Schenck Process (Continued)
DC-Touch OP1
Concentrating on the essentials
Many processes involve a lot of recurring tasks which can be very time-consuming, especially if they are carried out in shift operations by different users, for example. Schenck Process has designed the DC-Touch operating unit for these very circumstances.
Simple operation, impressive results
The DC-Touch operating unit isn‘t fancy but works just as the operator expects it to. Designed for quick and easy, routine control tasks on loss-in-weight feeders, belt weighers, weigh feeders and mass flow meter and feeding devices, it concentrates on the essentials. DC-Touch can be used to parameterise and configure all connected weigh feeders. Usage is further simplified by intuitive menu support when changing bulk materials, carrying out routine setting and calibration work and optimising control parameters. Even less experienced staff will quickly be able to operate the DC-Touch operating unit OP1.
Clear screens for control, calibration, trends graphs and parameters also reduce the operator‘s workload. The program itself contains help texts which are self-explanatory and save users the time they would otherwise spend consulting manuals.
Tough on action
The device can be used at temperatures of between -10°C and +60°C in protection class IP 65. It is available as a built-in unit in the MechaTron control electronics, as a switch cabinet or in the separate field housing for wall mounting.
Overview of special features:
- Touchscreen operating unit for DISOCONT
- 5.6“ colour LCD with graphics
- Integrated help texts to assist users
- Multi-level password protection
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Schenck Process (Continued)
Mobile Touch Panel FSB
The wireless service operating concept
Wireless concepts are in greatest demand when structural circumstances hamper access to the scales. Schenck Process has designed the high-convenience Mobile Touch Panel FSB wireless service operating concept for these very situations. This concept also delivers benefits to everyday work even if your structural circumstances aren’t complicated.
Convenient wireless-based access to the weigh feeder allows you to undertake setting work and temporary user intervention even if you can’t access the scales directly. Even if the ambient conditions aren’t suited for standard notebooks, all work can be carried out with ease.
The wireless module installed in the scales explains the high level of operating convenience. Access is either via a standard notebook using Bluetooth or an operating unit optimised for the industrial environment in question, the Mobile Touch Panel, which is of course also equipped with a wireless interface.
Convenient to use, tough on action
We know that ambient conditions are sometimes really tough, so we designed the Mobile Touch Panel to be sturdy enough to withstand being dropped onto solid ground from a height of 1m. Its wireless performance is also impressive. Under ideal conditions, the operating unit can be positioned at a distance of up to 30m from the scales.
The EasyServe® or Disoplan configuration software recommended by Schenck Process runs on the operating unit. All the components you need are therefore supplied from one source: designed by specialists, ideally configured and assembled.
Self-explanatory functions. A scanner in the operating unit’s software recognises the scales in the vicinity. When scales are selected, the operating unit uses Bluetooth standard wireless transmission to establish a connection. The EasyServe® or Disoplan configuration software recommended by Schenck Process runs on the operating unit.
Overview of special features:
- Wireless service access
- Robust design suitable for industrial use
- Operation without direct access to the scales
- Incredibly easy to use
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Schenck Process (Continued)
DISOMAT® B plus Ex, Zone 1
Versatile and communicative
Customisable technology for demanding logistics
Weighing, monitoring, controlling, feeding – the modular DISOMAT® system can be individually adjusted to any task using logical functional modules.
DISOMAT® B plus Ex is a compact device with multifunctional advantages, equipped with six different, preconfigured weighing sequences. It also has a built-in printer controller enabling individual formatting of the documents.
Network-ready:
Communication between several DISOMAT® B plus Ex units allows the shared use of resources, such as printing, communication via an interface or common databases.
Flexible:
The “SMALL” software program enables the programming of task-specific weighing sequences and functionalities.
Convenient operation from a PC:
The Windows-based DISOPLAN B program enables even non-technical personnel to make the usual adjustments, while sophisticated optimisations can be performed by specialists. The scale data can also be accessed by remote data transmission.
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Schenck Process (Continued)
DISOMAT® Opus
Compact and economical for logistics applications
The cost-effective solution for legal-for-trade applications: DISOMAT® Opus
The basic solution that pays off in legal-for-trade applications. It registers weight values, displays them, prints them out, and forwards them to a higher-level system if desired. The DISOMAT® Opus offers two housing options, which include a tabletop device and a wall-mounted device both in stainless steel design. Problem-free interaction is achieved due to optimal hardware and software technology.
The DISOMAT® Opus is ideal for platform scales, container scales or single-component dosing. The selection of different interfaces enables a wide range of simple process applications.
Convenient (operation from a PC):
The DISOMAT® Opus configuration software permits parameterization and adjustment of the device from a PC over serial interface and customer network.
Compact:
The calibration memory (optional) integrated into the device frees the user from the need to create and file legal-for-trade references on paper.
Smart:
The parameters of the scale, including the adjustment data, are stored in the connector plug of the load cell cable (device dongle). If, in the worst case, it becomes necessary to exchange every component of the device, this dongle makes it possible.
Compatible:
A broad spectrum of serial interfaces and fieldbuses makes it easy to integrate the DISOMAT® Opus into your process control system. Apart from this efficient communication with automating systems you can continue to use conventional interfaces for communication.
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Schenck Process (Continued)
DISOMAT® Satus
Manifold, flexible and safe
The inexpensive solution for decentralised measuring and control
Excellent cost-effectiveness and variety of applications are what single out the DISOMAT® Satus digital scale transmitter. It is suitable for a large number of simple, standard weighing tasks.
