News. Vehicle Weighing. Going to Greater Lengths to Improve Loading Efficiency. Industrial Weighing and Measuring

Transcription

1 Vehicle Weighing Industrial Weighing and Measuring 8 News Going to Greater Lengths to Improve Loading Efficiency The process of loading trucks can be a complex procedure. For some applications, trucks must be repositioned on a scale several times while they are being loaded. To handle these jobs, you need an unusually long scale combined with the right weighing technology. Asphalt loading Loading procedures have a direct effect on the quality of some materials. Hotmix asphalt is a perfect example. If the asphalt mix is loaded improperly, the aggregate used in the mix can become segregated (separated according to size). Segregation occurs when an entire load of asphalt is dumped into the center of a truck s bed. Smaller aggregate stays within the pile, while larger aggregate rolls toward the walls of the truck bed. The problem with segregated asphalt mix is that it tends to create weak spots in a paved surface. Eventually, the asphalt breaks down at these weak spots, causing the roadway to deteriorate. One solution is to load a truck in stages, repositioning the truck for each stage. The first load of asphalt is dropped at the front of the truck, the second at the rear, and the third in the middle. As the first two drops of asphalt are positioned against the front and rear walls of the truck bed, there is less opportunity for segregation. Longer trucks can be loaded in multiple drops, starting at the front of the truck and progressing toward the rear. Both methods involve moving trucks several times while they are being loaded. Although moving trucks during loading takes extra time and requires a longer scale, it is essential for maintaining the quality of the asphalt.

2 Vehicle Scales A truck scale must be long enough to weigh the entire truck regardless of which end of the truck is positioned under the filling equipment. Many asphalt-loading operations require scales that are several times the length of the longest trucks being weighed on them. Lengths of 130 feet (40 meters) or more are common. Sand loading Frac sand is another material with loading procedures that require longer truck scales. This high-purity silica sand is used in the hydraulic-fracturing process at oil and gas wells. After being mined, the sand is processed and separated according to its size and type. Many mining operations load trucks from a series of silos, each containing a specific type of frac sand. When a truck is ready to be loaded, it pulls onto a scale located underneath the line of silos. De- pending on which silo will dispense sand, the truck must park at a specific position on the scale. Trucks designed for hauling sand often have compartments, each with its own inlet and outlet. To fill all compartments, a truck must be repositioned on the scale several times. If a different type of sand is loaded into each compartment, the procedure becomes more complicated. The scale must be long enough to accommodate a truck regardless of whether its front compartment is being loaded from the first silo or its rear compartment is being loaded from the last silo. For frac sand operations, scales measuring 140 feet (43 meters) or longer are common. Several 220-foot (67-meter) scales with 24 load cells have been installed at large facilities. Design considerations When purchasing a long truck scale, take a good look at its weighing technology. The key to making exceptionally long scales practical is the type of load cell used. As longer scales require more load cells, they magnify any drawbacks to a load cell s technology. Analog load cells use a low-voltage signal to relay weight data. In a longer scale, the analog signal is transmitted by longer runs of cable with more junction-box connections. As the number of load cells increases, there is a greater potential for disruption by radio-frequency interference (RFI) and electromagnetic interference (EMI). More junction boxes also means an increased potential for moisture damage to the scale s electronics. Service is another complication. With analog load cells, shift adjustment is a To prevent segregation, hot-mix asphalt is loaded into trucks in multiple drops. Publisher / Production Mettler-Toledo AG MarCom Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Subject to technical changes 02/2014 Mettler-Toledo AG Printed in Switzerland Trucks used to transport sand often have compartments that must be filled separately. 2 METTLER TOLEDO Vehicle Weighing News 8

