New Scale platform for ATEX Zone at IXOM Chile.

 At IXOM Chile, we were upgrading some elements of the high volatile solvents area (white spirit, xylol etc). 

 

One of the devices that raised concerns was the scale. It came to our attention that the conventional scale we were using did not adhere to regulations. As a result, we embarked on thorough research and consulted various scale providers for technical expertise. Ultimately, we opted to acquire a unit from PRECISION Chile. This device guarantees operational safety due to its sealed design and lower voltage operation, in contrast to a standard scale. This innovative feature effectively prevents the emission of heat or sparks from its electrical components.

Electronic-Technicians Installing the new device.

 

 

 

After installation and conducting preliminary tests, it is time to certify the device using a pre-certified weight of 500kg. This certification process involves thorough testing to ensure precise measurements, thereby preventing any issues with the final results and potential wastage of raw materials. In the accompanying image, a truck is shown carrying one ton of certified weight (indicated by the black squares), along with other certified weights, to perform tests and validate measurements up to 1500kg. This meticulous certification procedure guarantees accurate and reliable outcomes.

 

 

 

The test to ensure the proper functioning of the device is conducted as follows:

 

 

Initially, the technicians are required to position 500kg at the designated points (as illustrated in the image) on the scale. This step allows for the evaluation of whether each sensor (with each scale equipped with four sensors near each corner) detects an equivalent weight. Should any discrepancies arise, necessary adjustments are made within the counting board (the scale's central processing unit). Subsequently, this process is reiterated two more times, if not more, to establish a precise and consistent measurement.

 

 

 

 Following the preceding steps, the technicians proceed to incorporate the complete range of weight loads. This procedure is essential to validate the scale's capability to measure weights within the specified range, which, in this instance, spans from 4 to 1500kg, serving the requirements of various operational processes.

 

Finally, they meticulously ensure that all components are in proper order before providing the client with a comprehensive documentation package. This documentation not only certifies the installation's compliance with fire safety standards but also guarantees correct functionality. Additionally, a one-year warranty is included to provide further assurance.

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After the installation, as the maintenance department, we took measures to ensure the safeguarding of such a valuable asset. This proactive approach was prompted by previous experiences involving forklift operations and the resulting challenges we encountered.

 

 

We had to devise an ingenious method to safeguard the device; constructing a frontal wall was out of the question...

As you can observe, our anticipation revolved around the possibility of an operator inadvertently damaging the front of the scale. This concern stemmed from the fact that when loading pallets, there is no alternative but to position them directly ahead, leaving no room for deviation.

General Goal: "Protect the scale in a safe  and friendly way to any operator"

As evident from the preceding sketch, I conceived the following idea, which serves multiple purposes:

1. It prevents the need to confront a solid metal wall head-on, reducing torque exertion when the operator advances and potentially encounters the barrier (indicated by the blue arrows). This design distributes the applied force along the ramp.

2. To ensure the sustained stability of the protective device, aside from utilizing concrete bolts to secure it to the ground, we incorporated an enlarged plate. This enlarged plate guarantees that the forklift necessarily aligns with it during pallet placement on the scale (the red arrow indicates the point where the forklift's wheel initiates downward pressure on the entire device).

3. The structure did not require extensive material thickness; a 5mm sheet metal plate was employed for the "ribs" within the device, while 3mm thickness sufficed for the remaining plates.

This innovative solution not only addresses the operational challenge effectively but also minimizes material usage.

After few days of normal operation, I checked with the operators:

Both they and the production chief expressed their satisfaction with the straightforward yet highly effective solution.

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After the previous successful experience, we bought another conventional scale for another place within the factory and we asked to the same scale provider to build a similar protective device with the previous specification.

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