一、背景介紹
寶鋼馬跡山港位于浙江省嵊泗縣泗礁島西南約1.5公里的馬跡山島,,居于我國(guó)南北海岸線的中部和長(zhǎng)江出??冢俏覈?guó)南北運(yùn)輸必經(jīng)的黃金水域,,也是進(jìn)出上海港,、長(zhǎng)江流域的必由之路,瀕臨國(guó)際航線,,是距離長(zhǎng)江口最近的大型礦石中轉(zhuǎn)基地,,具有獨(dú)特的區(qū)位優(yōu)勢(shì)。
寶鋼馬跡山港二期工程于2005年12月28日開(kāi)工建設(shè),,二期工程是在一期工程的基礎(chǔ)上,,新建30萬(wàn)噸級(jí)卸船泊位1個(gè),1萬(wàn)噸級(jí),、5萬(wàn)噸級(jí)裝船泊位各1個(gè),,圍海形成0.32平方公里礦石堆場(chǎng),以及配套和輔助設(shè)施,,設(shè)計(jì)年吞吐量3000萬(wàn)噸,。二期工程投產(chǎn)后,馬跡山港形成年吞吐5000萬(wàn)噸能力,。
馬跡山港二期工程籌建之初就以世界先進(jìn)港口為樣板,,確定了建設(shè)世界一流的現(xiàn)代化港區(qū)的目標(biāo)及實(shí)現(xiàn)規(guī)模擴(kuò)張型向自主創(chuàng)新型轉(zhuǎn)變的思路。寶鋼自主研發(fā)成功了 “散貨堆,、取自動(dòng)化控制系統(tǒng)”,,使馬跡山港生產(chǎn)管制、料場(chǎng)管理和堆取料無(wú)人作業(yè)實(shí)現(xiàn)集中控制,,成為迄今為止國(guó)內(nèi)領(lǐng)先的、與世界上同類型先進(jìn)港口相媲美的信息化,、數(shù)字化,、智能化港口。
此前我們?cè)褂昧藝?guó)內(nèi)外多家企業(yè)的皮帶秤產(chǎn)品, 包括多托輥,,全懸浮,,雙杠桿等各種不同類型的皮帶稱, 普遍存在性能不穩(wěn)定,計(jì)量數(shù)值波動(dòng)大, 重復(fù)性差,,每次標(biāo)定差異較大,,不能滿足高精度計(jì)量的要求;而有些電子皮帶秤在安裝使用初期能實(shí)現(xiàn)非常高的計(jì)量精度,,但是使用一段時(shí)間后,,其測(cè)量精度就開(kāi)始不斷漂移,最后不得不進(jìn)行定期或不定期的標(biāo)定和維護(hù)工作,現(xiàn)場(chǎng)的維護(hù)人員對(duì)此意見(jiàn)比較集中,。
如何選擇和利用合適的電子皮帶秤產(chǎn)品,,既要實(shí)現(xiàn)高精度的內(nèi)部管理計(jì)量,又要減少電子皮帶秤的日常維護(hù)量,,實(shí)現(xiàn)無(wú)人作業(yè)的目標(biāo),。這對(duì)于該系統(tǒng)的完整實(shí)現(xiàn)有著至關(guān)重要的影響。
二,、港口裝卸設(shè)備對(duì)皮帶秤的應(yīng)用要求
現(xiàn)代港口散貨裝卸系統(tǒng)按照貨物流向可分為:水路-水路,;水路-陸路;陸路-水路等,。馬跡山港口作為重要的大型礦石中轉(zhuǎn)基地,,主要實(shí)現(xiàn)海路進(jìn)港,陸路(汽車,、鐵路,、皮帶輸送機(jī))出港。電子皮帶秤主要的應(yīng)用及物流方向進(jìn)出港時(shí)為:
A, 卸船機(jī),。機(jī)上輸送機(jī)可配備電子皮帶秤用于控制給料量,。
B, 皮帶輸送系統(tǒng)。系統(tǒng)配備電子皮帶秤用于監(jiān)測(cè)瞬間流量和生產(chǎn)量的統(tǒng)計(jì),。
C, 斗輪堆取料機(jī),。堆料狀態(tài)下臂架皮帶機(jī)配備電子皮帶秤,用于控制斗輪瞬時(shí)取料量,。
