FORM-2
THE PATENT ACT,1970
(39 OF 1970)
AND
THE PATENT RULES, 2003
(As Amended)
COMPLETE SPECIFICATION (See section 10;rule 13)
"A METHOD FOR DETERMINING, MONITORING AND CORRECTING MISALIGNMENT OF WEIGHING BINS USING LOAD
CELLS AND A SYSTEM THEREOF"
TATA CONSULTING ENGINEERS LIMITED, a corporation organized and existing under the laws of India, of Tata Consulting Engineers Limited, Unit No. NB 1502 & SB 1501,15th Floor, Empire Tower, Cloud City Campus, Opp. Reliable Tech Park, Thane-Belapur Road, Airoli, Navi Mumbai - 400 708, India.

A METHOD FOR DETERMINING, MONITORING AND CORRECTING MISALIGNMENT OF WEIGHING BINS USING LOAD CELLS AND A SYSTEM
THEREOF
TECHNICAL FIELD
The present subject matter generally relates to a plurality of weighing bins of a blast furnace top charging system, and more particularly, relates to the free-standing plurality of weighing bins, undergoing material filling and empty cycle along with weighing bin pressurizing and depressurizing cycles. The present subject matter particularly relates to a method and a system that safeguards the plurality of weighing bins from misalignment using the primary weight, pressure and volumetric elements.
BACKGROUND
In view of automation of the process in a blast furnace top charging bin operation, the degree of continuity or uninterrupted flow of raw material to the blast furnace is vitally important to prevent inefficiency. This is achieved by improving upon individual or multiple systems used in a blast furnace.
In general, blast furnace is an iron making continuous process, but not limited to, which demands uninterrupted raw material charging from furnace top which is ensured using hopper system. The hopper system charges the raw material to a pressurized weighing bin which further charges it to the top charge distribution system to distribute material in furnace. To achieve an uninterrupted output of iron, the raw material is continuously charged to the weighing bin, thereby resulting in repeated material fill and empty operations. Due to such continuous operations of filling and emptying, the pressurized weighing bins tend to rotate or shift in position owing to torque from the connected pressurized pipes. Further, the weighing bin tends to misalign and transfer its load to the connected pipes, show less weight and thereby poses a risk of overfill. In case, if dislocation or misalignment of the weighing bin continues, the probability of fall hazard increases.
This triggered misalignment of the weighing bin causes the expansion bellows or the charging bin itself, to get connected to the nearby structural supports. Such connection results in two-fold effects. Firstly, an unpredicted increase or decrease in weighment data and secondly, an unpredicted rotation or tilting torque on weighing bin as a resultant of temporary

unbalanced forces. While the first effect generates a delay in weighing batches and thereby production, the second tend to misalign the weighing bin.
Therefore, the accuracy of measuring the data of charging bin is significant to reduce the risk of overfill. Conventionally, the delay in batching cycle was minimized by applying bin pressure compensations to weighment data. Also, there is a conventional usage of spring-loaded motion containers to prevent rotational motion on vertical axis. Further, the use of Guide rods with expansion bellows to keep the bins free from connecting structure is a conventional manual practice. Furthermore, the usage of cameras and edge detection techniques for identification of bin misalignment and some instances of additional sensors are the current techniques available in market.
However, these conventional techniques are limited in determining actual misalignment only. Additionally, most of these techniques are one time misalignment detection techniques for determining misalignment in limited direction and torque, thereby reducing the scope of their application to restricted areas and limited scenarios.
Therefore, a need arises for a method of continuous detection of weighing bin misalignment or tendency to misalign and further correction to achieve uninterrupted flow of raw material in blast furnace.
SUMMARY
In a preferred embodiment, the present subject-matter discloses a method to detect, monitor and correct misalignment in a plurality of weighing bins in a blast furnace, comprising measuring, by at least three load cells weight, pressure and volumetric data of the plurality of weighing bins and expansion bellows in the form of voltage readings; wherein at least three load cells are circumferentially disposed around each of the plurality of weighing bins, reading of voltage produced by each of the plurality of load cells are either matches or deviates from the permissible threshold voltage (V0), wherein in the event of deviation of the voltage readings produced by each of the plurality of load cells from the permissible threshold voltage (V0), alerting, by raising a bin misalignment alarm, to indicate the misalignment or tendency of misalignment of the plurality of weighing bins; and correcting, by a plurality of hydraulic jacking cylinders, the misalignment of the plurality of weighing bins by impacting in reverse order of the voltage readings.