Application examples:
Weight monitoring and control of single-component feeding processes. Together with Schenck Process DMA measuring eyes, it can be used easily and inexpensively for fill level measurements with lower accuracy requirements.
Diverse and flexible:
Barrier sets are directly installed in the field housing or in the 19" rack mounting as a scale transmitter or as a slender model. This is optimal for multiple-scale applications.
Fully system-ready:
A wide range of serial interfaces and field buses enable integration into the process control system. Communication is also possible via conventional interfaces.
Convenient operation using a PC:
The Windows program DISOPLAN enables even non-technical personnel to make the necessary adjustments via a PC/Notebook.
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Schenck Process (Continued)
DISOMAT® Tersus
Flexible, sustainable
The very best solution for demanding logistics applications
The DISOMAT® B weighing terminal has long been the last word in logistics. But now it’s gone one step further. The terminal is more efficient, extremely adaptable, highly flexible and sustainable, delivering the very best solution for complex tasks.
The DISOMAT® Tersus detailed below has been designed with the future in mind. It is compatible with the previous version and also offers a range of noteworthy optimisations for ambitious planning.
Sustainable in all regards:
The DISOMAT® Tersus features greatly increased processing power which makes light work of demanding processes requiring intensive computation.
Its wealth of communication options allows it to be easily incorporated in a wide range of current and future data processing and control systems. Whether you use PLC, PC, industrial fieldbuses, USB, Bluetooth or other inputs and outputs, the DISOMAT® Tersus adapts and fits in perfectly, even if you have a standard, integrated Ethernet interface. The total number of digital and analogue inputs and outputs has been doubled.
The optional memory expansion provided by the USB stick makes the device ideal for even more extensive applications. The version with two measuring channels increases efficiency by making parallel measuring and feeding possible on both channels. Filling or discharge scales can also be easily combined at the same time. All in all, these features save time and money. And there’s more to come.
Maximum performance. Convenient control: When operating via a PC or laptop using Bluetooth or Ethernet and DISOPLAN, the graphic interface, device parameters can be set quickly and conveniently. Device adjustment and configuration of the print layout are child’s play. The firmware and all individual set parameters are backed up and restored in next to no time.
Other benefits at a glance:
- Legal for trade version (8000d, multi-range multi-division scale 3 x 4000d)
- Temperature range -30ºC to +60ºC, legal for trade between -30ºC and +40ºC
- Four integrated USB ports (for PC keyboard, printer, calibration memory and memory expansion)
- Scope for connecting up industrial fieldbuses
- Wireless communication via Bluetooth – interface optional
- Wireless configuration of scale electronics via Bluetooth interface
- Clear user guidance on the backlit LCD with graphics
- Different operating languages and case designs
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Schenck Process (Continued)
DISOBOX®
The new convenience standard
The smart alternative with terrific prospects for the future
With the DISOBOX®, the Schenck Process specialists have logically extended their successful concept and enhanced it with some new features. DISOBOX® converts conventional analogue scales into digital scales, both for legal-for-trade and for process applications. It can be combined with the DISOMAT® family analysis devices or DISOVIEW E PC software to produce high-precision, multi-talented weighing systems.
The most important feature of the new electronics unit is that the output signal of each load cell is separately digitised. This provides access to the measuring voltage of the individual cells at any time. It also enables precise analysis of the dead load distribution during commissioning – including convenient, electronic corner balancing.
During running operation the load distribution on the scale is analysed and each load cell is individually monitored. In the event of an error, the affected component is quickly identified. This provides key savings in terms of time, materials and costs, and also ensures greater process reliability.
Universal use:
The DISOBOX® has virtually unlimited applications and shows its worth wherever maximum flexibility and digital, fault-proof signal transmission are required.
Typical applications:
Truck scale applications, rail vehicle scales, crane scales, and hopper scales. Above all, it is used in systems in which the load distribution is important, e.g. in wheel load scales, test systems or in scales designed to determine the centre of gravity.
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Schenck Process (Continued)
MULTIDOS® VDP
An apron weighfeeder for poorly flowing and “sticky” materials
In the past, transporting “sticky” bulk materials presented an almost insoluble challenge. However, achieving the impossible has never been an obstacle to Schenck Process’s development specialists. With the MULTIDOS® VDP, they have developed a perfect economic solution.
There’s no such word as “impossible”!
MULTIDOS® VDP reliably feeds even sticky materials such as clay, marl, trass or sludge with the high degree of accuracy that a weighfeeder can provide.
More precise feeding, with stable, reproducible quality improvement
The weighing technology has been integrated into the track of the VDP apron weighfeeders. Silo discharge and gravimetric feeding functions are now united in a single unit. This results in significantly better feeding accuracy compared with volumetric extraction apron feeders in the past.
The result:
stable, repeatable quality improvement in the mixing plants. This represents quality which is well worth it, thanks to its low investment costs and high feeding accuracy of ± 1%, compared to the actual feed rate.
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Schenck Process (Continued)
Semi-mobile Compact System for Secondary Fuels
Getting the job done with a low level of investment and in the smallest space possible
Saving energy costs is a top priority. The solution is to use alternative fuels for kilns/boilers such as classic and secondary fuels (e.g. shredded plastic and production wastes, old tires and grinding dusts, meat and bone meal and processed domestic waste).
The problem with this is that these very different materials pose extremely difficult challenges regarding the design of the feeding and conveying systems.
A solution that saves costs and personnel
Schenck Process’s semi-mobile compact system is extremely economical, uses variable concepts, and only requires 9 x 6 m of space. It does not require either structural changes or reserve silos.