D, 堆場(chǎng)皮帶輸送機(jī),。用于監(jiān)測(cè)統(tǒng)計(jì)從堆場(chǎng)輸送到各生產(chǎn)單位的物料量,常作為企業(yè)內(nèi)部管理計(jì)量用,。
卸船機(jī)
在馬跡山港大量使用了抓斗式卸船機(jī),,在二期工程中所采用大起大重提供的2250t/h抓斗式卸船機(jī),達(dá)到了九十年代末國(guó)際先進(jìn)水平,。卸船機(jī)橋式抓斗卸船機(jī)被廣泛應(yīng)用在我國(guó)沿海各大港口和內(nèi)河港口的大宗散貨專業(yè)化碼頭的卸船機(jī)械類型中(如圖1),。
圖1:抓斗式卸船機(jī)(紅圈為皮帶秤安裝位置)
通常,計(jì)量皮帶秤通常安裝在料斗下方和運(yùn)輸船平行的位置(如圖中紅圈所指位置),??筛鶕?jù)應(yīng)用的具體要求,在卸船機(jī)配置中選擇內(nèi)部結(jié)算精度(0.5%)或貿(mào)易結(jié)算精度(0.25%)的電子皮帶秤,。同時(shí),,由于安裝位置的特殊性,通常也對(duì)皮帶秤長(zhǎng)期穩(wěn)定性和低維護(hù)量提出較高的要求,。
皮帶輸送機(jī)
帶式輸送機(jī)是一種摩擦驅(qū)動(dòng)以連續(xù)方式運(yùn)輸物料的機(jī)械,。應(yīng)用它,,可以將物料在一定的輸送線上,從最初的供料點(diǎn)到最終的卸料點(diǎn)間形成一種物料的輸送流程,。它既可以進(jìn)行碎散物料的輸送,,也可以進(jìn)行成件物品的輸送。除進(jìn)行純粹的物料輸送外,,還可以與各工業(yè)企業(yè)生產(chǎn)流程中的工藝過(guò)程的要求相配合,,形成有節(jié)奏的流水作業(yè)運(yùn)輸線(如圖2)。帶式輸送機(jī)與其堆料機(jī)和取料機(jī)相配合,,已經(jīng)成為大規(guī)模堆取塊狀物料(如煤,、礦石等)的唯一有效的方法。
圖2:皮帶輸送機(jī)
皮帶輸送機(jī)的皮帶秤選擇相對(duì)比較簡(jiǎn)單,,根據(jù)精度要求的不同,,可以選擇0.5%企業(yè)內(nèi)部結(jié)算和0.25%貿(mào)易結(jié)算等級(jí)別。
斗輪堆取料機(jī)
在馬跡山港口堆場(chǎng)采用大量自動(dòng)化程度很高的斗輪式堆取料機(jī),,尤其是在二期工程中采用的按照無(wú)人化標(biāo)準(zhǔn)設(shè)計(jì)的堆取料機(jī),,在國(guó)內(nèi)是首次安裝使用,對(duì)所采用的設(shè)備提出了非常高的要求,。斗輪堆取料機(jī)是現(xiàn)代化工業(yè)大宗散狀物料連續(xù)裝卸的高效設(shè)備,,廣泛應(yīng)用于港口、碼頭,、鋼鐵廠,、焦化廠、儲(chǔ)煤廠,、電廠等散料(礦石,、煤、焦碳,、及砂石)堆存料場(chǎng)的堆,、取料作業(yè)(如圖3)。
通常皮帶秤安裝在堆取料機(jī)的大臂的皮帶輸送機(jī)上,,由于堆取料機(jī)的大臂會(huì)根據(jù)堆料的高度不同而上下自有活動(dòng),,因此皮帶秤傳感器的負(fù)載(Load Cell)在垂直方向的力是一直在變化的,通常這種角度的變化在0~20º不等,,有時(shí)候會(huì)達(dá)到20~30º。因次,,為了修正由于堆取料機(jī)大臂角度變化帶來(lái)的影響,,應(yīng)用于堆取料機(jī)的皮帶秤通常都需要配置一個(gè)傾角補(bǔ)償器,來(lái)修正這個(gè)誤差,,保證皮帶秤的高精度,。
堆取料機(jī)是一種既能堆料,,又能取料的一種設(shè)備。因此也對(duì)速度傳感器提出了雙向測(cè)量要求,, 通常都會(huì)采用能夠正反向都能測(cè)量的軸速度傳感器,,而不采用線速度傳感器。
