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?？?，是我國南北運輸必經(jīng)的黃金水域，也是進出上海港、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，二期工程是在一期工程的基礎上，新建30萬噸級卸船泊位1個，1萬噸級、5萬噸級裝船泊位各1個，圍海形成0.32平方公里礦石堆場，以及配套和輔助設施，設計年吞吐量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港口為樣板，確定了建設世界一流的現(xiàn)代化港區(qū)的目標及實現(xiàn)規(guī)模擴張型向自主創(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)實現(xiàn)集中控制，成為迄今為止國內(nèi)領先的、與世界上同類型先進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，計量數(shù)值波動大, 重復性差，每次標定差異較大，不能滿足高精度計量的要求；而有些電子皮帶秤在安裝使用初期能實現(xiàn)非常高的計量精度，但是使用一段時間后，其測量精度就開始不斷漂移，最后不得不進行定期或不定期的標定和維護工作，現(xiàn)場的維護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，既要實現(xiàn)高精度的內(nèi)部管理計量，又要減少電子皮帶秤的日常維護量，實現(xiàn)無人作業(yè)的目標。這對于該系統(tǒng)的完整實現(xiàn)有著至關重要的影響。

二、港口裝卸設備對皮帶秤的應用要求

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，主要實現(xiàn)海路進港，陸路（汽車、鐵路、皮帶輸送機）出港。電子皮帶秤主要的應用及物流方向進出港時為：

A, 卸船機。機上輸送機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。

C, 斗輪堆取料機。堆料狀態(tài)下臂架皮帶機配備電子皮帶秤，用于控制斗輪瞬時取料量。

D, 堆場皮帶輸送機。用于監(jiān)測統(tǒng)計從堆場輸送到各生產(chǎn)單位的物料量，常作為企業(yè)內(nèi)部管理計量用。

卸船機

在馬跡山港大量使用了抓斗式卸船機，在二期工程中所采用大起大重提供的2250t/h抓斗式卸船機，達到了九十年代末國際先進水平。卸船機橋式抓斗卸船機被廣泛應用在我國沿海各大港口和內(nèi)河港口的大宗散貨專業(yè)化碼頭的卸船機械類型中（如圖1）。

圖1：抓斗式卸船機（紅圈為皮帶秤安裝位置）

通常，計量皮帶秤通常安裝在料斗下方和運輸船平行的位置（如圖中紅圈所指位置）?？筛鶕?jù)應用的具體要求，在卸船機配置中選擇內(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，由于安裝位置的特殊性，通常也對皮帶秤長期穩(wěn)定性和低維護量提出較高的要求。

皮帶輸送機

帶式輸送機是一種摩擦驅(qū)動以連續(xù)方式運輸物料的機械。應用它，可以將物料在一定的輸送線上，從最初的供料點到最終的卸料點間形成一種物料的輸送流程。它既可以進行碎散物料的輸送，也可以進行成件物品的輸送。除進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)運輸線(如圖2)。帶式輸送機與其堆料機和取料機相配合，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

皮帶輸送機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

在馬跡山港口堆場采用大量自動化程度很高的斗輪式堆取料機，尤其是在二期工程中采用的按照無人化標準設計的堆取料機，在國內(nèi)是首次安裝使用，對所采用的設備提出了非常高的要求。斗輪堆取料機是現(xiàn)代化工業(yè)大宗散狀物料連續(xù)裝卸的高效設備，廣泛應用于港口、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的大臂的皮帶輸送機上，由于堆取料機的大臂會根據(jù)堆料的高度不同而上下自有活動，因此皮帶秤傳感器的負載(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，有時候會達到20~30º。因次，為了修正由于堆取料機大臂角度變化帶來的影響，應用于堆取料機的皮帶秤通常都需要配置一個傾角補償器，來修正這個誤差，保證皮帶秤的高精度。

堆取料機是一種既能堆料，又能取料的一種設備。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。

由于堆取料機的皮帶秤測量相對比較復雜，安裝環(huán)境很難達到理想狀態(tài)，即使采用了貿(mào)易結(jié)算級精度的皮帶秤系統(tǒng)，也很難達到0.25%的精度，因此在堆取料機上能夠?qū)崿F(xiàn)0.5%的企業(yè)內(nèi)部計量精度也已經(jīng)是相當不錯的了，主要技術要求通常還是集中在皮帶秤使用的長期穩(wěn)定性和維護量的問題上。

因此，在港口裝卸設備上的皮帶秤的選擇和應用，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)查和權衡比較以后，我們在馬跡山港口的卸船機、斗輪堆取料機和皮帶輸送機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計是很具有特色，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，即：無杠桿、無支點、無平衡重（如圖4），也就是沒有稱重承載器。這種設計帶來的好處是顯而易見的：

Ø 維護方便

在秤架上沒有杠桿支點，沒有可動部件，也不存在諸如支點磨損等問題。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，積灰引起零點變化也小，可無需經(jīng)常清掃。

Ø 秤架結(jié)構簡單

直承式秤架結(jié)構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)構非常簡單，重量也非常輕。

Ø 秤架具有模塊化特點，通用性好

秤架結(jié)構不僅簡單，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、動態(tài)梁的寬度相應變化外，其余部分幾乎是一樣的。同時，模塊化設計結(jié)構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的名義精確度0.5%來說不僅足夠，而且還有余地。因為采用直接承重式結(jié)構，也相應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械震動給稱量系統(tǒng)帶來的干擾。

MMI多托輥皮帶秤為高精度皮帶秤，可實現(xiàn)貿(mào)易結(jié)算的目的，它采用一種獨特的模塊化設計結(jié)構，秤架采用兩個MSI單托輥秤架組成，配用4個稱重傳感器，在20%～100%量程范圍內(nèi)精確度指標為0.25%，為安裝、維護、以及更換備件帶來了極大的方便。

BW500是為高精度皮帶秤設計的功能強大的積算儀。它具有以下主要特點：

具有專利技術的雙稱重傳感器（最多四個傳感器）平衡功能，能排除不均勻側(cè)向負荷的影響，不需傳感器匹配機械平衡；

具有在線標定、批量處理、濕度補償、傾斜補償?shù)裙δ埽?/font>