3 Promotion Tips & Tricks Webinar: The Latest Weighing Technology Weighing technology has come a long way in the past few years. A vehicle scale equipped with the latest technology is more accurate, more reliable, and easier to maintain than scales that were installed as recently as five years ago. time-consuming procedure that requires numerous manual adjustments for each load cell. Imagine the difficulty of making repeated manual adjustments to fine tune a scale that has 24 load cells. Advanced technology The POWERCELL PDX load-cell network provides a big advantage for long truck scales. This METTLER TOLEDO technology uses a strong digital signal and shielded cables that protect against interference. The entire network can be sealed against leaks to IP68 standards because there are no junction boxes. With POWERCELL PDX technology, shift adjustment is not complicated by the number of load cells in a scale. There is no need for repeated manual adjustments. Instead, the scale terminal makes a single mathematical adjustment for each load cell. Even the longest scale can be shift adjusted quickly and easily to ensure a consistent weight reading regardless of where a truck is positioned on the scale. There is no reason to sacrifice weighing performance for increased scale length. METTLER TOLEDO has many years of experience designing and building exceptionally long truck scales for loading applications. Regardless of scale length, POWERCELL PDX load cells provide improved weighing accuracy, greater reliability, and easier service. Find out how the POWERCELL PDX load cell has revolutionized vehicle weighing. The POWERCELL PDX webinar explains what makes this load cell different and how that difference can improve your weighing operation. It covers environmental protection, predictive diagnostics, eliminating downtime, and other issues that affect your bottom line. Visit the METTLER TOLEDO website to view this free webinar. METTLER TOLEDO Vehicle Weighing News 8 3

4 Vehicle Scale Terminals Basic Weighing Solution Offers Exceptional Versatility Simpler can be better. If your application calls for a simple weighing solution, the IND246 scale terminal fills the bill. With this new terminal, you get all-purpose weighing without paying for a lot of bells and whistles. The IND246 scale terminal is a simple weighing solution that is designed for versatility. It provides basic weighing plus the capability to process transactions for a variety of applications: vehicle weighing, counting, over/under checkweighing, peak-weight measurement, and animal weighing. You can change weighing applications with the touch of a button. Operator prompts make the IND246 easy to use. The terminal s vivid display can be read clearly in all lighting conditions. An alphanumeric keypad allows quick entry of tare and ID information. Navigation and function keys simplify setup and weighing operations. The IND246 terminal features two option slots that connect to a variety of interfaces. Serial, USB, or Ethernet connections exchange transaction data and ID files using the PC-based file transfer tool. Choose from two power options. The terminal is available in a version that runs on standard AC power and a version that uses a long-life nickel-metal hydride (NiMH) battery. The battery-powered terminal is a portable unit that can be moved easily to wherever it is needed. Scoreboard Weight Display Personal Computer Analog Scale Printer The IND246 terminal can be equipped to control external devices and to share transaction data with a personal computer or network. 4 METTLER TOLEDO Vehicle Weighing News 8

5 Vehicle-weighing applications The IND246 terminal is an excellent choice for basic weighing. It is a key part of a product family designed to offer solutions for the full range of vehicle-weighing applications. IND246 Scale Terminal Inbound/outbound vehicle weighing on one scale Multiple scales networked with a single database (combine vehicle scale software with terminals that control individual scales) IND560 Scale Terminal Inbound/outbound vehicle weighing on one scale Multiple scales networked with a single database (combine vehicle scale software with terminals that control individual scales) Vehicle weighing integrated with filling or loading Unattended vehicle weighing (combined with an IND9U unattended terminal) IND780 Scale Terminal Inbound/outbound vehicle weighing on one scale Inbound/outbound vehicle weighing on two scales with a shared database Multiple scales networked with a single database (combine vehicle scale software with terminals that control individual scales) Vehicle weighing integrated with filling or loading Unattended vehicle weighing (combined with an IND9U unattended terminal) Hazardous-area weighing (Zone 2, 22 / Division 2 with POWERCELL PDX load cells) In-motion weighing for railroad scales (combined with an IND9R86 controller) METTLER TOLEDO Vehicle Weighing News 8 5

