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，居于我國南北海岸線的中部和長江出?？?，是我國南北運(yùn)輸必經(jīng)的黃金水域，也是進(jìn)出上海港、長江流域的必由之路，瀕臨國際航線，是距離長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。

寶鋼馬跡山港二期工程于2005年12月28日開工建設(shè)，二期工程是在一期工程的基礎(chǔ)上，新建30萬噸級卸船泊位1個(gè)，1萬噸級、5萬噸級裝船泊位各1個(gè)，圍海形成0.32平方公里礦石堆場，以及配套和輔助設(shè)施，設(shè)計(jì)年吞吐量3000萬噸。二期工程投產(chǎn)后，馬跡山港形成年吞吐5000萬噸能力。

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、料場管理和堆取料無人作業(yè)實(shí)現(xiàn)集中控制，成為迄今為止國內(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。

此前我們曾使用了國內(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，其測量精度就開始不斷漂移，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)場的維護(hù)人員對此意見比較集中。

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)無人作業(yè)的目標(biāo)。這對于該系統(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, 堆場皮帶輸送機(jī)。用于監(jiān)測統(tǒng)計(jì)從堆場輸送到各生產(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，通常也對皮帶秤長期穩(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)的皮帶秤選擇相對比較簡單，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)算等級別。

斗輪堆取料機(jī)

在馬跡山港口堆場采用大量自動(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人化標(biāo)準(zhǔn)設(shè)計(jì)的堆取料機(jī)，在國內(nèi)是首次安裝使用，對所采用的設(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、儲煤廠、電廠等散料（礦石、煤、焦碳、及砂石）堆存料場的堆、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。因此也對速度傳感器提出了雙向測量要求， 通常都會采用能夠正反向都能測量的軸速度傳感器，而不采用線速度傳感器。

由于堆取料機(jī)的皮帶秤測量相對比較復(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期穩(wěn)定性和維護(hù)量的問題上。

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期穩(wěn)定性和維護(hù)工作量的問題，這對于節(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)過多方調(diào)查和權(quán)衡比較以后，我們在馬跡山港口的卸船機(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”的直接承重式秤架結(jié)構(gòu)，即：無杠桿、無支點(diǎn)、無平衡重（如圖4），也就是沒有稱重承載器。這種設(shè)計(jì)帶來的好處是顯而易見的：

Ø 維護(hù)方便

在秤架上沒有杠桿支點(diǎn)，沒有可動(dòng)部件，也不存在諸如支點(diǎn)磨損等問題。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，可無需經(jīng)常清掃。

Ø 秤架結(jié)構(gòu)簡單

直承式秤架結(jié)構(gòu)保證了物料的重量通過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)不僅簡單，對不同寬度皮帶來說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%。這樣的高精確度對于稱重給料機(jī)的名義精確度0.5%來說不僅足夠，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的測量精確度損失和在物料輸送過程中機(jī)械震動(dòng)給稱量系統(tǒng)帶來的干擾。

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>