design)
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Training of the belt

As weight feeders are short, and carrying idlers and
head pulleys are normally not adjustable, belt training

mostly consists of aligning the tail pulley. Align in small
steps and wait for reaction of belt.
The belt is tensioned on the side
it has the tendency to move out
or
Respectively un-tensioned on the side
it has the tendency to move inward
After each training of the belt the
weigh feeder has to be calibrated
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Weigh Feeder
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Changing the belt

The belts for the weigh feeders are normally supplied to
a specific length, and in certain cases endless.

The sequence for changing a non endless belt is:
Cut the old belt

Pull the new belt in
Make the splice
Tension adequately
After each change of a belt the

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Changing the belt

The sequence for changing an endless belt is:
Cut the old belt out

Loosen the tensioning system
The upper parts of the system have to be supported
Remove all components situated between the belt top and
bottom on one side
Shift the belt in position
Place back all components in the original position
Tension adequately
After each change of a belt the

Back to Main menu
Weigh Feeder
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Splicing of the belt - Methods

The following methods for belt splicing exist:
Hot vulcanization is normally not required as the belt
tension is low.
Mechanical fastener are to be strictly avoided
Cold vulcanisation is the preferred solution

it is highly cost-effective and fast (half expensive and time
consuming than hot splicing)
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Cold Vulcanisation vs. Endless Belt

Cold vulcanisation is the preferred solution, in competition
with endless belts which are already spliced
The most economical solution according to the local

circumstances shall be applied. Factors to be considered
are:
- Belt costs (higher for endless belt)
- Cost of equipment downtime (and required availability)
- Labor for installation
After the new belt is in the weigh

feeder has to be calibrated
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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
and fabric surfaces.
Cold vulcanisation places high demands on the quality of the vulcanisation
materials and the skills of the personnel
Cold vulcanising fluids contain solvents which must be well vented prior to
jointing the gluing surfaces
The belt must be longer than the final length needed

Both ends are cut in diagonal and layers are removed to assure overlapping
of the belt web
Gluing and pressing assure cohesion (waiting time is at least 4 hours)
depending on temperature and glue characteristic
The splicing must be of high quality, with no change of the belt thickness in
the spliced area.
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Weigh Feeder
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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
"Tracing back" is the recommended strategy

It is the method used by experts
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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
locate a breakdown in a rather complex machine.
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Systematic Testing of all Components

Testing every component in turn until you locate a defective one is
another possible strategy for an experienced user

This is a strategy that can surely lead to the result but it might be
very slow (and therefore costly)!
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This is a more effective strategy used by professionals to trace the source of

the breakdown based on the symptom.
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.
It is the METHOD USED BY EXPERTS.
Here are the two rules to trace back effectively:
1st Rule: Find the component up-stream which doesnt operate

within the normal range of parameters and follow its trace.
2nd Rule: Find the component lying up-line which operates within
the normal range of parameters and exclude investigation of
what lies up-stream of this component.
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There is another recommendation to follow for finding the correct channel rapidly.
Since the weigh feeder is a device regulating the FLOW. The symptom of the
breakdown generally appears when reading the flow indication.
Following the logic of the system, the channel may either be:
The weight or
The speed
That may be visualized like a tree!
The problem may come from

FLOW = OK
- an incorrect WEIGHT or
- an incorrect SPEED.
What exactly do we mean by incorrect?
WEIGHT
SPEED
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An incorrect signal may be a result of:
A. Bad transmission of a signal
The cause of which may be:
the measurement of the signal
the routing of the signal
the signal assessment
the display of the measured value
B. Incorrect measurement of a physical value or of the phenomenon itself.
Let us examine what this means
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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
The actual flow of material, or the

indicator output signal is incorrect.
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Troubleshooting
This can be formulated in rule no.3
3rd Rule: If a signal is incorrect, first check the physical value

that is at the origin of the measurement stream.
In this way, you can immediately eliminate from the investigations, either:
the origin (physical value, for example the speed, belt load, etc.)
or
the connections between the origin and the output signal (the cables, the
components, either of transformation or of signal transmission).
With the help of the 3rd rule, the tree diagram of causes can be extended. If
the indicated WEIGHT is abnormal the cause may be:

at the origin: a problem in the material flow, or
in the connections: the difference between the actual load of the belt and
the indicated load could be due to:
- the measuring circuit of the weight
- the mechanical construction of the weigh feeder
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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
- the mechanical connection between the motor and tachometer

The tree-diagram of causes now appears as follows:
FLOW = OK
WEIGHT
SPEED
Material Flow
Motor Speed
Mechanical Construction
Mechanical Connection
Weight Measurement Circuit
Weigh Feeder
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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
Weight Measurement Circuit
To identify the defective component, all you have to do is apply the three rules in
the respective circuit.
Back to Main menu
Weigh Feeder
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Set Point Increase System Reaction (1/2)

The Flow Controller records a deficit between the measured flow
and the required flow.

The Flow Controller transmits a signal to the Monitoring Module
of the Driving Motor to increase the motor speed.

The thyristor card increases the induced voltage and the Motor
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
the output voltage of the Tachometer and of the Ampere Meter.

The output voltage of the tachometer is amplified by the Amplifier
and the new belt speed is displayed by the Speed Monitoring.
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Set Point Increase System Reaction (2/2)

The Amplifier is informed of the speed increase. The belt load,
relatively unchanged, is then multiplied by the new belt speed to

give the new flow.
The measured flow is compared with the set point. If there is no
difference, the motor stops accelerating and the belt speed

stabilizes at the flow set point.
At all times, the measured flow is displayed by the Speed Indicator
and the quantity of the transported material is accumulated by the

Totalizer, via the Integrator.
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
adjustment process again. A reduction of the set point will obviously

lead to a reduction of the flow.
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HGRS MASTER - MAINTENANCE

Weigh Feeder Training Module.ppt

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Taring and Zero Setting

Tracing Back the Defect

Set Point Increase System Reaction

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Function of a Weigh Feeder

spillages, leakages, and dust emissions

Back to Main menu

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Operating Principle of a Weigh Feeder

The weighbridge is limited by two carrying idlers. By means of a centrally

The speed and load of the belt

In all cases: This is the first control

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Operating Principle of a Weigh Feeder

the weigh bridge

converted into a flow and compared to a preset value

adjusted to achieve the desired flow

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Applications in the Plant

Coal Mill Feed

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storage and the proportional feeder. It absorbs large flow

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Manual Control Gate

range of the load cell.

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spillages to the sides

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the correct functioning of the load cell.

They must be removed after calibration !!!!!!!!

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Idlers and Idler Support

around the load cell must be fixed with precision supports

mechanism on the load cell

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Mechanical Drive Parts

and the driving pulley

Any mechanical problem will obviously disturb the operation of the

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variable speed motor via a reducer or a chain

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Belt Cleaning Device

and alter the calibration

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the load cell

guiding idlers or limit idlers are additionally fitted on the sides)

The device normally consists

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Electrical Components of a Weigh Feeder

WEIGH MEASURING CIRCUIT

FLOW CONTROL CIRCUIT

SPEED MEASURING CIRCUIT

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Weight Measuring Circuit

The circuit consists of:

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