In another preferred embodiment, a system to detect, monitor and correct misalignment in a plurality of weighing bins in a blast furnace, comprising at least three load cells are circumferentially disposed around each of the plurality of weighing bins, wherein at least three load cells are configured to measure weight, pressure and volumetric data of the plurality of weighing bins and expansion bellows in the form of voltage readings; voltage produced by each of the plurality of load cells are compared with the permissible threshold voltage (V0), wherein in the event of deviation of the voltage readings produced by each of the plurality of load cells from the permissible threshold voltage (V0), wherein a bin misalignment alarm configured to raise alarm to indicate the misalignment or tendency of misalignment of the plurality of weighing bins; and a plurality of hydraulic jacking cylinders are configured to correct the misalignment of the plurality of weighing bins, by impacting in reverse order of the voltage readings.
OBJECT OF THE INVENTION
It is an object of the present subject matter to provide a method and a system for using diagnostic features of primary load cells for detection of weighing bin misalignment.
It is yet another object of the present subject matter to develop a method and system to calculate the extent of weighing bin misalignment.
It is yet another object of the present subject matter to Real-time monitoring and detection of misalignment of weighing bin during filling and emptying by using Load Cells.
It is yet another object of the present subject matter to send alerts in case of weighing bin misalignment well in time and also inform about tendencies to misalign.
It is yet another object of the present subject matter to give extent and orientation of misalignment by using Three-point load cell readings combined with volumetric data of the weighing bins.
It is yet another object of the present subject matter to a method and a system for correcting the misalignment on the plurality of weighing bins.
BRIEF DESCRIPTION OF DRAWINGS
The foregoing and further objects, features and advantages of the present subject matter will become apparent from the following description of exemplary embodiment with reference to the accompanying drawings, wherein like numerals are used to represent like elements.

It is to be noted, however, that the appended drawings illustrate only typical embodiment of the present subject matter, and are therefore, not to be considered for limiting of its scope, may admit to other equally effective embodiments.
FIGURE 1 illustrates a basic arrangement of a blast furnace in accordance with an embodiment of the present subject matter.
FIGURE 2 illustrates filling and emptying cycles of the weighing bin.
FIGURE 2a illustrates voltage reading of three load cells at an ideal alignment of the weighing bins on the blast furnace.
FIGURE 3 illustrates working of three load cells on top charging bins.
FIGURE 4 illustrates configuration of weighing bin misalignment detecting & corrective system
FIGURE 5 illustrates weighing bin misalignment using individual load cell readings.
FIGURE 6 illustrates flowchart of the load cells of system design.
FIGURE 7 illustrates flow chart for weighing bin misalignment alarm generation, validation & correction.
DETAILED DESCRIPTION
The embodiment of the present subject matter is described in detail with reference to the accompanying drawings. However, the present subject matter is not limited to this embodiment which is only provided to explain more clearly the present subject matter to a person skilled in the art of the present disclosure. In the accompanying drawings, like reference numerals are used to indicate like components.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless expressly stated otherwise. It will be further understood that the terms “includes”, “comprises”, “including” and/or “comprising” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