Secondary fuels are either discharged directly from tractor trailers with “walking floors", or are delivered in tipping containers. The material is added to the MULTIDOS® weighfeeder via the extraction screws and troughed chain conveyor. An appropriate amount of fuel is then fed into the blow-through star feeder, and then conveyed directly to the burner.
This process can be controlled from the control station without the need for additional personnel. Truck drivers from the logistics partner deliver the fuels and change the tractor trailers.
DISOCONT® and PLC technology represent our measuring and control technology for continuous automatic operation.
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Schenck Process (Continued)
Vibrating Discharge Feeders
Solutions la Carte
No easy task
When medium, heavy or extremely abrasive materials have to be transported over different conveyor lengths from silos or other storage containers.
Our solution
We offer the perfectly adapted solutions la Carte for even the most demanding tasks– from individual solutions to individual components and product solutions.
Schenck Process vibrating discharge feeders are preferably used for discharging bulk solids from silos. They transport medium to large material flows over conveyor routes of varying length. Even very heavy, highly abrasive materials can be discharged under the most difficult of conditions with the aid of our specially designed vibrating discharge feeders.
Feeders with magnetic exciters, balancing motors or force exciters are used, depending on the application.
Service and know-how inclusive
Talk to our specialists, and let us put forward a tailor-made solution that will be well worthwhile.
- Discharge feeder with unbalance exciter
- Discharge feeder with force exciter
- Magnetic feeder for dosing/bunker feeding
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Schenck Process (Continued)
Force exciters
Economical, smooth running, low
Long-distance runners with high force potential
The directed force exciter ranges from Schenck Process make the ideal drivers for linear vibration screens and vibrating conveyors. With exciter forces from 43 kN to 493 kN, they cover a wide performance range.
High economy – guaranteed
Oil lubrication and optimised roller bearing and gear pairing ensure smooth running, long exciter working life, and low maintenance, resulting in outstanding economy.
The high availability in particular makes these force exciters the ideal drives for use in continual operation.
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Schenck Process (Continued)
Rotary Force Exciters
Durable, low operating costs, Low maintenance
Powerful arguments for use in the foundry industry as well as in the pit & quarry industry
With the Schenck Process rotary force exciter cells, a new drive concept with exciter forces from 26 to 493 kN is available for the circular-motion vibro screens. Lubricated by oil, the cells stand out for the long working life of the bearings, simplified accessibility and maintenance and an outstanding price/performance ratio.
The sum of all benefits
In the foundry industry as well as in the pit & quarry industry above all, vibro screens from Schenck Process equipped with the new rotary force exciter cells have proved their worth: high availability, long service life, low maintenance and low operating costs, making them a worthwhile investment day by day and year by year.
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Schenck Process (Continued)
Hopper scales
High precision, easy maintenance
Designed with extreme conditions in mind
Hopper scales in the burdening area have to retain their reliability and accuracy even under the most extreme of conditions. The high levels of dirt produced during the process mustn’t impact negatively on their function or ease of maintenance.
Schenck Process hopper scales have been designed for just these applications. Since they are fitted with RTN load cells which are optimised with VEN elastomer mounts along with bumber checks, neither dirt nor material admission can harm them.
The dampening effect of the elastomer mount reduces building vibrations and the dynamic loads of the discharge feeders. The bumber checks can be easily checked and set which greatly simplifies and speeds up all maintenance work.
Benefits
Continuously reliable results, even under extreme conditions. Bumber checks are easy to check and set. All maintenance work becomes much simpler and faster and servicing costs are cut.
Applications
Schenck Process hopper scales are used in burdening areas for the production of pig iron.
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Schenck Process (Continued)
Blast furnace top scales
Robust, reliable, durable
Highly resistant scales
Blast furnace top scales are subject to the most extreme of ambient conditions. The weighing systems used must be designed to withstand a lot, such as the lifting forces resulting from the pressure of the blast furnace top gases (approx. 2bar).
Schenck Process blast furnace top scales are designed for just these conditions.
Nowadays we recommend that customers screw blast furnace top scales directly onto DWB weighbeamsfor such applications.
The benefits of this application are obvious: the scales contain no parts requiring adjustment (e.g. guides or spring elements). They are pleasantly simple to install and maintain.
Other benefits
Schenck blast top furnace scales are very robust and are characterised by high reliability and outstanding durability. A benefit that not only satisfies the very particular requirements of this type of scales, but also makes economic sense.
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Schenck Process (Continued)
Test equipment
Safe, mobile, adjustable
The clever mobile solution
If processes are to be carried out with accuracy, the hopper scales must be adjusted with precision. But structural circumstances mean that the burden hoppers cannot always be checked for accuracy or adjusted by fitting or adding external weights. Or if this is possible, it is simply too complex a process.
As an alternative Schenck Process can supply mobile check wear to provide a smart solution to this task.
The mobile check wear consists of a two-section frame with an integrated hydraulic cylinder and master load cell. This unit is supplied pre-assembled by Schenck Process and is suspended between the base of the hopper and the foundation using terminal links.
Reliability through correct adjustment
Once the hydraulic pressure has been applied, the test equipment produces a tractive force between the hopper and foundation, a proportion of which is forwarded to the scales’ load cell as the resultant weight. The result is displayed on the DISOMAT® Tersus.
A comparison of the two evaluation electronics provides information about correct adjustment or shunt forces on the hopper scales if required.
Mobile or stationary
Depending on size and usage, Schenck Process check wear can be fitted permanently to the hopper or used as a mobile unit for several hoppers.
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Schenck Process (Continued)
Scrap ferries and scrap trailers
Adaptable, precise, tough
Mobile applications
One thing is of paramount importance for scales in scrap ferries or trailers: you must be able to position them anywhere.
