文献翻译——数字式智能称重传感器的发展与应用

第1页外文文献资料Thedevelopmentandapplicationofintelligentdigitalloadcell1.OverviewSincetheearly1940s,theuseofpastetyperesistancestraingaugeofanalogueweighingsensorwasdeveloped,aftermorethan60yearsofimprovementanddevelopment,fromthestructuredesign,manufacturingprocesstotheintegratedperformanceindex,stabilityandreliabilityareatahigherlevel,inallkindsofelectronicweighingapparatusandweighingmeasurementandcontrolhasbeenwidelyusedinthesystem.Withtheprogressofscienceandtechnologytoraisethelevelofindustrialprocessautomation,especiallythedevelopmentofdigitaltechnologyandinformationtechnology,inweighingmeasurementandcontrolsystem,theapplicationofdigitaltechnologyandthedigitalsystemdemandmoreandmore,todigital,intelligentelectronicweighingapparatus,weighingapparatusindustryproposedusingdigitalweighingsystemsimulationbreakthroughthelimitationoftheweighingsystemrequirements.Asweallknow,thedigitalweighingsystemforweighingsensorandweighinginstrumentsystemoutputindigitalform.Atpresentintheuseofanalogweighingsensor,theresistancestraintransformationprincipledeterminestheregardlessofwhatkindofresistancestraingaugeusedformanufacturing,itsitselfcannotproducetheoutputcharacteristicofdigitalsignal,andoutputanalogsignalexistsmallgeneralis2040mv;Shorttransmissiondistance;Anti-interferenceabilityispoor;Weighingdisplayingcontrolinstrumentcomplex;Itisnotconvenienttoinstallation,debugging,birthdefects.Dontadapttotheelectronicweighingapparatusdigitalintelligentized.Therefore,causedthepeopletotheanalogweighingsensoranddigitalweighingsysteminterfaceandintelligentdigitalweighingsensor.Somefamousforeignweighingsensormanufacturers,hascarriedoutalotofresearchworkandbreakthroughsin第2页scientificandtechnologicalachievements,developedavarietyofproductswithindependentintellectualpropertyrights.Asearlyasin1983inordertoadapttotheneedsofindustrialprocessautomation,TOLEDOcompaniesintheUnitedStatesistointroducetheconceptofdigitalandgraduallyappliedtotheweighingarea.DedicatedtothestudyUSESthemicroprocessortechnology,thedigitalcompensationtechnology,tomakeitwiththetraditionaltechnology,thecombinationofstrainsensorsafteryearsofefforts,developedarockingcolumntypeintelligentdigitalweighingsensors.STScompaniesintheUnitedStatesnationalinstrumentsexhibition,in1988andhasintroducedtheintegratedintelligentdigitalweighingsensors.Botharebasedonthebasicprincipleofanalogweighingsensor,useofmodernelectronictechnologyandcomputersoftwaretechnologyanddevelopedanewtypeofweighingsensor.Inanalogweighingsensorinternalincreaseamplification,filtering,A/Dconversion,themicroprocessorchipandtemperaturesensitivecomponents,suchasmorethan10componentsusingscaletransform,digitalfiltering,digitalzero,digitalcompensationtechnologyandmanufactureprocessiscomplete.Intelligentdigitalweighingsensormanufacturingtechnology,thetestitems,testmethods,formacompletesetofweighinginstrumentwithanalogweighingsensorisverydifferent.Therefore,theintelligentdigitalweighingsensorsaredevelopedjointlywiththeweighinginstrumentandsoonasystemsengineering.Intelligentdigitalweighingsensor,withlargeoutputsignals,digitalsignalsissethighandlowlevelsignal,format,regular,generalofplusorminus5v;Radiofrequencyelectromagneticradiationinterferenceabilitystrong;Signaltransmissiondistance,averageofupto150m,afteradditionalpowercanbemorethan600m;Easyinstallation,debugging;Thecharacteristicsofeasytorealizeintelligentcontrol,completelyovercomesthedrawbackofanalogueweighingsensor,isadigitalelectronicscale,automaticweighingmeasuringandcontrolsystem,automaticcalibrationoftheweighingsystem,complexstructureofallkindsofbatchingscale,volumeofchoiceforscaleandsuperlargeelectronicweighingapparatusproducts.Fromavarietyofelectronicweighingapparatus,structure,purpose,第3页intelligentdigitalweighingsensors,cantcompletelyreplaceanalogweighingsensor,alongerperiodoftimeinthefuture,analogweighingsensor,isstillweighingsensoristhemainstreamofthedevelopmentandapplication.Butwemustpayattentiontoandresearcheddigitalintelligentweighingsensoranditsapplicationinthedigitalweighingsystem.2.IntelligentdigitalweighingsensorsTherearetwowaystorealizeintelligentdigitalweighingsensor,ortherearetwokindsofstructureforms,namelytheintegraltypeandseparatedtype.1.IntegraltypeintelligentdigitalweighingsensorsAsmentionedabove,withintheweighingsensorinstallationhasamplifying,filtering,A/Dconversion,themicroprocessorchipanddigitalprocessingcircuitoftemperaturesensitiveelement,theuseofmicroprocessorchipshavebeendepositedinthesoftware,applicationofscienceandtechnologytoimplementthedigitalcompensationtechnologyforcomprehensiveperformancetestandverification,thelastissealedwiththeelectronbeamweldingandlaserwelding.Fordigitaltransformationandcompensationcircuitandtheweighingsensorisawhole,iscalledtheintegratedintelligentdigitalweighingsensors.Manufacturingtechnologyofintelligentdigitalweighingsensoriscompletelydifferentfromanalogweighingsensor.Mainlytwolinks,oneisintheelasticelementofwheatstonebridgecircuit,throughthetest,thetest,tosetupthedigitalcompensationtechnologyandtechnicalrequirementsofthecompensationmathematicalmodeloftheproject,formtofacilitateprogrammingcalculationformula,facilitateprogramsasoftwaretocalculateacompensation.Mainlyisthelinearcreepcompensation,compensation,mathematicalmodel,zeroandsensitivitytemperaturecompensation.Becausedigitalcompensationtechnologyandtheprocessisbasedonareasonablephysicalmodelandmathematicalmodel,basedontheaccurateandreliablemathematicalmodelistheprerequisiteofdigitalcompensationprecision.Secondly,accordingtothemathematicalmodeldevelopedissimpleandpracticalandeffectivecompensationcalculationsoftware,storedinamicroprocessorchipforeacherrorcorrectionandcompensation.Software第4页technologymainlyinclude:digitalfilteringtechnologyinasimulationoftheweighingsensoroutputsignal,through!A/Dtransformationlastindetailwhentheprocessor,ofteninrandomnoisespike,mustbeweakenandfiltering;Scaletransformtechnology,analogsignalsoftheweighingsensor,afterA/DconversionbyAseriesofdigital,itshouldbeconvertedtothedatabeforeoperation,displaywithAquantityofsteel;Digitalzerotechnologyausedinavarietyofprogramstoachievezerodriftandgaindrifterrorcalibration;Mathematicalmodeloftemperaturecompensationtechnologyasetuptoexpresstemperature(suchaspolynomial,etc.)withdifferentialmathematicaltreatmentmethods,suchas,caneffectivelyrealizetemperaturecompensation;Nonlinearcompensationtechnology,accordingtothemeasuredcurve,thepiecewiseinterpolation,gettingtheproperandenough,aslongastheinterpolationpointscanobtainexcellentlinear.TOLEDOcompany,STS,CARDINALcompaniesintheUnitedStatesandtheGermanHBMonintelligentdigitalweighingsensor,hasitsownuniquedigitalcompensationtechnologyandprocess.Inthedigitaloutputeliminateelectricalnoise;Digitalcircuitstorealizeautomatictemperaturecompensation;Solvingradiofrequencyinterference(RFI)andelectromagneticinterference(EMI);Implementadaptive,selfcalibration,andbuilt-inself-diagnosisfunctionforthelightningovervoltageprotectionplatecausedbyelectricaltransientaspectsoftechnologyandprocessareinaleadingposition.Thecharacteristicsoftheintegraltypeintelligentdigitalweighingtransduceris:(1)production,processingandstorageofthedigitalsignaliseasy,theoutputsignal,theoutputsignalissethighandlowlevelsignal,generallyofplusorminus5v.(2)hastheveryhighresolution,generally20-bit,cancountupto1000000,andhighaccuracy,goodstability;(3)highleveldigitalsignalexternalradiofrequencyinterferenceandelectromagneticinterferenceresistanceability;(4)strongsignaloutput,transportdistance,usuallyupto150m,afteradditionalpowercanbemorethan600m;第5页(5)thefourerrorcanbeadjustedwithsoftwarearithmeticmethod,usingthedigitalsystemtorealizethecalibration,therefore,installation,debugging,verificationisveryconvenient,isonlyaquarterofthetraditionalmethods;(6)inawiderangeofelectronicweighingapparatusandunabletouseweightsweighingdevice,canbecarriedoutwithoutcalibrationweights.Usingthedigitalweighingsystemsoftware,inputthecalibrationoftheweighingsensorparameters,canensuretheweighingaccuracyandworkingreliabilityoftheelectronicweighingapparatus.Problemsofintegraltypeintelligentdigitalweighingsensorsareprominentmainlyare:(1)duetotheincreasedinternalA/Dconversionofformerlevelaftertheamplifierandmicroprocessor,thetemperaturesensitiveelementand350morethan60electroniccomponentssuchassolderjoints,considerablymorethantheinternalonly11analogelectroniccomponentsand30weldsweighingsensor.Andmeantimebetweenfailuresoftheweighingsensoranditscontainisinverselyproportionaltothenumberofelectroniccomponentsandsolderjoints,therefore,thestabilityandreliabilityofinevitabledecline;(2)theinternalelectroniccomponentsdeterminestheoperatingtemperaturerangeissmall,generallyfor-1040C.Forunder-10Cwhileworkingenvironment,shouldchoosethelowtemperaturecomponents,thecostwillrisebyseveraltimeseven48times;(3)putthedigitalcircuitafterweighingsensorinside,inadditiontotheconventionaldetection,calibration,stillshouldaccordingtotherequirementsoftheweighinginstrumentelectrostaticputreactanceimmunity,radiofrequencyelectromagneticfieldradiationimmunityandelectricaltransientburstsimmunitytest;(4)internaldigitalintelligentcircuitintheweighingsensor,reducedthelevelofexplosion-proof,ifmeettherequirementsofexplosion-proof,mustusethemoreexpensiveexplosion-proofandflame-proofmeasures;(5)themanufactureandmaintenancecostishigher,bothpartoftheresistancestraingaugebridgecircuitanddigitalintelligentcircuitpartfails,allneedstochangeawholenewintelligentdigitalweighingsensors.