由于堆取料機(jī)的皮帶秤測(cè)量相對(duì)比較復(fù)雜,,安裝環(huán)境很難達(dá)到理想狀態(tài),,即使采用了貿(mào)易結(jié)算級(jí)精度的皮帶秤系統(tǒng),也很難達(dá)到0.25%的精度,,因此在堆取料機(jī)上能夠?qū)崿F(xiàn)0.5%的企業(yè)內(nèi)部計(jì)量精度也已經(jīng)是相當(dāng)不錯(cuò)的了,,主要技術(shù)要求通常還是集中在皮帶秤使用的長(zhǎng)期穩(wěn)定性和維護(hù)量的問(wèn)題上。
因此,,在港口裝卸設(shè)備上的皮帶秤的選擇和應(yīng)用,,除了要考慮精度之外,還需要充分考慮皮帶秤的長(zhǎng)期穩(wěn)定性和維護(hù)工作量的問(wèn)題,,這對(duì)于節(jié)約企業(yè)生產(chǎn)成本和提高企業(yè)生產(chǎn)效益很重要,。
三、皮帶秤工作原理和選擇
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經(jīng)過(guò)多方調(diào)查和權(quán)衡比較以后,,我們?cè)隈R跡山港口的卸船機(jī),、斗輪堆取料機(jī)和皮帶輸送機(jī)上大量選擇使用了西門子公司基于直接承重式原理的電子皮帶秤。
西門子的皮帶秤秤架部分的設(shè)計(jì)是很具有特色,,與一般常用的杠桿式秤架涉及不同,,它采用了被稱為“三無(wú)”的直接承重式秤架結(jié)構(gòu),即:無(wú)杠桿,、無(wú)支點(diǎn),、無(wú)平衡重(如圖4),也就是沒(méi)有稱重承載器,。這種設(shè)計(jì)帶來(lái)的好處是顯而易見(jiàn)的:
Ø 維護(hù)方便
在秤架上沒(méi)有杠桿支點(diǎn),,沒(méi)有可動(dòng)部件,也不存在諸如支點(diǎn)磨損等問(wèn)題,。杠桿式秤架秤體大,,水平面方向的表面積大,大面積積灰需經(jīng)常清掃,,否則會(huì)引起零點(diǎn)變化,,而直接承重式秤架尺寸短小,水平方向的表面積更小,,積灰量很小,,積灰引起零點(diǎn)變化也小,,可無(wú)需經(jīng)常清掃。
Ø 秤架結(jié)構(gòu)簡(jiǎn)單
直承式秤架結(jié)構(gòu)保證了物料的重量通過(guò)稱量托輥組直接加在稱重傳感器上,,皮重,、料重一起稱,所以秤架結(jié)構(gòu)非常簡(jiǎn)單,,重量也非常輕,。
Ø 秤架具有模塊化特點(diǎn),通用性好
秤架結(jié)構(gòu)不僅簡(jiǎn)單,,對(duì)不同寬度皮帶來(lái)說(shuō)零部件的通用性也比較好,,除了靜態(tài)梁、動(dòng)態(tài)梁的寬度相應(yīng)變化外,,其余部分幾乎是一樣的,。同時(shí),模塊化設(shè)計(jì)結(jié)構(gòu)大大減少了維修和更換備件的工作量和成本,。
Ø 秤架精確度高
由于采用的是高精確度的三梁平行四邊形稱重傳感器,,其重復(fù)性是0.01%,非線性和滯后均為0.02%,。這樣的高精確度對(duì)于稱重給料機(jī)的名義精確度0.5%來(lái)說(shuō)不僅足夠,,而且還有余地。因?yàn)椴捎弥苯映兄厥浇Y(jié)構(gòu),,也相應(yīng)減少了因這些部件帶來(lái)的測(cè)量精確度損失和在物料輸送過(guò)程中機(jī)械震動(dòng)給稱量系統(tǒng)帶來(lái)的干擾,。