Schenck Process weighing system solutions are designed with this in mind. As mobile equipment, they can always be positioned in close proximity to various scrap fractions. The best place to fit weighing systems is inside the vehicle frame under the scrap bucket but sufficiently clear of the ground. This protects the weighing system from scrap parts, dampness and mud.
Scrap ferry scales on vehicles with shock absorption are usually designed as double-frame solutions with large RTN load cells. We recommend weighbeams with integrated overload protection for vehicles without suspension or damping.
High levels of weighing accuracy. Guaranteed!
Despite being highly dynamic, the weighing equipment we fit in scrap ferries achieves accuracies of up to ± 0.1% of the weighing range’s limit value.
The precise charging of smaller volumes of high alloy steels is of particular importance in scrap yards. Once taring (based on a defined minimum load) is complete, Schenck Process guarantees accuracies of up to ±1% of the actual value of the loaded scrap. If one grade of approx. 10t is loaded in a single load, the weighing tolerances will therefore be no more than ± 100kg.
Our experts would be happy to draw up a complete quotation for your mechanical installation, energy supply concept and data transfer, including guaranteed levels of weighing accuracy. Give us a call to discuss the details.
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Schenck Process (Continued)
Ladle ferry
Adaptable, robust, reliable
Operational reliability under the toughest of conditions
Ladle ferries in steel plants transport the steel to the downstream crane or secondary metallurgy. The weighing system used must have extremely robust characteristics.
Schenck Process weighing systems are designed for just these tough conditions. They remain unscathed in the face of the high mechanical impact of inserting the casting ladle into the ladle support, high horizontal forces resulting during insertion impact and extreme temperatures of the liquid pig iron or steel. Even dirt or slag splash have no impact on reliable operation.
Other benefits inlude: short changeover time, quick production start-up after installation and maintenance
Individual solutions or the complete package
Depending on the amount of space available on the ferry, we recommend fitting RTN load cells with VEN elastomer mounts or WDI weighing discs with fixed or loose bearings on ferries with a double-frame setup.
DWB weighbeams
are perfectly suited for ferries without double frames but with ladle supports in the centre of the vehicle.
Changing a ladle ferry to a DWB weighbeam increases operational reliability because each weighbeam is fitted with an integrated temperature sensor displayed on the control panel.
The complete MULTILADLE package from Schenck Process is a very reliable system for ladle ferries. Since the package is fitted with infrared or radio data transfer, damage to the trailing cable installation and cable drum, for example, is avoided.
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Schenck Process (Continued)
Platform scales or weighbridges
Robust, precise, easy to maintain
The robust solution from the professionals
Tried and tested, solid, fixed location platform scales or weighbridges are often used when there is no connection to the track.
The tailor-made concept for all environments
Schenck Process weighbridges are designed as solid welded constructions. The surface of the scales is also often weighted and protected through the addition of slabs which are secured in place.
Depending on the construction and logistical circumstances, we offer overload protection as a mechanical form of protection when loading the weighbridges with trailers or heavy-duty trucks.
Minimising the penetration of dampness and the levels of dirt accumulating in the scales pit have to be taken into account when designing both scales and foundation. The top scales gap is also critical. If it is blocked, weights will be distorted by shunt forces. All these factors need to be considered when planning precise installation.
Schenck Process is an experienced partner to have on board. Our specialists know how to plan and fit these robust, precise and low-maintenance scrap weighbridges perfectly. We will select the right mechanical concept for you depending on your existing conditions. The tried and tested RTN load cells, the DWB weighbeam or WDI weighing disc round off your individual solution.
Since the weighing system is fixed in one location, the transfer of signals and supply of energy is also guaranteed and can be carried out with the DISOMAT®Tersus weighing terminal.
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Schenck Process (Continued)
Train scales
Convenient, adjustable, cost-effective
The convenient solution
Train scales for torpedo vehicles allow pig iron to be weighed with ease.
Static or dynamic
The scales can be fitted statically under the blast furnace’s discharge position or dynamically in the track between the blast furnace and steel plant.
Both the static and the dynamic MULTIRAIL® versions can operate fully automatically and calculate e.g. the net pig iron production volume per day for internal balancing purposes.
The mechanical solution favoured by Schenck Process for both scenarios involves sleepers fitted with DMR weighbeams, or if the torpedo vehicle is exposed to higher wheel loads, the WDI weighing disc. These are also mounted straight on to the standard concrete sleepers (B70W) and feature a lower overall height. Depending on the torpedo vehicle type, any bridge length can then be produced.
Loud and clear arguments
Cost-effective:
The concrete foundations usually required are not needed for torpedo vehicles with gross weights of up to 800t. Production costs are saved and production losses caused by downtimes minimised.
Precise results:
When weighing both bogies, accuracy levels of +/- 0.1% of the weighing range’s limit value can be achieved and when weighing one side only, the figure is +/- 0.5%.
Time-saving:
To balance the volume of pig iron at the steel plant, the weight of torpedo vehicles travelling at 4-8km/h can be calculated without long delays. An accuracy of +/- 0.5% of the weighing range’s limit value is achieved.
Versatile:
- Level control/monitoring
- Monitoring and analysis of wear to the torpedo’s refractory and recognition of baked-on crude steel
- Level monitoring with static scales
- Analysis of changes in torpedo weight of vehicles which may arise as a result of refractory wear
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Schenck Process (Continued)
MULTIRAIL® HotMetalWeight
Every second counts when you're processing pig iron - which is why fully automatic in-motion weighing is the ideal solution for torpedo wagons. The high-precision MULTIRAIL® HotMetalWeight train scales developed by Schenck Process enable you to weigh pig iron as it travels from the steel plant to the blast furnace. You don't waste any time as it's fully automatic and doesn't require a scales operator.