第6页2.SeparationtypemodulardigitalweighingsensorsystemOntheanalysisoftheproblemsofintegraltypeintelligentdigitalweighingsensors,applicationexperienceandmarketrequirements,onthebasisoftheSTSseparatedtypecompanylaunchedin1992,2200seriesdigitalweighingsensormodule.Itisoriginallyplacedinsidetheweighingsensor,A/Dconversiondigitalprocessingcircuittoanexternalterminalbox.WithA/Dconversionmoduleofjunctionboxcalleddigitalterminalblock.Ordinaryanalogweighingsensoraccessdigitalterminalblock,theoutputofdigitalsignaltransmissiontothematchedweighingcontrolinstrument.Willusuallyanalogweighingsensoranddigitalterminalboxmodel,calledmodulardigitalweighingsensorsystem.Isitretaintheanalogintegratedperformanceindexoftheweighingsensor,andhasallthecharacteristicsofthedigitalintelligentweighingsensorsizeandfunction.Atthesametime,themaximumimproveworkingconditionsfortheA/Dconversioncircuit.Thecharacteristicsofmodulardigitalweighingsensorsystemis:(1)Inanaloguenochangeundertheconditionofweighingsensor,thedigitalterminalbox,changetheoutputanalogsignaltodigitalsignaloutput,makeithasthecharacteristicsofintegraltypeintelligentdigitalweighingsensorsandfunction;(2)Adoptingmodulardigitalweighingsensorsystem,butwithoutchangingtheoriginalstructureofelectronicweighingapparatus,onthebasisofrealizingdigitalelectronicscales;(3)theanalogueweighingsensorcanbein-4070Cenvironmentundertheconditionofnormalwork,withdigitalterminalboxcanmakethemodulardigitalweighingsensorsystemworkinawidetemperaturerange;(4)andtheoverallscore,moldmodulardigitalweighingsensorsystemstabilityandreliabilityareimprovedgreatly;(5)installthewiringisverysimple,fromonlyonedigitalterminalboxtodigitalweighinginstrumentcables;(6)duetomeetwiththeordinaryanalogweighingsensor,easymaintenance,repairsandmaintenancecostisalsolowerthanintegraltype.TheSTSmodulardigitalweighingsensorsystemmaintechnicalindicatorsareasfollows:第7页(1)A/Dchannels:20-bitconversionchannelfourindependenteachother.(2)theconversionrate:100samplespersecond.(3)Theresolution:1048000.(4)degreeresolution:200000.(5)signalsensitivity:0.1uv/degree.(6)signalrange:0.5mv/vto6mv/v.(7)excitationvoltage:9.510.5VDC.(8)calibration:regular/number(noneedtoweight).(9)serialport1:bidirectionalRS232or20macurrentloop.