Views: 23 Author: Site Editor Publish Time: 2024-08-09 Origin: Site
Truck scales are an essential component in industries where weighing large vehicles and their cargo is crucial. From logistics and transportation to agriculture and mining, these scales ensure accurate measurements that are vital for operational efficiency and regulatory compliance. However, the accuracy and longevity of truck scales depend heavily on proper installation. In this guide, we will walk you through the step-by-step process of installing truck scales, along with key considerations to ensure you get the best results.
Understanding the different types of truck scales is important before starting the installation process. The type of scale you choose will influence the installation procedure and the tools required.
Surface-mounted truck scales are installed above ground and require ramps for vehicles to drive onto the weighing platform. These scales are easier to install compared to other types and are suitable for locations where excavation is not possible or practical.
Pit-mounted truck scales are installed flush with the ground level, requiring excavation. This type of installation is ideal for sites with limited space and where a level surface is necessary for vehicle movement. Pit-mounted scales provide a more permanent solution and are typically used in industries with high-traffic volumes.
Portable truck scales offer flexibility, allowing them to be moved and set up at different locations as needed. These scales are ideal for temporary sites or operations that require mobility. Installation is relatively simple, but the scales need to be properly aligned and calibrated after each move.
Before starting the installation process, several factors must be considered to ensure the successful operation of your truck scale.
Choosing the right location for your truck scale is critical. The site should be level, stable, and accessible for trucks. Consider factors like proximity to loading and unloading areas, traffic flow, and the availability of utilities such as electricity.
Understanding the maximum load your truck scale will need to handle is essential. Determine the required scale length according to the vehicle model. This will influence the scale’s design, foundation requirements, and calibration. Ensure the scale can accommodate the heaviest vehicles and loads expected in your operations.
Environmental conditions such as temperature, moisture, and wind can affect the performance of your truck scale. Choose a site that minimizes exposure to extreme conditions, and consider installing protective features like shelters or drainage systems if necessary.
For surface-mounted and pit-mounted scales, constructing a solid foundation is crucial. This usually involves laying a concrete slab that can support the weight of the scale and the vehicles that will use it. Ensure the foundation is level and has adequate drainage to prevent water accumulation.
Our company will provide a foundation design reference drawing. The user will design the foundation construction drawing based on the reference drawing provided and the on-site geological conditions. The foundation excavation must be below the local permafrost line or a concrete slab. The entire foundation becomes a whole and has sufficient rigidity. The bearing capacity of each bearing pier must meet the technical requirements of the foundation drawing provided by our company. Drainage channels should be considered around the foundation to ensure that the scale is not damaged by water.
Check the relevant dimensions of the foundation: Use a steel tape measure to check the relevant dimensions according to the requirements of the foundation drawing. They must meet the requirements of the drawing. Use a hammer to knock on the upper surface of the embedded parts. It must be compacted. If empty sound is found, it must be reworked.
Its tonnage is determined by the maximum weight of the unit scale and the working position of the crane at the work site. It is recommended to select the crane model and specifications according to twice the weight of the single scale (the weight can be transported by a forklift during commissioning).
For steel structure countertops, the maximum lifting force of the jack is greater than 5t. For concrete countertop truck scales, due to the heavy weight after pouring, the maximum lifting force of the jack should be greater than 10t.
Basic tools include a level, measuring tape, shovel, wrenches, screwdrivers, and a power drill. These tools are necessary for preparing the site, assembling the scale, and making necessary adjustments.
After arriving at the site, the installer should check the following indicators:
1.Technical requirements of the foundation design drawing, check the quality of foundation construction, and review the position and size of the embedded foundation plates of each support of the sensor, the size of the longitudinal and transverse limit plates, the horizontality and the relative elevation size. The following work can be carried out only after acceptance.
2.Check whether the metal threading pipe of the signal cable is unobstructed.
3.Check whether all grounding points are reliable and whether the grounding resistance meets the requirements (not more than 4Ω).
4.Check whether the drainage channel at the foundation pit is unobstructed.
5.Clean up the garbage and debris in the foundation pit.