6 Weigh Modules New Weigh Module Designed for Safety When safety is at stake, you cannot afford to cut corners. Weigh modules must support heavy loads without tipping or other accidents. With built-in safety features, the new MultiMount weigh module is the obvious choice for weighing material safely and accurately. The MultiMount weigh module is versatile enough to handle both static and dynamic weighing. Designed for compression loading, it is available in capacities of 11 to 10,000 pounds (5 to 4,400 kilograms). Thanks to its versatility and safety, this new product can be used for weighing material in tanks, hoppers, silos, conveyors, and mixers. The new MultiMount weigh module combines with the proven PinMount product line to offer a consistent weighing solution throughout a full range of capacities. Like the successful Pin- Mount weigh module, it was engineered to be safe, accurate, and simple to install. A built-in anti-lift system protects against tipping caused by high winds or earthquakes. Safety Safety is a big concern for tank scales and other weigh-module applications. Unlike conventional platform scales, these applications often include large structures built to hold heavy materials. Considering the wind and seismic forces that can be exerted on the structures, the potential for tipping and other accidents is obvious. When designing the MultiMount weigh module, METTLER TOLEDO made safety a priority. The weigh module is engineered to handle heavy loads and has dependable safety features built in: A strong anti-lift bolt protects the tank against tipping. A vertical down stop supports the weight of the tank in case of catastrophic failure. 360-degree checking limits horizontal movement. Accuracy Weighing accuracy depends on the load cells and suspension that are at the heart of any scale. MultiMount weigh modules use high-quality MTB and 0745A load cells. With NTEP and OIML approvals, these load cells provide the accuracy required for legal-for-trade applications and the repeatability required for batching. The rocker-pin suspension is selfaligning to ensure that the load is always applied vertically for accurate weighing. Simplicity Most scales are supplied as self-contained weighing systems. Weigh modules, on the other hand, are components that can be installed under various types of structures. Installing them correctly is essential to a scale s weighing performance. To simplify installation, each weigh module is equipped with a SafeLock locking plate. This unique tool aligns the weigh module in the ideal position for shipping and installation. By locking the top-plate assembly in position during installation, the tool helps prevent misalignment and the weighing problems it can cause. Visit our website to learn more about how the MultiMount weigh module can increase your operation s safety and weighing accuracy. 6 METTLER TOLEDO Vehicle Weighing News 8

7 What You Should Know Before Buying a Truck Scale A truck scale is not an impulse buy. It is a big investment that will affect a company s profits for 10 to 20 years. To help you make an informed decision about this investment, we have created a new truck scale buying guide. The buying guide contains more than 75 pages of information about every aspect of the buying process: How a Truck Scale Works Scale and Weight Regulations Basic Scale Choices Initial Scale Costs Weighbridge Specifications Load Cells Site Planning Installation and Certification Maintenance and Service FREE Download your free buying guide The new guide is designed to help anyone who plans to buy a truck scale. For the first-time buyer, the guide provides a step-by-step explanation of the entire process so that there will be no surprises. For someone who has been through the process before, it covers product innovations that were not available a few short years ago. Visit the METTLER TOLEDO website and download the buying guide: METTLER TOLEDO Vehicle Weighing News 8 7

8 Expert Service Keep Costly Problems from Eroding Your Profits Are you getting full value from your weighing equipment? Even the best product is only as good as its support network. METTLER TOLEDO provides comprehensive service and support that adds value in four ways. Uptime How important is weighing equipment to your company s productivity? Consider how much time and money you stand to lose if a scale is out of commission. METTLER TOLEDO keeps your weighing systems operating efficiently by monitoring performance, diagnosing problems, and making repairs quickly. Performance Make sure your scale delivers the performance that your business demands. Weighing errors often mean that you are giving away valuable material. METTLER TOLEDO protects your profits every step of the way, from installation through to regularly scheduled checkups that keep your scale weighing accurately. Compliance Regulation is a fact of life for weighing and measuring operations. METTLER TOLEDO will work with you to ensure that your equipment meets all applicable regulations and standards. We provide complete weights-and-measures support: qualification, validation, calibration, testing, documentation, and verification. Expertise Get the most out of your scale by putting our expertise to work for you. METTLER TOLEDO provides a wealth of information about how to use and apply products. On-site training and tutorials help your operators get up to speed quickly. Consulting services provide full support for system and process integration. 8 METTLER TOLEDO Vehicle Weighing News 8