Precise force measuring technology for process optimisation
The measured pig iron production weight can then be balanced according to the shift, daily and monthly total. This data serves as a basis for the performance record for the blast furnace plant. Because the information about the actual weight is also available before the supply of pig iron reaches the steel plant, subsequent processes on the converter can also be optimised.
The precise force measuring technology under the rails weighs the actual weights of all laden and empty wagons as the vehicle passes over. Special force sensors integrated in the standard concrete sleepers safely transfer the forces and torque affecting the track to the track bed and at the same time record the axle loads with a high level of accuracy and reproducibility.
The system also detects the wagon numbers and registers all values. Only the static function of the scales is used for adjustment; the customer does not need to provide reference scales.
Structure and integration. Without wasting time
The scales are integrated without the need for foundations by simply laying the weighing concrete sleepers. The rails are then welded without gaps. The weighing system can therefore be installed in the roadbed during regular track overhaul without wasting time.
The weighing values and the other process data is processed with the help of the Windows-based software DISOWARE Terra.
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Attachments
multirail-hotmetalweight (JPG)
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Schenck Process (Continued)
Train scales, principle of the weighing track
Safe, easy to maintain, robust
The solution with added benefits
The true value of these static train scales from Schenck Process can be appreciated by adding up all their adapted application-specific features.
Each wheel load is recorded by its own weighbridge when the loading vehicle is parked in the defined position. Our direct weighing system allows the left and right sides of the wheels to be separated by firmly screwing each weighed track piece onto two DWB weighbeams. When the scales are in use, the weighbeams can be relied upon to transfer all forces and torque without distorting the measurement.
Loud and clear arguments:
can be refitted quickly, shallow foundation depth, simple to implement, low risk of contamination, no foundation pit.
Other benefits
If the weighbeams are large enough, the train scales require virtually no maintenance since no additional bearing elements or guides have to be fitted.
The weighing mechanism is protected from overload without the need for additional elements by the flexible transfer of dynamic impact forces to the track body via a chute, vehicle frame and wheel-rail connection.
The right evaluation electronics: DISOBOX®
can monitor all individual load cell signals. DISOPLAN® records proportions of dynamic impact load by quantity over time and helps to quickly detect shunt forces caused by high levels of contamination.
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Schenck Process (Continued)
Crane scales - Weighing in the chassis
Low installation height, low-maintenance, precise results
Weighing the crane trolley near the chassis
Which technical weighing solution is the most cost-effective and most reliable for the given circumstances? This is always the key question asked by customers wanting to plan scales for ladle transfer cranes. Especially when the amount of space available is limited as is often the case when retrofitting.
Our solution
The extremely low installation height of our crane scales solution even allows for retrofitting in the tightest of spaces. The principle our solutions use is that several weighing units are integrated at the interface between crane frame and chassis. From there they can record the transferred ladle weight in full and transfer any motion forces which arise.
The weighing units consist of several DWB weighbeams.
Precision, reliability and ease of maintenance
We achieve very low maintenance levels by using permanently screwed down weighing units which contain no moving or wearing parts requiring adjustment. There are no critical cable connections, as you would find in cross-beam installations. Last but not least, the scales offer very good protection from radiant heat thanks to their compact and modular design.
Their accuracy is up to +/- 0.1% of the limit value of the weighing range.
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Attachments
stahlerzeugung-kranwaage (JPG)
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Schenck Process (Continued)
Crane scales – upper sheave-block weighing
Pre-assembled, space-saving, highly accurate
Weighing in the upper sheave-block
Upper sheave-block weighing is perfectly suited to cases where an elegant solution is needed and needed quickly. This solution uses DRA radial load transducers that measure and transfer the radial loads of the crane cables, in turn making the supporting structure a technical weighing element.
Special technical features
The crane’s structural calculations do not have to be changed or limited in any way. The bolt diameters or rope sheaves used do not have to be changed. No extra height is needed for installation.
Other benefits
Can be retrofitted very quickly as the weighing system is pre-assembled in a new bearing stand on the floor which is then permanently welded to the crane trolley and mortised.
There are no critical cable connections. Extremely easy to maintain and protected against extreme temperatures.
Up to 80% of the crane cables can be recorded by the weighing system when using an upper sheave-block setup. At the end of the day, an accuracy of up to +/- 0.2% of the limit value is achieved.
Signal transfer and energy supply are simple as the system is fitted on the crane trolley. The scales can also be fitted with the DISOMAT® Tersus plus scales terminal.
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stahlerzeugung-oberflasche (JPG)
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Schenck Process (Continued)
MoveMaster
En-Masse Conveying & Elevating
Gentle Handling of Bulk Materials
MoveMaster - The Mechanics of En-Masse Conveying and Elevating
En-Masse movement is the term used to describe the unique method of conveying bulk materials smoothly, gently and economically. Material is induced to move like a liquid through a slender dust tight steel casing, horizontally, on an inclined plane, vertically and around bends. The conveyor feeds itself at any point with a uniform load. The skeletal flight configuration induces the material to flow in a solid, placid column. There is no internal disturbance or pressure on the material and the load can be discharged at any opening, where it is permitted to fall away from the flights. The conveyor is not a scraper conveyor. There is no dragging or scraping action, material simply moves forward in a solid placid column, ‘En-Masse.