MMI多托輥皮帶秤為高精度皮帶秤,可實(shí)現(xiàn)貿(mào)易結(jié)算的目的,,它采用一種獨(dú)特的模塊化設(shè)計(jì)結(jié)構(gòu),,秤架采用兩個(gè)MSI單托輥秤架組成,配用4個(gè)稱重傳感器,,在20%~100%量程范圍內(nèi)精確度指標(biāo)為0.25%,,為安裝、維護(hù),、以及更換備件帶來(lái)了極大的方便,。
BW500是為高精度皮帶秤設(shè)計(jì)的功能強(qiáng)大的積算儀。它具有以下主要特點(diǎn):
具有專利技術(shù)的雙稱重傳感器(最多四個(gè)傳感器)平衡功能,,能排除不均勻側(cè)向負(fù)荷的影響,,不需傳感器匹配機(jī)械平衡;
具有在線標(biāo)定,、批量處理,、濕度補(bǔ)償、傾斜補(bǔ)償?shù)裙δ埽?/font>
雙路PID調(diào)節(jié)功能,可以根據(jù)不同的工藝需要設(shè)定PID的響應(yīng)時(shí)間和調(diào)節(jié)范圍,;
有效地解決傳感器的特性匹配問(wèn)題, 相比于外接電位器, 可以顯著提高系統(tǒng)的長(zhǎng)期穩(wěn)定性。
配合高精度的MD256軸速度傳感器,,可以實(shí)現(xiàn)正反方向的雙向測(cè)量(如圖5),。
四、安裝調(diào)試和應(yīng)用效果
在安裝皮帶秤的初期,,我們也遇到了不少問(wèn)題,,主要表現(xiàn)為精度較差,不能達(dá)到要求,。經(jīng)過(guò)和廠家的技術(shù)溝通,、現(xiàn)場(chǎng)考察和重新安裝、調(diào)試后,,發(fā)現(xiàn)了問(wèn)題的主要原因,,并且經(jīng)過(guò)標(biāo)定和測(cè)試后,證明能夠滿足工藝的要求,。
西門子電子皮帶秤在馬跡山港口遇到的主要安裝問(wèn)題:
1,、 皮帶跑偏問(wèn)題(如圖6)。在寶鋼馬跡山堆取料機(jī)現(xiàn)場(chǎng)調(diào)試過(guò)程中,,皮帶秤托輥的支架兩側(cè)水平偏差很大,,按照西門子MMI皮帶秤安裝要求做設(shè)備校正,,發(fā)現(xiàn)偏差最大的地方需要加高64mm,,才能保證皮帶秤處于正確的位置,但也由此造成皮帶跑偏,,最大擺動(dòng)幅度達(dá)150mm左右,。
2、 安裝位置離斗輪機(jī)太近,,現(xiàn)場(chǎng)振動(dòng)太大,。不僅嚴(yán)重影響了皮帶秤的測(cè)量精度,也容易導(dǎo)致皮帶秤原器件的損壞,。
在廠家的建議下,,我們采取了如下措施進(jìn)行改進(jìn):
a. 改變安裝位置:遠(yuǎn)離斗輪機(jī),減少震動(dòng),,找變形較小的位置安裝,,將稱重輥向后移五米,實(shí)測(cè)高度落差減小為14 mm,,再做水平矯正調(diào)試,。這是最佳的解決方案。
b.對(duì)六組托輥的前后偏差大的托輥相應(yīng)的墊高:減少皮帶跑偏,,減少相鄰?fù)休侀g高度差,,緩解運(yùn)輸料抖動(dòng)大造成的散料現(xiàn)象,。
西門子這種直接承重式結(jié)構(gòu)的皮帶秤,由于秤架結(jié)構(gòu)小巧,、緊湊,,整個(gè)整改的工作很快就按照廠家的要求完成。通過(guò)鏈碼標(biāo)定和實(shí)物標(biāo)定測(cè)試后(如圖7,、8),,最終得到的標(biāo)定數(shù)據(jù)能完全滿足原先設(shè)計(jì)的要求。
這批皮帶秤自安裝使用至今超過(guò)1年半的時(shí)間里,,都沒(méi)有派專人去維護(hù)皮帶秤,,精度基本能夠滿足生產(chǎn)的要求。西門子這種基于直承式結(jié)構(gòu)的皮帶秤所具有維護(hù)量低的特點(diǎn),,為實(shí)現(xiàn)馬跡山港料場(chǎng)管理,、堆取料無(wú)人化作業(yè)起到了關(guān)鍵的作用。