9 Remote Scale Service Prevents Costly Downtime New tools are making scales easier than ever to troubleshoot. With the right technology, service technicians can check a scale s performance from anywhere. Remote access and advanced diagnostic tools can prevent downtime by solving problems quickly. During the winter, a waste facility in Idaho had a problem with one of its outbound truck scales. The scale would not return to zero consistently, at times indicating thousands of pounds of weight when the scale was empty. The facility has four truck scales, a pair of inbound/ outbound scales for weighing residential trucks and a pair for weighing commercial trucks. Shutting down any of these scales could cause serious delays. Concerned that the problem was affecting weighing accuracy, the scale manager called Sean Solledener, application specialist at Total Scale Service. At the time, I was 250 miles away at a gas station in the desert, said Solledener. Using Log- MeIn on my smart phone and the customer s computer network, I was able to access the indicator s website. What he found was that the load cells were all showing weight and there was no indication of scale error. But the weight reading at one end of the scale wasn t right. Because of his familiarity with the facility s layout, he knew that dirt and debris tend to build up under that end of the scale. Armed with that information, he directed the customer to check under the problem end of the scale. Sure enough, a large amount of frozen mud and ice had built up around the load cells. In a matter of minutes, the customer was able to remove the material with a pressure washer and had the scale weighing accurately. By solving the problem over the phone, Solledener helped the customer avoid a time-consuming service call and possible Remote service capabilities made it possible to correct a scale s weighing errors within minutes. downtime. The keys were his know-how and the right diagnostic tools: LogMeIn software to enable remote access to a computer, the IND780 website to allow access to the scale terminal, and POWERCELL PDX technology to check the performance of individual load cells. Many METTLER TOLEDO products have built-in diagnostic tools that simplify troubleshooting. Checking a scale remotely can give a service technician a basic understanding of the problem within a few minutes. More importantly, it can prevent costly downtime by getting the scale back in service quickly. An IND780 scale terminal can be checked remotely using a smart phone. METTLER TOLEDO Vehicle Weighing News 8 9

10 Vehicle Weighing Relying on Legal Tolerances Can Cost You Money Weighing accuracy is easy to take for granted. You know that your truck scale is certified by a regulatory agency, so you assume that it weighs accurately. What you might not know is that accuracy levels that are acceptable to regulators could be costing you an unacceptable amount of money. If you buy or sell truckloads of material by weight, your scale s accuracy is important to your business. A truck scale used for this type of application is the equivalent of a cash register. It determines how much money the buyer is charged for a truckload of material. With every weighing error, you could be losing money. Perfect weighing accuracy is hard to attain. The goal is usually to get as close to that target as possible. To ensure a reasonable level of accuracy, weights-andmeasures authorities set maximum allowable errors for scales used in legalfor-trade applications. These scales are tested regularly to verify that they are within tolerance. Testing is done with certified test weights. Any variation between a scale s weight reading and the test weight placed on the scale is considered to be an error. If the error is greater than regulations allow, the scale must be adjusted to bring it within tolerance. Legal tolerance Can you feel confident that a certified truck scale is weighing accurately? When weights-and-measures authorities set a legal tolerance, they are saying that a certain amount of error is allowed. In their eyes, a scale with the maximum allowable error is just as acceptable as a scale that weighs with perfect accuracy. If you want to maximize profits, your target should be the highest accuracy possible, not just the legal tolerance. The accuracy of your scale can make a big difference. For a single truckload, the maximum allowable error might not seem like much (see Figure 1). For a business that weighs a large number of trucks, the errors add up quickly. Suppose the typical truck weighed on your scale transports 28 tons of material and has a gross weight of 40 tons. The weight reading could be 88 pounds (40 kilograms) below the actual weight and still be within the legal tolerance. If you weigh 100 trucks per day with this amount of error, you would be giving away a full truckload of material every seven days. Truck Weight Allowable Error (NIST HB44 - USA) Preventing losses How can you prevent these losses? You might try recalibrating the scale frequently to keep it close to the target weighing accuracy. Those constant service calls would require a considerable amount of time and money. A better solution is to invest in a digital technology that makes it easy to attain and maintain a high level of weighing accuracy. The POWERCELL PDX load cell uses a unique digital weighing technology that outperforms conventional analog technologies. Studies of field data from hundreds of truck scales demonstrate the ability of POWERCELL PDX load cells to hold a much tighter accuracy level than other load cells. With POWERCELL PDX technology, it takes less time to certify a scale and the results are more accurate. Shift adjusting Allowable Error (OIML - International) 10 tons 40 lb 20 kg (44 lb) 20 tons 80 lb 40 kg (88 lb) 30 tons 120 lb 40 kg (88 lb) 40 tons 160 lb 40 kg (88 lb) 50 tons 200 lb 60 kg (132 lb) Figure 1: Legal-for-Trade Allowable Error 10 METTLER TOLEDO Vehicle Weighing News 8