The term “cycle” when used in this specification, specify filling of one weighing bin and emptying of other weighing bin and vice-versa. The term “top-bottom direction” in this specification, specify as” top” is marked at the hopper and moving downward is “bottom”.
The figures depict a simplified structure only showing some elements and functional entities, all being logical units whose implementation may differ from what is shown.
Figures 1-3 illustrate a basic arrangement of a blast furnace 100 in accordance with an embodiment of the present subject matter. The blast furnace 100, a vertical shaft furnace that produces liquid metals by the reaction of a flow of air introduced under pressure and temperature into the bottom of the furnace with a mixture of metallic ore, coke, and flux fed from the top of said blast furnace 100. Blast furnaces are used to produce pig iron from iron ore and also employed in processing lead, copper, and other metals.
The blast furnace 100 incudes at least two weighing bins 102, 104. A hopper 200 is installed at the top end of the blast furnace 100. The hopper 200 is configured to supply raw materials such as metallic ore, coke, and flux etc. to the plurality of weighing bins 102, 104 uninterruptedly. The raw material is loaded into the receiving hopper 200, which in turn delivers the raw material to the rotating distributor. The rotating distributor assures a uniform distribution of the charge into the plurality of weighing bins 102, 104 of the blast furnace in a cycle. As a result, the hopper 200 is configured to fill only one of the plurality of weighing bins 102, 104 at a time. Further, the receiving hopper 200 includes an acoustic transmitter (AT) which is configured to assess the acoustic noise of material movement from the receiving hopper 200 to the plurality of weighing bins 102, 104. Also, the acoustic transmitter (AT) is configured to detect blockage in flow of raw material from the receiving hopper 200. Thus, the acoustic transmitter (AT) determines the filling and emptying state of the weighing bins and thus detects blockage in flow of raw material from the receiving hopper 200.
A pressurising pipe 106 and a de-pressurising pipe 108 are disposed on each of the plurality of weighing bins 102, 104 through an expansion bellows 110. The pressurising pipe 106 is configured to pressurize at least one of the plurality of weighing bins 102, 104 by the Blast furnace Gas (BFG) before supplying raw materials into the pressurized blast furnace 100. After supplying raw materials into the blast furnace 100, as the weighing bins 102, 104 gets unloaded, the de-pressurising pipe 108 depressurizes the plurality of weighing bins 102, 104. Thereafter, the hopper 200 again supplies the raw material into the plurality of weighing bins

102, 104. A pressure transmitter (PT) is configured to be disposed on each of the weighing bins 102, 104 to identify pressurizing/de-pressurizing state of the weighing bins 102, 104.
To summarize the above process, the hopper 200 supplies raw material into one of the plurality of weighing bins 102, 104 at a time. The weighing bin filled with raw material is pressurised by the pressurising pipe 106 using Blast furnace Gas (BFG). Subsequently, the raw material is supplied from the filled weighing bin into the blast furnace 100. The empty weighing bin is now depressurized by the de-pressurising pipe 108 to allow supply of fresh raw material from the hopper 200.
The expansion bellows 110 connected on plurality of weighing bins 102, 104 are configured to expand during pressurising cycle. As a result, the expansion bellows 110 and thereby the weighing bins 102, 104 gets connected to nearby structural supports. This generates unbalanced /incorrect loads over the load cell and thereby incorrect weighment disturbing operations of blast furnace 100. Independently, the emptying and filling of individual weighing bin generate torque due to unbalanced weight on each weighing bins 102, 104. As a result, misalignment may occur in the position of weighing bins 102, 104 with respect to initial position of respective bins and may result in interrupting the continuous supply of the raw material.
Figure 2 illustrates filling and emptying cycles of the plurality of weighing bin 102, 104. The three load cells 300a, 300b, 300c, 400a, 400b, 400c are disposed circumferentially at the bottom of each of the weighing bins 102, 104. The load cells are 120ⴰ apart circumferentially from each other, that is, at 0ⴰ,120ⴰ and 240ⴰ circumferentially. The load cells 300a, 300b, 300c, 400a, 400b, 400c are configured to measure weight data of the plurality of weighing bins 102, 104 by compensating Bin load cell data (in the range of mili-volts mV), pressure data (4-20milliamps mA) and volumetric data (based on type of material for a specific charge) in a process loop as indicated in figure 3 for one of the two bins. Thus, voltage data of each of the load cells 300a, 300b, 300c, 400a, 400b, 400c may change during filling and emptying cycle of the plurality of weighing bins 102, 104 due to change in the weight. Moreover the compensated weight changes with Bin pressure and volumetric compensations. Further, the weighing elements (WE), as shown in figure 3, due to change in the voltage reading of each load cells 300, 400 indicate or calculate bin weighment readings and also calculate shifts in center of gravity of individual weighing bins 102, 104.

