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電阻應(yīng)變式稱重傳感器是基于這樣一個(gè)原理：彈性體(彈性元件，敏感梁)在外力作用下產(chǎn)生彈性變形,，使粘貼在他表面的電阻應(yīng)變片(轉(zhuǎn)換元件)也隨同產(chǎn)生變形,，電阻應(yīng)變片變形后，它的阻值將發(fā)生變化(增大或減小),，再經(jīng)相應(yīng)的測(cè)量電路把這一電阻變化轉(zhuǎn)換為電信號(hào)(電壓或電流),，從而完成了將外力變換為電信號(hào)的過(guò)程。
由此可見(jiàn),，電阻應(yīng)變片,、彈性體和檢測(cè)電路是電阻應(yīng)變式稱重傳感器中不可缺少的幾個(gè)主要部分。下面就這三方面簡(jiǎn)要論述稱重傳感器工作原理,。
稱重傳感器原理圖
一,、傳感器電阻應(yīng)變片
電阻應(yīng)變片是把一根電阻絲機(jī)械的分布在一塊有機(jī)材料制成的基底上，即成為一片應(yīng)變片,。他的一個(gè)重要參數(shù)是靈敏系數(shù)K,。我們來(lái)介紹一下它的意義。
設(shè)有一個(gè)金屬電阻絲,，其長(zhǎng)度為L(zhǎng),，橫截面是半徑為r的圓形，其面積記作S,，其電阻率記作ρ,，這種材料的泊松系數(shù)是μ。當(dāng)這根電阻絲未受外力作用時(shí),，它的電阻值為R：
R = ρL/S(Ω) (2—1)
當(dāng)他的兩端受F力作用時(shí),，將會(huì)伸長(zhǎng)，也就是說(shuō)產(chǎn)生變形,。設(shè)其伸長(zhǎng)ΔL,，其橫截面積則縮小，即它的截面圓半徑減少Δr。此外,，還可用實(shí)驗(yàn)證明,，此金屬電阻絲在變形后，電阻率也會(huì)有所改變,，記作Δρ,。
對(duì)式(2--1)求全微分，即求出電阻絲伸長(zhǎng)后,，他的電阻值改變了多少,。我們有：
ΔR = ΔρL/S + ΔLρ/S –ΔSρL/S2 (2—2)
用式(2--1)去除式(2--2)得到
ΔR/R = Δρ/ρ + ΔL/L – ΔS/S (2—3)
另外，我們知道導(dǎo)線的橫截面積S = πr2,，則 Δs = 2πr*Δr,，所以
ΔS/S = 2Δr/r (2—4)
從材料力學(xué)我們知道
Δr/r = -μΔL/L (2—5)
其中，負(fù)號(hào)表示伸長(zhǎng)時(shí),，半徑方向是縮小的,。μ是表示材料橫向效應(yīng)泊松系數(shù)。把式(2—4)(2—5)代入(2--3),，有 ΔR/R = Δρ/ρ + ΔL/L + 2μΔL/L =(1 + 2μ(Δρ/ρ)/(ΔL/L))*ΔL/L = K *ΔL/L (2--6)
其中
K = 1 + 2μ +(Δρ/ρ)/(ΔL/L) (2--7)
式(2--6))說(shuō)明了電阻應(yīng)變片的電阻變化率(電阻相對(duì)變化)和電阻絲伸長(zhǎng)率(長(zhǎng)度相對(duì)變化)之間的關(guān)系,。
需要說(shuō)明的是：靈敏度系數(shù)K值的大小是由制作金屬電阻絲材料的性質(zhì)決定的一個(gè)常數(shù)，它和應(yīng)變片的形狀,、尺寸大小無(wú)關(guān)，不同的材料的K值一般在1.7—3.6之間;其次K值是一個(gè)無(wú)因次量,，即它沒(méi)有量綱,。
在材料力學(xué)中ΔL/L稱作為應(yīng)變，記作ε,，用它來(lái)表示彈性往往顯得太大,，很不方便
常常把它的百萬(wàn)分之一作為單位，記作με,。這樣,，式(2--6)常寫作： ΔR/R = Kε (2—8)
二、稱重傳感器彈性體的原理