(10)serialport2:bidirectionalRS232orRE485or20macurrentloop.3.TheapplicationofintegraltypeandseparatedtypedigitalweighingsensorIntegraltypeintelligentdigitalweighingsensorismainlyusedinindustrialprocessautomationofdigitalweighingsystemanddigitalelectronicweighingapparatus.Applicationmorestructureismorecomplexelectronichopperscale,electronicbatchingscale,tankscales,electronicplatformscale,inawiderangeofelectronictruckscale,dynamicrailweighbridgeandhasalargedeadload,liveloadofsmallspecialelectronicscale.Theformerismainlyondigitalweighingsensorsystem,canusesoftwareinputintelligentdigitalweighingsensorcalibrationparameterswithoutcalibrationweights,thelatteristheuseofintelligentdigitalweighingsensorsprovide1000000counthighresolutionareavailable,andthisisall,analogweighingsensorcannotachieve.Separationtypedigitalweighingsensorhasflexibleconfiguration,wideapplicationrange,easyinstallationanddebugging,testingmethodissimple,environmentaladaptationabilityandothercharacteristics,marketsharecontinuetoincrease.DevelopmentofSTScompaniesintheUnitedStatesinthe2200series,2203220and2224digitalweighingsensormodule,canformallkindsofdigitalweighingsystem.2203,2204and2224digitalweighingsensormodule,justwithintheresolution,centdegreeresolutionisdifferent,suchasotherbasicsame,canconnect3mv/vanalogweighingsensor,upto12.ThesimulationoftheweighingsensoroutputsignalbyA/D第8页converterwithhighspeed,highresolutionandthemoduleofthemicroprocessor,convertedtodigitalsignal,highlevelthroughserialcommunicationinterface,transferredtotheprocessofdigitalweighingcontroller,bymeansofthiscontrollercanbedigitalandanalogdatatransmissionthroughthenetworktothedistributedcontrolsystem,programmablecontrollerandpersonalcomputer,itformedAtypicaldigitalweighingsystem.Thusitisnothardtosee,theoutstandingcharacteristicofthisschemecanbeintheoriginalweighingsystemdonotmakeanychanges,andwillnotbechangedunderthepremiseofweighingsensor,throughthedigitalweighingsensormodule,simulationofweighingsystemforthedigitalweighingsystem.Cansaythisisthetraditionalweighingsystemforashortcuttodigitaltransformation,theremustbeaverygooddevelopmentprospect.4.conclusionTheneedsoftheelectronicweighingapparatusandweighingsystemisweighingsensorresearchanddevelopmentofthepermanenttopic.Withtheadventoftheeraofdigitalinformation,intheindustrialprocessmeasurementandcontrolsystemoftestingandweighing,digitalelectronicweighingapparatusandtheapplicationofthedigitalweighingsystemmoreandmore,itrequiresintelligentdigitalweighingsensorsandrelatedsupportingtechnology,instrumentdevelopmentassoonaspossible.TheweighingapparatusmanufacturerinChinamusthaveenoughunderstanding.Intheearly1980s,theUnitedStates,Germanyandotherdevelopedcountries,beganadigitalweighingsensorsanddigitalweighingsystemresearchanddevelopmentoftheearlyworkinadvance,aftermorethantenyearsofefforts,launchedavarietyofintelligentdigitalweighingsensorandweighingsystem,attentioninthefieldofelectronicweighing.STScompaniesintheUnitedStates2200seriesmodulardigitalweighingsensors,TOLEDO,CARDINALcompaniesintheUnitedStatesshakecolumntypesealintelligentdigitalweighingsensors,GermanHBMcompanyC16bit3cylindricalstainlesssteellaserweldingsealofintelligentdigitalweighingsensors,powerfullypromotedthedevelopmentofdigitalizationofelectronicweighingapparatusandweighingsystem.