The individual weighing elements (WE) reading of each load cells 300, 400 on the plurality of weighing bins 102, 104 is transferred to a weighing transmitter (WT) for further processes of the individual reading of each load cells 300, 400 to calculate the weighment readings of the plurality of weighing bins 102, 104.
Figure 3 illustrates working of three load cells 300a, 300b, 300c, 400a, 400b, 400c on each of the weighing bins 102, 104. Herein, the embodiment shows only for one weighing bin. These load cells 300, 400 along with pressure transmitter and material type are configured to measure weight, pressure and volumetric data of the weighing bins 102, 104 during filling and empty condition. The voltage readings of each of the load cells 300a, 300b, 300c, 400a, 400b, 400c, indicate the ideal alignment or misalignment of the respective weighing bins 102, 104.
Figures 4 illustrate configuration of weighing bin misalignment detecting, monitoring & corrective system of the blast furnace 100. The weighing bin misalignment detecting & corrective system includes a smart junction box 500, a weighing transmitter and a hydraulic jacking cylinders 802 804 (802a 802b 802c and 804a 804b 804c). The smart junction box 500 is configured to receive voltage data of each of the load cells 300, 400. Thereafter, said processed voltage data from the smart junction box 500 transfers to the weighing transmitter via Profibus communication, and then to PLC controller 600. The controller 600 is configured to analyze the voltage data of the load cells 300, 400 as follows:
In case, the voltage data of each of three load cells 300, 400 are exactly same or if mutual deviations are less than threshold (V0), then the weighing bins 102, 104 are centrally placed and there is no mis-alignment of the weighing bins 102, 104.
However, in case, the voltage data of each of three load cells 300, 400 are different and if mutual deviations are greater than threshold (V0), then the respective weighing bins 102, 104 are mis-aligned from centrally placed location. The mis-alignment of the either of weighing bins 102, 104 interrupts the supply of raw material to the blast furnace 100.
Thereafter, in the event of misalignment of weighing bins 102, 104, the transmitter via the controller 600 is configured to operate the hydraulic jacking cylinders 802 804 to correct the misalignment of weighing bins 102, 104. The hydraulic jacking cylinders 802 804 include a backend operating system 800 including hydraulic power packs, hydraulic solenoid coil box and hydraulic lines. The working of hydraulic cylinder is described as follows:

The hydraulic jacking cylinders 802 804 are also circumferentially disposed around the weighing bins 102, 104 and at a predetermined distance from the load cells 300, 400 of the weighing bins 102, 104 during the normal alignment of the weighing bins 102, 104. Thus, three hydraulic cylinders are disposed on each of the weighing bins 102, 104 at 0 degree, 120 degree and 240 degree circumferentially on the weighing bins 102, 104. Further, said hydraulic cylinders are at a distance from the load cells 300, 400 on each of the weighing bins 102, 104. However, in case, the voltage reading of the load cells 300, 400 indicates misalignment, the hydraulic cylinders energize and the cylinders come in contact with the weighing bins 102, 104 to lift the weighing bins 102, 104. Thus, by sequencing one by one operation of three cylinders 802a 802b 802c and 804a 804b 804c , the position of weighing bins 102, 104 gets restored.
Further, figure 3 illustrates the position control valve (XV) 800a to indicate the sequence of active cylinder to restore the position of weighing bins and Position feedback (XS) 800b to indicate the restoration feedback after restoration of the weighing bins 102, 104 via hydraulic jacking cylinders 802 804.
FIGURE 5 illustrates weighing bin misalignment using individual load cell readings. Figure 5a depicts the misalignment of weighing bins 102, 104 towards the left side. In this figure 5a, the voltage deviations readouts of two load cells 300a 300c is less than the deviations of third 300b and also for third 300b, its more than allowed threshold (V0) for the particular weight of material filled in bin. Thus, the voltage readings of said load cells indicate misalignment of weighing bins 102, 104.
FIGURE 5b depicts the misalignment of weighing bins 102, 104 towards the right side. In this figure 5b, the voltage deviations readouts of two load cells 300a 300c is more than the deviations of third 300b and also its more than allowed threshold (V0) for the particular weight of material filled in bin. Thus, the voltage readings of said load cells indicate misalignment of weighing bins 102, 104.
FIGURE 5c depicts the minor misalignment of weighing bins 102, 104. In this figure 5c, the voltage deviation readings of the three cells 300, 400 are slightly different from the threshold voltage (V0), wherein the voltage readings of said load cell indicates minor misalignment of weighing bins 300, 400.
FIGURE 6 illustrates flowchart of the load cells of the system design. The load cells 300, 400 installed at 0°, 120°, 240° circumferentially at the bottom of the weighing bins 102, 104, are configured to generate individual voltage reading based on filling and empty charging