彈性體是一個(gè)有特殊形狀的結(jié)構(gòu)件,。它的功能有兩個(gè),，首先是它承受稱重傳感器所受的外力，對(duì)外力產(chǎn)生反作用力,，達(dá)到相對(duì)靜平衡;其次,，它要產(chǎn)生一個(gè)高品質(zhì)的應(yīng)變場(chǎng)(區(qū))，使粘貼在此區(qū)的電阻應(yīng)變片比較理想的完成應(yīng)變棗電信號(hào)的轉(zhuǎn)換任務(wù),。
以托利多公司的SB系列稱重傳感器的彈性體為例,，來(lái)介紹一下其中的應(yīng)力分布。
設(shè)有一帶有肓孔的長(zhǎng)方體懸臂梁。
肓孔底部中心是承受純剪應(yīng)力,，但其上,、下部分將會(huì)出現(xiàn)拉伸和壓縮應(yīng)力。主應(yīng)力方向一為拉神,，一為壓縮,，若把應(yīng)變片貼在這里，則應(yīng)變片上半部將受拉伸而阻值增加,，而應(yīng)變片的下半部將受壓縮,，阻值減少。下面列出肓孔底部中心點(diǎn)的應(yīng)變表達(dá)式,，而不再推導(dǎo),。
ε = (3Q(1+μ)/2Eb)*(B(H2-h2)+bh2)/ (B(H3-h3)+bh3) (2--9)
其中：Q--截面上的剪力;E--揚(yáng)氏模量：μ—泊松系數(shù);B、b,、H,、h—為梁的幾何尺寸。
需要說(shuō)明的是,，上面分析的應(yīng)力狀態(tài)均是“局部”情況,，而應(yīng)變片實(shí)際感受的是“平均”狀態(tài)。
三,、檢測(cè)電路原理
檢測(cè)電路的功能是把電阻應(yīng)變片的電阻變化轉(zhuǎn)變?yōu)殡妷狠敵?。因?yàn)榛菟沟请姌蚓哂泻芏鄡?yōu)點(diǎn)，如可以抑制溫度變化的影響,，可以抑制側(cè)向力干擾,，可以比較方便的解決稱重傳感器的補(bǔ)償問(wèn)題等，所以惠斯登電橋在稱重傳感器中得到了廣泛的應(yīng)用,。
因?yàn)槿珮蚴降缺垭姌虻撵`敏度最高,，各臂參數(shù)一致，各種干擾的影響容易相互抵銷,，所以稱重傳感器均采用全橋式等臂電橋,。
其實(shí)稱重傳感器原理上就是壓力傳感器，形狀不一樣而已,，通常有很多種方法傳感的,，但我見(jiàn)到，用得比較多,，比如地磅用的那些,，一般為電渦流式。
也就是說(shuō),，他有一個(gè)電渦流觸發(fā)繞組,，然后還有一個(gè)傳感器感應(yīng)電渦流強(qiáng)度,。
由于這個(gè)傳感器整體是金屬封裝，電渦流在其內(nèi)部,，受到壓后形變,，渦流就發(fā)生變化，放大后就可以讀到數(shù)據(jù)了,。
然后,，封裝這個(gè)東西的材料，通常選用剛性材料,， 總之,，就是一般的金屬，比如鋼,，但肯定不會(huì)用很軟的東西的,。至少電渦流方式傳感的壓力傳感器，是不會(huì)用軟金屬制造的,。
因?yàn)榧词故卿?，就算受到壓力形變那么幾微米，那么電渦流的變化也足夠感應(yīng)出到底變化了多少而且如果是軟金屬,，稱很重東西的時(shí)候,，可能很容易出問(wèn)題。
稱重傳感器的使用知識(shí)
隨著技術(shù)的進(jìn)步,由稱重傳感器制作的電子衡器已廣泛地應(yīng)用到各行各業(yè),實(shí)現(xiàn)了對(duì)物料的快速,、準(zhǔn)確的稱量,，特別是隨著微處理機(jī)的出現(xiàn)，工業(yè)生產(chǎn)過(guò)程自動(dòng)化程度化的不斷提高,，稱重傳感器已成為過(guò)程控制中的一種必需的裝置,，從以前不能稱重的大型罐、料斗等重量計(jì)測(cè)以及吊車秤,、汽車秤等計(jì)測(cè)控制，到混合分配多種原料的配料系統(tǒng),、生產(chǎn)工藝中的自動(dòng)檢測(cè)和粉粒體進(jìn)料量控制等,，都應(yīng)用了稱重傳感器，目前,，稱重傳感器幾乎運(yùn)用到了所有的稱重領(lǐng)域,。