6.Check whether the power supply meets the regulations (the phase line and neutral line of the power supply cannot be used as the power line. If it cannot be avoided, protective measures must be taken to prevent the instrument from being interfered with). And install a purification and voltage-stabilized power supply system.
7.Count the number of all accessories according to the delivery list.
(1) If there is a crane, the scale body can be directly lifted into the foundation pit with the crane. If there is no crane or the crane cannot be used, a tripod and a hoist should be used in combination. Special attention should be paid to safety during the lifting process. The scale body is lifted off the car and placed on a round rolling log. It is pulled into place with a hoist or multiple people use sticks.
(2) If there are multiple weighing platforms, pay attention to the order of placing the weighing platforms. Place the main weighing platform first, and then place the second and third weighing platforms in turn (see the drawing).
Use four jacks to lift the load-bearing platform, then install the weighing sensor on the base plate, install the steel ball bowl of the load-bearing platform, and then put the steel ball into the weighing sensor bowl. Then gently release the jack on one side to make the load-bearing platform fall slowly, and observe whether the upper and lower ball bowls are vertical. There are two ways to observe:
(1) Use a steel ruler to check the edges of the upper and lower ball bowls. The visual error should be less than 1mm.
(2) Without a steel ruler, you can visually check the movement of the steel ball by the ball bowl pressing the steel ball. When the upper ball bowl just presses the steel ball, if the steel ball moves to the right, it means that the weighing sensor is biased to the left. The sensor should be gently moved to the right; otherwise, it should be moved to the left until the steel ball stops moving. This means that the sensor and the load-bearing platform are under vertical force at this time.
(1) Open the junction box and connect the sensor wires to the corresponding positions, and pay special attention to the sealing of the leads
(2) The wiring sequence should be regular to facilitate the adjustment of the eccentric load;
(3) Connect the wires connected to the weighing room and introduce them into the weighing room through the reserved traction wire;
(4) Cover the junction box to prevent water ingress and moisture.
(1) After connecting the output wires of the weighing sensor to the junction box and to the weighing display instrument, measure the actual output of each sensor when the weighing platform is empty. According to the data provided during the sensor calibration, adjust the horizontal state of the combined load-bearing platform again according to the consistency requirement of the electrical signal output value.
(2) After the empty stalk adjustment, use a standard weight equivalent to the rated weight (n is the weight of the weighing sensor) and place it in the middle of the weighing platform to check whether the output of each weighing sensor is basically consistent. If a large difference is found and it is determined that it is not caused by the unqualified horizontal height of the load-bearing platform, different precision resistors are connected in series to the bridge supply circuit of the corresponding weighing sensor in the junction box to make the output sensitivity of each sensor close.
(3) Setting of range, scale value and scale number
According to the designed range and the scale value and scale number that should meet the grade, the range, scale value and scale number of the display instrument connected to the scale are set.
(4) Adjustment of full scale and corresponding weighing point
The scale is calibrated at full scale with full-scale standard weights. The calibration procedure varies with the display instrument connected. When calibrating the corresponding weighing point, due to the nonlinearity of the system, the nonlinear calibration of the weighing point is generally required. The method and procedure also vary with different instruments.
(5) Calibration of electronic truck scale
According to the accuracy grade of the electronic truck scale, the local metrology department shall calibrate the adjusted electronic truck scale according to the corresponding calibration procedures or OIML requirements.
Proper maintenance is key to ensuring the longevity and accuracy of your truck scale. Here are some tips to keep your scale in top condition.
Regularly inspect the scale for signs of wear, damage, or misalignment. Catching these issues early can prevent more serious problems down the line.
Keep the scale clean and free of debris. Dirt, gravel, and other materials can accumulate on the weighing platform and affect readings. Regular cleaning helps maintain accuracy.
Even after installation, regular calibration is necessary to ensure the scale remains accurate. Follow the manufacturer’s guidelines for calibration intervals, and adjust as needed based on your operational requirements.
Installing a truck scale is a significant investment that requires careful planning and execution. By following the steps outlined in this guide, you can ensure your truck scale is installed correctly and operates efficiently for years to come. Proper installation and maintenance not only enhance the accuracy of your measurements but also extend the lifespan of your equipment.