11 Best Tips & Practice Tricks How Costly Are Weighing Errors? Don t take your scale s accuracy for granted. A scale that is not accurate can give away expensive material with every truck it weighs. You could be losing significant amounts of money without knowing it. a truck scale equipped with analog load cells can be especially time consuming. Because repeated adjustments are needed to fine tune the scale, service technicians can spend a day or more trying to get close to their target accuracy. Shift adjusting a truck scale equipped with POWERCELL PDX load cells is an automated procedure performed by the scale terminal in a small fraction of that time. A newly certified scale will not necessarily maintain its accuracy until the next scheduled recertification. Environmental forces such as temperature routinely affect weighing accuracy. As the temperature rises and falls, the weight signal produced by an analog load cell changes. In climates where extreme temperature changes are common, the weighing errors can be significant. Each POWERCELL PDX load cell is equipped with a microprocessor that tracks environmental conditions and adjusts the load cell output to compensate for changes. The truck scale maintains weighing accuracy by providing built-in compensation for temperature change, zero change, hysteresis, linearity, creep, and vibration. Verified performance The POWERCELL PDX load cell has a unique predictive diagnostics system that constantly monitors the performance of the entire load cell network. This system verifies network health and identifies any components that might need attention. Compare that with analog systems, which often hide problems for months. A truck scale equipped with POWERCELL PDX load cells is easier to calibrate to a higher degree of accuracy, maintains accuracy longer, and alerts you if proactive service is needed. There is no better way to protect your profits against weighing errors. See for yourself Learn more about weighing accuracy and how it affects your business s profits. View the online webinar: Understanding Truck Scale Accuracy. Then find out how much money weighing errors can cost your business. Use the free allowable-error calculator to estimate the potential losses. METTLER TOLEDO Vehicle Weighing News 8 11

12 Learn about Innovative Technology for the Mining and Aggregates Industries Knowledge is power. If you want the power to improve your weighing process, you need to know as much as possible about weighing technology. Learn about the latest technology and its benefits by exploring our free online library of white papers, guides, and webinars. Online library Profit from our know-how. This online library contains a wealth of information about weighing technology and how you can use it to make your business more profitable. Guides How to select the right scale for your operation How to get the highest return on your investment How to increase the efficiency of your process How to ensure regulatory compliance Visit our comprehensive library today: White Papers Webinars For more information Mettler-Toledo AG CH-8606 Greifensee Switzerland Tel Fax neutral Printed Matter No myclimate The Climate Protection Partnership