本系統(tǒng)由微機(jī)控制稱重傳感器的稱重和比較，并輸出控制信號(hào),，執(zhí)行定值稱量,，控制外部給料系統(tǒng)的運(yùn)轉(zhuǎn)，實(shí)行自動(dòng)稱量和快速分裝的任務(wù),。
系統(tǒng)采用MCS-51單片機(jī)和V/F電壓頻率變換器等電子器件,，其硬件電路框圖如圖1所示,，用8031作為中央處理器，BCD拔碼盤作為定值設(shè)定輸入器,，物料裝在料斗里,，其重量使傳感器彈性體發(fā)生變形，輸出與重量成正比的電信號(hào),，傳感器輸出信號(hào)經(jīng)稱重變送器放大后,，輸入V/F轉(zhuǎn)換器進(jìn)行A/D轉(zhuǎn)換，變送成的頻率信號(hào)直接送入8031微處理器中,，其數(shù)字量由微機(jī)進(jìn)行處理,。微機(jī)一方面把物重的瞬時(shí)數(shù)字量送入顯示電路，顯示出瞬時(shí)物重,，另一方面則進(jìn)行稱重比較,，開(kāi)啟和關(guān)閉加料口和變送器，放料于箱中等一系列的稱重定值控制,。
傳統(tǒng)概念上,，負(fù)荷傳感器是稱重傳感器、測(cè)力傳感器的統(tǒng)稱,，用單項(xiàng)參數(shù)評(píng)價(jià)它的計(jì)量特性,。舊國(guó)標(biāo)將應(yīng)用對(duì)象和使用環(huán)境條件完全不同的“稱重”和“測(cè)力”兩種傳感器合二為一來(lái)考慮，對(duì)試驗(yàn)和評(píng)價(jià)方法未給予區(qū)分,。舊國(guó)標(biāo)共有21項(xiàng)指標(biāo),，均在常溫下進(jìn)行試驗(yàn);并用非線性、滯后誤差,、重復(fù)性誤差,、蠕變、零點(diǎn)溫度附加誤差以及額定輸出溫度附加誤差6項(xiàng)指標(biāo)中的最大誤差,，來(lái)確定稱重傳感器準(zhǔn)確度等級(jí),，分別用0.02、0.03,、0.05......1.0表示,。
稱重傳感器的原理是在被測(cè)物體上的重力按一定比例轉(zhuǎn)換成可計(jì)量的輸出信號(hào)?？紤]到不同使用地點(diǎn)的重力加速度和空氣浮力對(duì)轉(zhuǎn)換的影響,，稱重傳感器的性能指標(biāo)主要有線性誤差、滯后誤差,、重復(fù)性誤差,、蠕變、零點(diǎn)溫度特性和靈敏度溫度特性等,。在各種衡器和質(zhì)量計(jì)量系統(tǒng)中,，通常用綜合誤差帶來(lái)綜合控制傳感器準(zhǔn)確度,，并將綜合誤差帶與衡器誤差帶(圖1)聯(lián)系起來(lái)，以便選用對(duì)應(yīng)于某一準(zhǔn)確度衡器的稱重傳感器,。國(guó)際法制計(jì)量組織(OIML)規(guī)定,，傳感器的誤差帶δ占衡器誤差帶Δ的70%，稱重傳感器使用知識(shí)的線性誤差,、滯后誤差以及在規(guī)定溫度范圍內(nèi)由于溫度對(duì)靈敏度的影響所引起的誤差等的總和不能超過(guò)誤差帶δ,。這就允許傳感器制造廠對(duì)構(gòu)成計(jì)量總誤差的各個(gè)分量進(jìn)行調(diào)整，從而獲得期望的準(zhǔn)確度,。
剪切梁式稱重傳感器原理是彈性體受力的作用后,，需要測(cè)量的不是其正應(yīng)力，而是由剪切力引起的切應(yīng)力,。但切應(yīng)力本身是測(cè)量不出來(lái)的,，它只能產(chǎn)生于與工字梁中心軸 線成45“的互相垂直的主應(yīng)力，也就是產(chǎn)生于由切應(yīng)力而引起的拉伸應(yīng)力及壓縮應(yīng)力,。因此,，將4片應(yīng)變計(jì)分別貼在工字梁腹板的兩面，并與中心軸線成45,。的 相互垂直的位置上,，如圖1所示。這4個(gè)應(yīng)變計(jì)組成全橋,，當(dāng)傳感器承受載荷時(shí),，應(yīng)變計(jì)R,,R3的電阻值增大，R2,R;的電阻值減小,，其結(jié)果在電橋的對(duì)角 線上產(chǎn)生與載荷成正比的不平衡輸出,。利用這一原理，便可測(cè)出力或載荷的大小,。