MoveMaster
Conveying & Elevating with Proven Technology
MoveMaster En-Masse Conveyors
Movement of the chain when buried in the material will induce the whole mass to move forward gently in a solid, placid column ‘En-Masse’. Material dragging, particle tumbling or rolling DOES NOT occur. MoveMaster Conveyors are manufactured in a standard range of sizes from 200mm wide upwards, enabling them to meet every requirement. Multiple inlets and/or outlets for conveyor intake or discharge. ‘Two-Way' Conveyors will convey in both directions.
MoveMaster En-Masse Eleveyors
Movement of the chain when buried in the material will induce the whole mass to move forward gently in a solid column. The eleveyor design permits the column of material to be moved vertically or on an inclined plane. Eleveyors are manufactured in a standard range of sizes from 200mm wide upwards, which enables them to meet every requirement.
The Benefits of MoveMaster En-Masse Handling
Cost Effective
Capital Costs prove very competitive with other forms of handling equipment, thus giving quicker ‘payback period’. Power Running Costs significantly lower than most other forms of equipment, i.e they can be as low a 1/10 of dense phase conveying. Low Cost Maintenance. Heavy duty rigid construction in simple modules, high strength chain, choke detectors, overload and underspeed switches all ensure easy maintenance at infrequent intervals.
Labour Saving
Manual to fully automatic control of single or multiple machine systems provided by proven BASIC control systems. No specialised maintenance staff required.
Environmentally Acceptable
Totally Enclosed machines and transfer points of dust-tight and weatherproof construction. Safe as all moving parts are totally enclosed.
Versatile
Specialised features of ‘En-Masse’ equipment offer versatility to plant layout. Handles virtually all types of dry bulk products.
Size
Size and duty comparison with alternative forms of handling equipment.
Gentle Handling
Materials moves ‘En-Masse’ slowly in a solid placid column with the conveying elements; thus degradation is virtually eliminated. Chain Design permits material column to change direction through bends, without degradation.
Proven
Over 80 years experience of handling hundreds of bulk materials worldwide within a wide range of industries
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Re: Schenck Process Gmbh
MaxiStore
Bridge Distribution System
Utilisation of Space that Maximises Profit
Flat Store or Silo?
The use of a flat store is virtually self selecting when considered against a number of criteria. High throughput volume. Throughput of different types and qualities of product. The need to keep them segregated. Storage characteristics of the material which make it difficult and or expensive to reclaim material from silos. The photograph shows how the material ‘stands up’ and creates almost vertical walls illustrates this point. Cost, where floor space is not a problem then the flat store provides an economic solution as opposed to the alternative silo arrangement. The overall operational philosophy of such a plant and its equipment is well established and very practical which simplifies control methods. Plant maintenance is simplified and personnel readily assimilate the operational requirements.
Feeding the MaxiStore
Material feed to the bridge conveyor is by means of conventional forms of belt conveyor with two different arrangements available:
1) The unit incorporates a belt conveyor mounted at low level on the sidewall along the whole length of the store and is fed from the outside of the building at the tail end of the belt conveyor. The belt conveyor is fitted with a travelling belt tripper that is attached to and moves with the bridge structure. Thus the bridge can be fed at any point along the length of the store. This option is normally used for systems within existing buildings.
2) This system utilises a travelling and reversible shuttle conveyor mounted along the sidewall of the store. However this time it is fed from outside the building at the mid point in the store. The length of the shuttle is approximately half the length of the store and feeds directly onto the bridge from either end. The MaxiStore is automatically attached to the selected end of the shuttle and then moves with the shuttle to fill one half of the store. To fill the other half of the store the bridge is un-coupled and then re-coupled to the opposite end of the shuttle. All functions on both systems are carried out automatically from the central control room.
Benefits of the MaxiStore
- Maximises storage space within flat store buildings
- Cost effective compared with other storage methods
- Fitted within traditional and common forms of structural buildings
- Employs only well proven forms of equipment. Installation is quick and easy
- High environmental status and features
- Fully automated
- Low level of operational and maintenance staff required
- Single or multiple material storage readily achieved
- Simple form of reclaim direct to road vehicles.
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Schenck Process (Continued)
IntraBulk
Reception Unit
- Above ground intake
- Feed from road vehicle or loader
- Fast vehicle turn around time
- Can act as a buffer store
- Controlled discharge into process
- Modular heavy duty construction
- Quick installation & commissioning
A Redler product, Schenck Process Group
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Schenck Process (Continued)
FloMaster
Circular Bin Discharger
Continuous Product Flow At A Controllable Rate
The FloMaster Circular Bin Discharger (CBD) is a well proven and established positive discharge aid for hoppers and silos where the material is to be handled has characteristics which make it difficult to discharge or control. A rotating arch breaker arm travels around the hopper bottom section of the silo breaking any bridge of material which may have formed. This ensures a flow of material to the discharger which can be supplied as a single, two or three stage unit to suit the characteristics of the material to be handled and the throughputs required. The standard range comprises of two sizes: 800mm and 1000mm diameter. Besides functioning as a bin discharger, the FloMaster can be used to maintain a head of normalised material in the outlet chute, thus assisting the accuracy of subsequent metering or weighing equipment. Material in excess of the take away rate is re-cycled. The FloMaster is driven by a single drive controlling the rotation of both the discharger and arch breaker arm. Actual drive arrangements vary according to the application or customer requirements.
Features and Benefits
- Positive Discharge: Archbreaker arm is immersed within the material to be discharged promoting positive flow.
- Compact: The FloMaster forms an integral part of the silo and occupies minimal space.
- Versatile: Can control the discharge of non free flowing materials and those subject to fluidsation.