bins 102, 104. The load cells 300, 400 are configured to transfer the individual voltage reading to the smart junction box 500.
Further, process loops of figure 3 are implemented in control system schematic figure 4. Figure 4 illustrates the control schematic which is established using programmed logic controllers (PLC’s) 600. The controller for process usually controls multiple process loops. The sequence and logic of acquisition, analysis and execution is programmed in PLC controllers. The Inputs and outputs (IO) to this system, is connected using Remote IO (RIO) panels 600a to field weighing transmitter (WT). The said connection is using a smart Profibus communication.
The Operator station is basically a simulation desk which informs operators for ongoing process. The HMI display for Misalignment alerts for operator takes place here. Operator choses whether to activate auto misalignment correction or manual misalignment corrections.
The outputs from PLC are conveyed to Remote IO panel (controller) 600 which activates -10-0-10 Volts from Analogue output cards of RIO 600a. This is wired to the on-board electronics of solenoid valve and operated the individual hydraulic jacking cylinders 802 804 in sequence. The sequence of selection is decided by the misalignment, that is, firstly operating the hydraulic jacking cylinders 802a / 804a at 0º, thereafter hydraulic jacking cylinders 802b / 804b at 120º and hydraulic jacking cylinders 802c / 804c at 240º in this order one-by-one, if deviation is towards load cells of 0 degree. The sequence decision is provided by PLC.
FIGURE 7 illustrates a flow chart for weighing bins 102, 104 misalignment alarm generation, alarm validation & bin misalignment correction. The load cells 300, 400 installed at 0°, 120°, 240° in circumferential direction at the bottom of the weighing bins 102, 104, generate online values of load data. The historical data, saved in PLC system with time stamp, along with online value generates a historical averaged value of relational voltage (mV/V) drift. A permissible drift is learned by PLC system during initial commissioning of system from averaged values. This permissible deviation data is referred herein as “Threshold (V0)”. When applied to vectored calculation in controller, the rationalised voltage deviations provide dynamic location of the centre of gravity. The “Threshold (V0)” puts a condition on the bin misalignment alarm, that is, in case of any deviation of relational voltage reading of any of the load cells 300, 400 greater than the “Threshold (V0)”, the bin misalignment alarm is raised on operator station 900.

During processing of raw material to produce iron from the blast furnace 100 having plurality of weighing bins 102, 104 and the hopper 200, the weighing bins 102, 104 receives raw material from hopper 200 alternatively, in a cycle. Thereafter, weighing bins 102, 104, filled with raw material, are pressurised by the pressurised pipe 106 using Blast furnace Gas (BFG) for transferring raw material into the blast furnace 100. After material discharge from the individual bins, they are depressurised by depressurized pipe 108. The pressurising and depressurising of weighing bins 102, 104 are performed in a four-step cycle as – Bin Filling → Pressurising → Discharging → Depressurising. The sequence is independent of each other for the bins with only one requisite that both hoppers cannot discharge the raw material into blast furnace 100, at the same time.
The plurality of load cells 300, 400 are disposed circumferentially at the bottom of the plurality of weighing bins 102, 104. The load cells 300, 400 are disposed in a count of at least three at 0°, 120° and 240° apart on the weighing bins 102, 104. Each of the load cells 300, 400 has historically assigned threshold (V0) for the ideal alignment of weighing bins 102, 104 with respect to blast furnace 100.
The voltage reading of each of the load cells 300, 400 during filling and emptying of the weighing bins 102, 104 may changes due to change in weight data, pressure data and volumetric data. The smart junction box 500 receives voltage data of each of the load cells 300, 400. Thereafter, said processed voltage data from smart junction box 500 is transferred to the transmitter and PLC Controller 600 via Profibus communication. The controller 600 is configured to analyze the voltage data of each of the load cells 300, 400 as follows:
In case, the voltage deviation data of each of three load cells 300, 400 are exactly same or less than the threshold voltage (V0), then the weighing bins 102, 104 are centrally placed and there is no mis-alignment of the weighing bins 102, 104.
However, in case, the voltage deviation data of any of the three load cells 300, 400 exceeds the threshold voltage (V0), then the weighing bins 102, 104 are mis-aligned from centrally placed location. The misalignment of the weighing bins 102, 104 interrupts the supply of raw material to the blast furnace 100.
Thereafter, in the event of misalignment of weighing bins 102, 104, the PLC controller 600 is configured to raise the bin misalignment alarm 700 to indicate the misalignment or tendency of misalignment of the plurality of weighing bins 102, 104 and to activate the hydraulic jacking system 800 and cylinders 802 804 for correcting the misalignment of the