2005年期間,，某電廠#4爐給煤機(jī)稱重傳感器故障率較高，有一個(gè)傳感器輸出信號(hào)超出使用范圍0-30mV,，有一個(gè)輸出信號(hào)時(shí)而超出使用范圍,，時(shí)而在正常范圍內(nèi)，最近,，又有兩個(gè)稱重傳感器輸出信號(hào)不隨稱重變化發(fā)生明顯變化的現(xiàn)象，工作人員認(rèn)為問(wèn)題比較嚴(yán)重,，做初步分析,，可能原因如下：
該時(shí)期機(jī)組負(fù)荷高，煤質(zhì)差,，煤量大,，給煤機(jī)稱重傳感器長(zhǎng)時(shí)間處在高負(fù)載的運(yùn)行工況下,，同時(shí)給煤機(jī)內(nèi)部濕度較大，有時(shí)溫度稍高,，可能超過(guò)60℃(稱重傳感器工作溫度不超過(guò)60℃),，不同程度影響使用壽命。
從#4爐密封風(fēng)機(jī)改造后,，故障率比改造前明顯增加,，懷疑改造后給煤機(jī)內(nèi)部工作環(huán)境發(fā)生變化，影響稱重傳感器的使用壽命,。
經(jīng)咨詢廠家,，建議將給煤機(jī)內(nèi)部的出煤擋板降低，減少出煤量,，稱重傳感器負(fù)載相對(duì)降低,，為保證目標(biāo)給煤量，給煤機(jī)的轉(zhuǎn)速自然會(huì)提高,，將目前的高負(fù)載低轉(zhuǎn)速改為低負(fù)載高轉(zhuǎn)速運(yùn)行方式,，會(huì)延長(zhǎng)重量傳感器的使用壽命。
該電廠采取的措施是將壞稱重傳感器切除,，維持單只給煤機(jī)傳感器運(yùn)行,。
#4機(jī)組小修進(jìn)入第2天，認(rèn)真進(jìn)行鍋爐熱風(fēng)門執(zhí)行機(jī)構(gòu)檢修和給煤機(jī)稱重傳感器更換工作,，截止目前,，三臺(tái)磨煤機(jī)熱風(fēng)門執(zhí)行機(jī)構(gòu)全部拆除完畢，A1,、A2給煤機(jī)4臺(tái)稱重傳感器更換接線完畢,，B1給煤機(jī)2臺(tái)稱重傳感器已經(jīng)更換，B2給煤機(jī)拆除2臺(tái)原稱重傳感器,。
三臺(tái)熱風(fēng)門執(zhí)行機(jī)構(gòu)位于12米平臺(tái)下方,，位置狹小，灰塵多,，光線暗,，檢修小組克服困難，首先在集控室將熱風(fēng)門全部關(guān)閉,，然后通過(guò)爬梯到達(dá)檢修場(chǎng)地,，清掃積聚的灰塵，打開(kāi)定位器端蓋,，記錄接線端子編號(hào)與對(duì)應(yīng)的端子,，解除接線用絕緣膠布包好，拆除氣源管路,，用白膠布包好敞開(kāi)的管口,，松開(kāi)固定底座上的四個(gè)螺絲并保管好,，抬好執(zhí)行機(jī)構(gòu)并使之脫離底座，用準(zhǔn)備好的繩索系牢靠后,，慢慢下放到地面,，最后用三輪車?yán)睫k公樓，克服執(zhí)行機(jī)構(gòu)笨重等困難,，一鼓作氣抬到二樓檢修間進(jìn)行檢修,。
給煤機(jī)稱重傳感器更換工作進(jìn)展順利，首先清除煤灰,，拆開(kāi)保護(hù)罩,，松開(kāi)銷子和壓緊螺絲帽，去除稱重托輥,，接著松開(kāi)固定傳感器的四個(gè)螺絲,，特別是靠近皮帶的里側(cè)2個(gè)螺絲，由于生銹特別難拆,，尤其是接近下班時(shí)間,，看不到螺絲，手電因?yàn)橐呀?jīng)使用一天不能發(fā)亮,，只能憑手感覺(jué),，本著高度的責(zé)任心和高超的技能，盡管煤粉弄黑了衣袖和雙手,，松動(dòng)劑帶著煤粉刺了一身,，大家沒(méi)有一句怨言，沒(méi)有一個(gè)退卻,，心中只有一個(gè)信念：更換給煤機(jī)傳感器,，讓入爐煤計(jì)量準(zhǔn)確，以便為供電煤耗等指標(biāo)的計(jì)算提供可靠依據(jù),。