- Cost Effective: Simple design ensures cost effective solution to discharge problems.
- Safe: All moving parts are totally enclosed.
- Minimal Wear: Machines operate at slow speeds for long life
- Quiet: Operation is virtually silent making the unit environmentally acceptable.
- Easily Maintained: Main shaft assembly removed from below.
- Unique: The FloMaster is a unique Redler® product and has been proven over 80 years.
- Totally Enclosed: Unit is totally enclosed ensuring dust tight operation.
Typical Materials Handled
Alloprene, Alumina Hydrate, Anthracite Coal, Anthracite Dust, Ash, Ball Clay, Calined Alumina, Calcium Fluoride, Calcium Sulphate, Cattle Feed Ingredients, Caustic Prills, Cellulose Pulp, Cement, Cereal Screenings, China Clay, Chocolate Crumb, Coal, Cocoa Cake, Cocoa Nibs, Cocoa Powder, Crushed Peat, Detergent Additive, Electrolitic Manganese, Feldspar, Fine Wet Coal, Fish Meal, Flock Pulp, Fluorspar, Gypsum, Hydrated Lime, Iron Oxide Dust, Lead Fume Dust, Leather Shavings, Light Soda Ash, Lime, Meat & Bone Meal, Mica, Mineral Wood Dust, Mixed Screenings, Nephylene Syenite, Oat Floor, Peat, Phosphate Rock (Ground), Phosphorous, Anhydride, Phosphorous Pentoxide, Phthalic Anhydride, Radox, Rice Bran, Rock Salt, Sawdust, Soda Ash, Sodium Sulphate, Soya Bean Meal (Dry), Spent Grains, Spent Hops, Starch, Sugar, Titaniun Dioxide, Winnofil, Wood Chips, Wood Flour
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Attachments
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Schenck Process (Continued)
MCPP Modular Coal Preparation Plants
Coal washing plants for the crushing, sizing, washing and drying of coal to enable it to be used in power stations
Products:
Modular Coal Preparation Plant (MCPP) comprising of crushers, vibratory screening equipment, filter presses and centrifuges
Description:
Modular Coal Preparation Plants (MCPP) prepare coal for a cleaner burning process, enhanced calorific value and cleaner emissions. MCPPs consist of several modules including a raw coal preparation (crushing and screening station), a coal feed and washing module (jigging and Heavy Medium cyclone) as well as a dewatering module.
Throughput Rate:
150 to 200 t/hr (per washing unit)
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Schenck Process (Continued)
Force exciters
Economical, smooth running, low
Long-distance runners with high force potential
The directed force exciter ranges from Schenck Process make the ideal drivers for linear vibration screens and vibrating conveyors. With exciter forces from 43 kN to 493 kN, they cover a wide performance range.
High economy – guaranteed
Oil lubrication and optimised roller bearing and gear pairing ensure smooth running, long exciter working life, and low maintenance, resulting in outstanding economy.
The high availability in particular makes these force exciters the ideal drives for use in continual operation.
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Re: Schenck Process Gmbh
Train Loading Systems
Accurate, high speed Loading Systems for any application
Reliable Operation
Schenck Process Train Loaders are designed to operate reliably in the harshest mining environment. High temperatures, dust, and water are commonplace in the mining industry. Schenck Process train loaders will not only handle this harsh environment, they will operate reliably for extended periods with only routine maintenance.
Extensive use of high quality corrosion resistant paints, environmentally sealed electrical equipment, and high quality hydraulic components ensure the reliable operation of a Schenck Process train loader throughout the life of the mining operation.
Low Maintenance Requirements
- Use of high quality corrosion resistant paints
- Environmentally sealed electrical equipment
- High quality hydraulic components
Ensure the reliable operation of a Schenck Process train loader throughout the life of the mining operation
Material Handling Expertise
The performance of a train loader is often limited by the operation of the stockpile and reclaim system and the capacity of the train loader surge bin. While both are separate systems, they operate in concert to achieve a given performance. Poorly designed reclaim systems, or insufficient train loader surge capacity can significantly downgrade train-loading performance. Equally it does not make good economic sense to provide excessive reclaim or train loader surge capacity. The two systems need to be designed with the performance and requirements of the other being considered.
The Schenck Process loading systems team has extensive experience in materials handling, and stockpile reclaim systems. Schenck Process's engineers are available to assist our clients with materials handling system design, thereby optimising operation of the reclaim system and train loader, while at the same time considering capital expenditure constraints.
Schenck Process can also incorporate electrical and PLC control of the clients' materials handling system into the train loader design if required
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Schenck Process (Continued)
Rotary Force Exciters
Durable, low operating costs, Low maintenance
Powerful arguments for use in the foundry industry as well as in the pit & quarry industry
With the Schenck Process rotary force exciter cells, a new drive concept with exciter forces from 26 to 493 kN is available for the circular-motion vibro screens. Lubricated by oil, the cells stand out for the long working life of the bearings, simplified accessibility and maintenance and an outstanding price/performance ratio.
The sum of all benefits
In the foundry industry as well as in the pit & quarry industry above all, vibro screens from Schenck Process equipped with the new rotary force exciter cells have proved their worth: high availability, long service life, low maintenance and low operating costs, making them a worthwhile investment day by day and year by year.
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Schenck Process (Continued)
Vibrating Discharge Feeders
Solutions la Carte
No easy task
When medium, heavy or extremely abrasive materials have to be transported over different conveyor lengths from silos or other storage containers.
Our solution
We offer the perfectly adapted solutions la Carte for even the most demanding tasks– from individual solutions to individual components and product solutions.