plurality of weighing bins 102, 104 , by impacting in reverse order of the misalignment voltage readings.
Further, the experimental tables 1 and 2 shows misalignment of weighing bins 102, 104 and the correction of misalignments by the hydraulic jacking cylinder 802 804. First row of table 1 indicates readouts of each load cells 300, 400 at 4 mV/V and thereby the deviations as 0 which satisfies less than or equal to the threshold voltage (V0) i.e. the weight which indicates that weighing bins 102, 104 are perfectly aligned. In rows 2 and 3, voltage readings of load cells 300 which are disposed at 120 degree and 240 degree show mutual deviation greater than the threshold voltage (V0) and thus, indicates misalignment of weighing bins 102, 104. Column five (Corrective Hydraulic shock order required (Jacking order)) describes the order of calibration of hydraulic jacking cylinder to correct the misalignment of weighing bins 102, 104.

Experimental Findings table 1:
SN BIN CONDITION (50 Ton loadcells) Load cell 0˚
mV/V
measured Load cell 120˚
mV/V measured Load cell 240˚ mV/V measured Corrective
Hydraulic shock
order required
(Jacking order)
0˚ 120 ˚ 240 ˚
1 2
3
4 Initial Balanced bin 4 4 4 Not required

Misalignment towards 240 º(simulated) 3.6 3.2 6.1 2 2 3 1 1 3

Misalignment towards 120 º(simulated) 5.2 5.5 3.1

Corrected after activating calibration cylinder jacks 4.2 4.2 3.9 Not required

Expe over riment performed on tare with forced the bins. connection of l oads and mino r test weight loads
Experimental table 2 shows the alarm and alert 900 in case of misalignment of the weighing bins 102, 104. Column 1 in table 2 shows BIN CONDITION (50 Ton load cells),

column 2 shows Centre of gravity location of the weighing bins 102, 104, wherein cross-section shows the horizontal space covered by the weighing bins 102, 104 and elevation shows height of material fill inside the weighing bins 102, 104. Column 3 (cross section and elevation) of table 2 defines the positional configuration of the weighing bins from column 2 of table 2. The load cells 300, 400 voltage reading may vary based on the positional configuration of the weighing bins 102, 104 shown in column 3 of table 2. Thus, smart junction box 500 readouts raise alarms or alert the alarm at operator station 900.

Experimental table 2:
SN
1 2 3 4 BIN CONDITION (50 Ton loadcells) Calculated Centre of gravity location Bin CG weight + Dimensional data Misalignment alarm & alerts

Cross-section Elevati on Current History

Initial Balanced bin X=0, Y=0 Z=0.40 X=0, Z=0.4 Y=0, NO NO

Misalignment towards 240 º(simulated) X= -0.5, Y= -0.05 Z=0.38 X=0, Z=0.4 Y=0, YES, Major NO

Misalignment towards 120 º(simulated) X=0.4, Y=0.04 Z=0.39 X=0, Z=0.4 Y=0, YES, Major YES

Corrected after activating calibration cylinder jacks X=0.1,Y=-0.01 Z=0.41 X=0, Z=0.4 Y=0, NO, alert only YES

Histo align ry alert is activated at end and if successive minor ment shall be activated alarms o ccur fo r longer d uration, re-
Although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the invention, will become apparent to persons skilled in the art upon reference to the description of the invention. It is therefore contemplated that such modifications can be made without departing from the spirit or scope of the present invention as defined.

