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海口，是我國南北運輸必經的黃金水域，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基地，具有獨特的區位優勢。

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代化港區的目標及實現規模擴張型向自主創新型轉變的思路。寶鋼自主研發成功了 “散貨堆、取自動化控制系統”，使馬跡山港生產管制、料場管理和堆取料無人作業實現集中控制，成為迄今為止國內領先的、與世界上同類型先進港口相媲美的信息化、數字化、智能化港口。

此前我們曾使用了國內外多家企業的皮帶秤產品, 包括多托輥，全懸浮，雙杠桿等各種不同類型的皮帶稱, 普遍存在性能不穩定，計量數值波動大, 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品，既要實現高精度的內部管理計量，又要減少電子皮帶秤的日常維護量，實現無人作業的目標。這對于該系統的完整實現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

現代港口散貨裝卸系統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基地，主要實現海路進港，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。系統配備電子皮帶秤用于監測瞬間流量和生產量的統計。

C, 斗輪堆取料機。堆料狀態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。用于監測統計從堆場輸送到各生產單位的物料量，常作為企業內部管理計量用。

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河港口的大宗散貨專業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）。可根據應用的具體要求，在卸船機配置中選擇內部結算精度(0.5%)或貿易結算精度（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動以連續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，還可以與各工業企業生產流程中的工藝過程的要求相配合，形成有節奏的流水作業運輸線(如圖2)。帶式輸送機與其堆料機和取料機相配合，已經成為大規模堆取塊狀物料(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，根據精度要求的不同，可以選擇0.5%企業內部結算和0.25%貿易結算等級別。

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。斗輪堆取料機是現代化工業大宗散狀物料連續裝卸的高效設備，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(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，安裝環境很難達到理想狀態，即使采用了貿易結算級精度的皮帶秤系統，也很難達到0.25%的精度，因此在堆取料機上能夠實現0.5%的企業內部計量精度也已經是相當不錯的了，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定性和維護工作量的問題，這對于節約企業生產成本和提高企業生產效益很重要。

三、皮帶秤工作原理和選擇

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經過多方調查和權衡比較以后，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，可無需經常清掃。

Ø 秤架結構簡單

直承式秤架結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，除了靜態梁、動態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帶來的干擾。

MMI多托輥皮帶秤為高精度皮帶秤，可實現貿易結算的目的，它采用一種獨特的模塊化設計結構，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、傾斜補償等功能；

雙路PID調節功能，可以根據不同的工藝需要設定PID的響應時間和調節范圍；

有效地解決傳感器的特性匹配問題, 相比于外接電位器, 可以顯著提高系統的長期穩定性。

配合高精度的MD256軸速度傳感器，可以實現正反方向的雙向測量（如圖5）。

四、安裝調試和應用效果

在安裝皮帶秤的初期，我們也遇到了不少問題，主要表現為精度較差，不能達到要求。經過和廠家的技術溝通、現場考察和重新安裝、調試后，發現了問題的主要原因，并且經過標定和測試后，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題：

1、 皮帶跑偏問題（如圖6）。在寶鋼馬跡山堆取料機現場調試過程中，皮帶秤托輥的支架兩側水平偏差很大，按照西門子MMI皮帶秤安裝要求做設備校正，發現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，最大擺動幅度達150mm左右。

2、 安裝位置離斗輪機太近，現場振動太大。不僅嚴重影響了皮帶秤的測量精度，也容易導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行改進：

a. 改變安裝位置：遠離斗輪機，減少震動，找變形較小的位置安裝，將稱重輥向后移五米，實測高度落差減小為14 mm，再做水平矯正調試。這是最佳的解決方案。

b.對六組托輥的前后偏差大的托輥相應的墊高：減少皮帶跑偏，減少相鄰托輥間高度差，緩解運輸料抖動大造成的散料現象。

西門子這種直接承重式結構的皮帶秤，由于秤架結構小巧、緊湊，整個整改的工作很快就按照廠家的要求完成。通過鏈碼標定和實物標定測試后（如圖7、8），最終得到的標定數據能完全滿足原先設計的要求。

這批皮帶秤自安裝使用至今超過1年半的時間里，都沒有派專人去維護皮帶秤，精度基本能夠滿足生產的要求。西門子這種基于直承式結構的皮帶秤所具有維護量低的特點，為實現馬跡山港料場管理、堆取料無人化作業起到了關鍵的作用。