第9页Intelligentdigitalweighingsensorresearchanddevelopmentinourcountrybeganinthelate1990s,injustafewyears,developedtheinstallationwithintheanalogweighingsensorofsmalldigitalunit,completestheconversionbetweenanalogsignalsanddigitalsignals,analogweighingsensorsforthedigitalweighingsensor,andappliedtothelarge-scaleelectronictruckscaleandelectronicbatchingscalesmall,weighingsystem,goodresultshavebeenachieved.Inrecentyears,andinadigitalweighingsensors,onthebasisoftheresearchandpracticeofintelligentdigitalcircuits,digitalcompensationtechnologyanddigitalcompensationtechnology,todeveloptheintegratedintelligentdigitalweighingsensorsandseparationtypemodulardigitalweighingsensorsystem,hasmadesomeprogress.Canbeexpected,willsoonbeinthedigitalizationofelectronicweighingapparatusandweighingsystem,seedomesticintelligentdigitalweighingsensorsandmodulardigitalweighingsensorsystem.第10页中文翻译稿数字式智能称重传感器的发展与应用一、概述自从20世纪40年代初，利用粘贴式电阻应变计的模拟式称重传感器问世以来，经过60多年的种种改进与发展，从结构设计、制造工艺到综合性能指标、稳定性和可靠性都达到较高的水平，在各种电子衡器和称重计量与控制系统中得到了广泛的应用。随着科学技术的进步工业过程自动化水平的提高，特别是数字技术与信息技术的发展，在称重计量与控制系统中，应用数字技术与数字系统的需求愈来愈多，对衡器行业提出了电子衡器数字化、智能化，用数字称重系统突破模拟称重系统的局限性等要求。众所周知，数字称重系统要求称重传感器和称重仪表系统以数字形式输出。目前在用的模拟式称重传感器，由于电阻应变转换原理决定了无论采用何种电阻应变计进行制造，其本身都不能产生具有数字特征的输出信号，而且存在着输出的模拟信号小一般为2040mv；传输距离短；抗干扰能力差；称重显示控制仪表复杂；安装、调试不方便等先天缺陷。根本适应不了电子衡器数字化智能化的要求。因此，引起了人们对模拟式称重传感器与数字称重系统接口和数字式智能称重传感器的重视。国外一些著名称重传感器生产厂家，对此开展了许多研究工作并取得突破性的科技成果，开发出多种具有自主知识产权的产品。早在1983年为适应工业过程自动化的需要，美国TOLEDO公司就引入了“数字式”概念并逐步将其应用于称重领域。致力于研究采用微处理器技术、数字补偿技术，使其与传统的应变式称重传感器技术相结合，经过多年的努力，开发出摇柱型数字式智能称重传感器。美国STS公司也在1988年全美衡器展览会上，推出了整体型数字式智能称重传感器。两者都是以模拟式称重传感器的基本原理为基础，利用现代电子技术及计算机软件技术而开发出的新型称重传感器。即在模拟式称重传感器内部增加放大、滤波、A/D转换、微处理器芯片和温度敏感元件等10多个元器件，利用标度变换，数字滤波，数字调零，数字补偿等技术与工艺制造完成。数字式智能称重传感器的制造工艺，检测项目，试验方法，配套的称重仪表与模拟式称重传感器有很大区别。因此，数字式智能称重传感器是与称重仪表等共同研制开发的一项系统工程。数字式智能称重传感器具有输出信号大，数字信号是一组组高低电平信号，有格式、有规律的组成，一般为正负5v；抗射频电磁场辐射等干扰能力强；信号传输距离远，一般可达150m，附加电源后可超过600m；安装、调试方便；易实现智能化控制等特点，完第11页全克服了模拟式称重传感器的缺点，是数字化电子衡器、自动称重计量与控制系统、需要自动校准的称重系统、复杂结构的各类配料秤、容积秤和超大型电子衡器的首选产品。从电子衡器的品种、结构、用途上看，数字式智能称重传感器，不可能完全取代模拟式称重传感器，在今后一个比较长的时期内，模拟式称重传感器，仍然是称重传感器发展与应用的主流。但我们必须重视并认真研究数字式智能化称重传感器及其在数字称重系统中的应用。二、数字式智能称重传感器数字式智能称重传感器有两种实现方法或者说有两种结构形式，即整体型和分离型。1.整体型数字式智能称重传感器如前所述，在称重传感器内部安装有放大、滤波、A/D转换，微处理器芯片和温度敏感元件等组成的数字处理电路，利用微处理器芯片已存入的软件，科技应用实施各项数字补偿工艺进行综合性能测试和检定，最后采用电子束焊或激光焊进行密封。因数字变换与补偿电路和称重传感器为一整体，故称为整体型数字式智能称重传感器。数字式智能称重传感器的制造工艺完全不同于模拟式称重传感器。主要是两个环节，其一是在弹性元件组成惠斯登电桥电路后，通过试验、测试、建立数字补偿技术与工艺要求的各补偿项目的数学模型，形成便于程序化计算的公式，便于编制成补偿计算软件。主要是线性、补偿、蠕变补偿、零点和灵敏度温度补偿等数学模型。因为，数字补偿技术与工艺是建立在合理的物理模型和数学模型基础上，给出准确、可靠的数学模型是保证数字补偿精度的前提。其二是根据数学模型编制出简单、实用、有效的补偿计算软件，存储在微处理器芯片中进行各项误差修正与补偿。软件技术主要有：数字滤波技术一称重传感器的模拟输出信号，经!A/D变换后进入微处理器时，常混进尖脉冲之类的随机噪声干扰，必须予以削弱和滤除；标度变换技术称重传感器的模拟信号，经A/D变换后得到一系列的数码，必须将其换算成带有量钢的数据后才能运算、显示；数字调零技术一采用各种程序来实现零点漂移、增益漂移等偏差校准；温度补偿技术一建立表达温度的数学模型（如多项式等），用差值等数学处理方法，便可有效的实现温度补偿；非线性补偿技术根据测得的特性曲线，进行分段插值，只要插值点数取得合理和足够多，就可获得优良的线形。美国TOLEDO公司、STS公司、CARDINAL公司和德国HBM公司研制的数字式智能称重传感器，都有自己独特的数字补偿技术和工艺。在数字输出消除电噪声；数字电路实现第12页自动温度补偿；解决抗射频干扰（RFI）和电磁干扰（EMI）；实现自适应、自校准、自诊断功能和内置过压保护板以应付闪电引起的电瞬变等方面的技术与工艺均处于领先地位。整体型数字式智能称重传感器的特点是：（1）产生、处理和存储数字信号容易，