We Claim:
1. A method to detect, monitor and correct misalignment on real-time in a plurality of
weighing bins (102, 104) in a blast furnace (100), said method comprising:
measuring, weight, pressure and volumetric data of the plurality of weighing bins (102, 104) and expansion bellows (110) by at least three load cells (300a, 300b, 300c,400a, 400b, 400c) in the form of voltage readings;
wherein the at least three load cells (300, 400) are circumferentially disposed around each of the plurality of weighing bins (102, 104), and
wherein the voltage reading produced by each of the plurality of load cells (300, 400) either matches or deviates from the permissible threshold voltage (V0);
raising a bin misalignment alarm (700) in the event of deviation of the voltage readings produced by each of the plurality of load cells (300, 400) from the permissible threshold voltage (V0), to indicate the misalignment or tendency of misalignment of the plurality of weighing bins (102, 104); and
correcting the misalignment of the plurality of weighing bins (102, 104) by a plurality of hydraulic jacking cylinders (802 ,804) for each bin comprising at least three hydraulic cylinders per bin (802a, 802b, 802c; 804a,804b,804c).
2. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 1, wherein the load cells (300, 400) are configured to dispose on each of the plurality of weighing bins (102, 104) in a count of at least three.
3. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 1, wherein the load cells (300,400) are configured to dispose circumferentially, 120° apart from each other at the bottom end of the plurality of weighing bins (102, 104).
4. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 1, wherein the weight,

pressure and volumetric data are measured during filling and emptying of the plurality of weighing bins (102, 104) by at least three load cells (300, 400).
5. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 4, wherein a voltage reading is generated by each of the load cells (300, 400) based on measured weight, pressure and volumetric data of the plurality of weighing bins (102, 104) during filling and emptying.
6. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 1,wherein processing the voltage readings of each of the load cells (300, 400) through a smart junction box (500) by the controller (600).
7. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claims 1 and 6, wherein comparing the voltage readings of each of the load cells (300, 400) with the permissible threshold voltage (V0) by the controller (600).
8. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104), of the blast furnace (100) as claimed in claims 1 and 8, wherein the step of raising the bin misalignment alarm (700) is operated by the process controller (600) in event of deviation of the voltage readings and derivatives of each of the load cells (300, 400) from the permissible threshold voltage (V0)
9. The method to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 1, wherein the step of correcting the misalignment of the plurality of weighing bins (102, 104) by a plurality of hydraulic jacking cylinders (802,804) is carried out by activating the plurality of hydraulic jacking system (800) operated by the controller (600).
10. A system to detect and correct misalignment in a plurality of weighing bins (102, 104) in a blast furnace (100), the system comprising:
at least three load cells (300, 400) configured to be circumferentially disposed around each of the plurality of weighing bins (102, 104), wherein

wherein the at least three load cells (300a, 300b, 300c,400a, 400b, 400c) are configured to measure weight, pressure and volumetric data of the plurality of weighing bins (102, 104) and expansion bellows (110) in the form of voltage readings;
wherein the voltage produced by each of the plurality of load cells (300, 400) is compared with the permissible threshold voltage (V0),
and wherein
a bin misalignment alarm (700) is raised to indicate the misalignment or tendency of misalignment of the plurality of weighing bins (102, 104) in the event of deviation of the voltage readings produced by each of the plurality of load cells (300, 400) from the permissible threshold voltage (V0); and
a plurality of hydraulic jacking cylinders (800) are configured to correct the misalignment of the plurality of weighing bins (102, 104), by bringing the deviated voltage to the permissible threshold voltage (V0).
11. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 10, wherein said load cells (300, 400) are disposed on each of the plurality of weighing bins (102, 104).in a count of at least three.
12. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 10, wherein each of the load cells (300,400) are configured to be disposed circumferentially 120° apart from each other at the bottom end of the plurality of weighing bins (102, 104).
13. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 10, wherein said at least three load cells (300, 400) are configured to measure the weight, pressure and volumetric data during filling and emptying of the plurality of weighing bins (102, 104).
14. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 13, wherein each of the load cells generate a voltage reading based on weight, pressure and volumetric data of the plurality of weighing bins (102, 104) during filling and emptying.

15. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 11, comprising at least one controller (600) configured to process the voltage readings of each of the load cells (300, 400).
16. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 15, wherein said controller (600) is configured to compare the voltage readings of each of the load cells (300, 400) with the permissible threshold voltage (V0).
17. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 15, wherein said controller (600) is configured to raise the bin misalignment alarm (700) in event of deviation of the voltage readings and derivatives of each of the load cells (300, 400) from the permissible threshold voltage (V0)
18. The system to detect, monitor and correct misalignment in the plurality of weighing bins (102, 104) of the blast furnace (100) as claimed in claim 15, wherein said controller (600) is configured to activate the plurality of hydraulic jacking cylinder (802, 804) for correcting misalignment in the plurality of weighing bins (102, 104).