Schenck Process vibrating discharge feeders are preferably used for discharging bulk solids from silos. They transport medium to large material flows over conveyor routes of varying length. Even very heavy, highly abrasive materials can be discharged under the most difficult of conditions with the aid of our specially designed vibrating discharge feeders.
Feeders with magnetic exciters, balancing motors or force exciters are used, depending on the application.
Service and know-how inclusive
Talk to our specialists, and let us put forward a tailor-made solution that will be well worthwhile.
- Discharge feeder with unbalance exciter
- Discharge feeder with force exciter
- Magnetic feeder for dosing/bunker feeding
Attachments
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Schenck Process (Continued)
MULTIRAIL® LegalWeight
Dynamic Weighing
Legal-for-trade, dynamic train scale for all lines
High-precision weighing
The dynamic train scale for weighing trains and rail cars is now a minor classic! No wonder: intelligent solutions are worth their while and deliver cost and time savings.
MULTIRAIL® LegalWeight from Schenck Process pays its way as a legal-for-trade application from the outset. It provides high-precision rail car weighing using fast and legal-for-trade calibrated weighing of the goods during transit, irrespective of whether individual rail cars or whole trains are being weighed.
Applications:
Legal-for-trade dynamic weighing to OIML R 106, class 0.5. Can be used within a temperature range from – 50°C to +70°C, for solids. It checks load distribution in the bogie. Used in logistics and as the basis for invoicing.
Advantages:
Schenck Process weighing ties, as a combination of robust concrete ties and legal-for-trade weighbeams. Stainless steel weighbeam IP 68. Optionally with an integrated control scale. The database is integrated into standard software; intelligent measurement data analysis plus online remote diagnosis of networked systems are possible.
Fast, gap-free installation by exchanging toes, modular design. EBA and PTB-approved – with an integrated static reference scale. Fast, precise calculation of rail car weights with less shunting. Up to 15 km/h legal-for-trade weighing.
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Schenck Process (Continued)
MULTIRAIL® LiquidWeight
Dynamic weighing. Save time
Eliminating disturbing factors when weighing liquids
Liquids are some of the most valuable goods and when it comes to measuring them, every kilogram counts. They also move about more than any other type of goods, and can only be measured accurately when completely still.
MULTIRAIL® LiquidWeight has been optimised for weighing liquids while eliminating disturbing factors. This certified system enables you to weigh with precision almost any type of wagon or complete train sets.
Efficient, economic material management
The solution is installed without gaps or foundations to avoid additional influences on the wagon while it is in motion. It enables rail vehicles to be weighed dynamically and with high precision – something that was not possible with liquid freight until now. MULTIRAIL® LiquidWeight can operate with precision at weighing speeds of up to 10 km/h. If not being weighed, wagons can travel at the permissible speed for the track.
The system is also optimised for monitoring wheel, axle and wagon load and the position of centre of gravity of the wagon.
Equipment:
Concrete weighing sleepers with high-precision DMR weighbeams which transfer forces and torques and precisely measure the vertical force components. The weighing system is integrated into the track without gaps. Weight values are recorded and processed by the scale electronics and individually adapted PC systems.
Special feature:
Capable of calibration in accordance with OIML R 106-1. Calibration approvals for DE, FR, AT and CH, including approvals for EBA, DB and ÖBB.
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Schenck Process (Continued)
MULTIRAIL® SpeedWeight
High-precision, dynamic, for all speeds
When railway lines are damaged by overloaded or incorrectly loaded wagons, it's too late for repairs. It is almost impossible to anticipate the material damage or to entirely prevent possible accidents where people are injured.
MULTIRAIL® SpeedWeight from Schenck Process, the system for recording wheel, axle and wagon weights at all speeds, reliably ensures that these situations do not arise in the first place while saving time and manpower.
The MULTIRAIL® system identifies vehicles with critical load statuses (e.g. overloading or tilted loads) on the track section. Diagnosis is carried out by wheel or wagon, a clear classification of all results is provided and the wagon type detected. The front/rear and right/left load distribution in the wagon is recorded, saved, printed out and clearly displayed. There are also a number of evaluations for exact diagnosis of loading on the section of track.
Equipment and design
The weighing concrete sleeper, which was specially developed for MULTIRAIL®, features high-precision weighing sensors that transfer all forces and torque and measure vertical force components. It is highly accurate and works at speeds between 10 and 240km/h.
The system is integrated into the track without gaps. Weighing values and data are processed using a PC.
Basic function, including:
- calculating and monitoring wheel, axle and wagon loads
- result classification by wheel or wagon
- wagon type detection
- calculating the front/rear and right/left load distribution in the wagon
- saving and printing out the diagnosis data
- visualisation
The MULTIRAIL® SpeedWeight is available in the version described above and in an ECO version. The MULTIRAIL® specialists at Schenck Process will be happy to explain which version provides the optimum solution for your setup. The linked pages below provide more accurate specifications.
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Schenck Process (Continued)
RoCon® Unit
Electronic rotational speed sensor
- Provides protection for all conveyors, elevators & items with a rotating shaft
- Detects speed change
- Detects machine stoppage
- Interface with PLC automated control
- ATEX compliant for zone 21
A Redler product, Schenck Process Group
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Schenck Process GmbH
Schenck Process GmbH
Schenck Process is the global market leader of solutions in measuring and process technologies in industrial weighing, feeding, screening and automation.
Schenck Process develops, manufactures and markets a full range of solutions, products and turnkey systems on the basis of combining process engineering expertise, reliable components and field-proven technology.
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"bulk-online Leader"
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