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FIELD OF INVENTION
The invention generally relates to an apparatus for functional testing of
electronic controllers in a control system for bulk solid feeder. More particularly,
the invention relates to an apparatus for testing and calibrating a feed control
system for bulk solid feeders which eliminates the need of a feeder mechanism
during the testing and calibration.
BACKGROUND OF THE INVENTION
Bulk solid conveying feeders are used in many utilities and process plants to feed
solid materials like coal/chemicals etc. in a controlled fashion. Feeding of bulk
solids by measuring the quantity of material being fed and adjust the feed
operation to maintain a set quantity of feedrate necessitates a Feed Control
system. The Feed Control system measures the mass of the material being fed
by weighing mechanism and determines the feed speed based on the speed of
the drive. Signals representative of mass of materials and feed speed are
processed to control the feedrate. Such control systems have to be tested and
calibrated along with the feeding mechanism. Conventionally these testing and
calibration requires the integration of the control system with the feed
mechanism.

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OBJECTS OF INVENTION
It is therefore an object of this invention is to propose an apparatus for testing
and calibrating a feed control system for bulk solid feeders, which eliminates the
requirement of a physical feed mechanism during the testing and calibration.
Another object of the invention is to propose an apparatus for testing and
calibrating a feed control system for bulk solid feeders, which is capable of
carrying-out the functional checking and calibration of the control system under
dynamic condition without the feed mechanism.
A still another object of this invention is to propose an apparatus for testing and
calibrating a feed control system for bulk solid feeders, which minimizes the
human intervention and time in course of the Testing and calibration of the feed
control system.
SUMMARY OF INVENTION
Accordingly, there is provided an apparatus for testing and calibrating a feed
control system for bulk solid feeder, the bulk solid feeder at least having a
centralized controller for the purpose, a weight sensing device, and a drive
mechanism, the apparatus comprising a computer system comprising a computer
device and a software structure incorporated in the device; a data connecting

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cable interfaced to the computer device at a first end, and to a control module at
a second end to allow the functioning of the control module, the control module
acting as a signal generator and receiving unit, comprising a DAC circuitry to
feed simulated signals corresponding to feedrate demand, and the mass of the
material being fed, the respective data being generated by the centralised
controllers, a timer/counter circuiting to feed simulated signals corresponding to
the speed signal from the drive mechanism including calibration probe pulse
signals and belt-movement sense pulse signal generated in the bulk solid feeder,
a digital output circuitry to feed simulated logical interlocks and switches
corresponding to the logics and interlocks in the bulk solid feeder; a digital input
circuitry to read and ascertion from the bulk solid feeder the logical potentional
free output and the potential output used in the circuit for indication, protection,
and interlock of the bulk solid feeder; an ADC circuitry to measure and feed the
simulated signals to the timer/counter circuitry to generate proportional speed
signal of the drive mechanism, and to measure and display the feedback from
the bulk solid feeder equivalent to the feedrate output; and a microcontroller to
process and control all the arithmetic and logical operation via transmitting and
receiving the processed signal data pertaining to the bulk solid feeder
mechanism.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
Figure 1 - depicts a Block diagram of the apparatus of the invention;

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Figure 2 - shows a block diagram of the signal generator and receiver unit of the
apparatus of the invention
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE
INVENTION
Figures 1 and 2, describe an Apparatus for testing and calibration of Control
system for Bulk Solid Feeder by Simulated Input and Output.
As shown in figure - 1, a laptop or a bench top Personal Computer (PC)
incorporating a software structure (1) is used to perform Testing and Calibration
of a Feed Control System (DUT). The computer system (PC; 1) is capable to
generate Pop-up Notes / Attention and Calibration of the Feed Control System.
In addition the computer system (PC; 1) is enabled to generate documentation
related to Test and Test and Calibration Reports.
A Data connecting cable (2) is used to interface the PC to a control module (3)
so as to control the functioning of the module (3), and further to transmit and
acquire data to and from the module (3) by the PC.
As shown in figure - 2, the Signal Generator and Receiver Unit (3) interalia the
control module (3), comprises a DAC circuitry (7) to feed simulated signals
equivalent or corresponding to a Feedrate demand generated by the centralized
controllers of the utility / process plant and Weight sensed by the weight sensing
device used in the Bulk Solid feeders (not shown).

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A Timer / Counter circuitry (9) to feed simulated signals equivalent or
corresponding to the Speed signal from the drive mechanism of the bulk solid
feeder, Calibration Probe pulse signals required for calibration of the Bulk solid
feeder and Belt movement sense pulse signal generated in the Bulk solid feeder
mechanism (not shown).
A digital output circuitry (8) to feed simulated logical interlocks and switches
equivalent or corresponding to the logics and interlocks in the Bulk solid feeder
mechanism.
A digital input circuitry (6) to read and ascertain the logical Potential free outputs
available for customer use from the Bulk solid feeder mechanism and Potential
outputs used in the indication / protection and interlock circuits of the Bulk solid
feeder mechanism.
An ADC circuitry (5) to Measure and feed the Timer / Counter circuitry (9) to
generate proportional speed signal of the drive mechanism and Measure and
display the feedback from Bulk Solid feeder corresponding to the feedrate
output.
A micro controller / processor unit (10) to process all the arithmetic and logical
operation by receiving and sending suitable signals / commands pertaining to
the Bulk solid feeder mechanism.

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A data transfer circuitry (11) used to link and transfer data / commands between
the Computer System (PC, 1) and the control module (3). The modules indicated
by reference numerals 5, 6, 7, 8, and 9 are connected through a bi-directional
bus structure (12) to receive and send data and commands from and to the
controller / processor (10).
The interfacing cables / circuitry to link the invented apparatus and the feed
control system viz. Bulk Solid conveying Feeder controller under test.

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WE CLAIM
1. An apparatus for testing and calibrating a feed control system (DUT) for
bulk solid feeders, the bulk solid feeder at least having a centralized
controller for the purpose, a weight sensing device, and a drive
mechanism, the apparatus comprising;
- a computer system comprising a computer device (PC) and a
software structure (1) incorporated in the device (PC);
a data connecting cable (2) interfaced to the computer device (PC)
at a first end, and to a control module (3) at a second end to allow
functioning of the control module (3);
the control module (3) acting as a signal generator and receiving
unit, comprising:
- a DAC circuitry (7) to feed simulated signals corresponding to
feedrate demand, and the mass of the material being fed, the
respective data being generated by the centralized controller;
- a timer / counter circuitry (9) to feed simulated signals
corresponding to the speed signal from the drive mechanism
including calibration probe pulse signals and belt-movement sense
pulse signal generated in the bulk solid feeder;

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a digital output circuitry (8) to feed simulated logical interlocks and
switches corresponding to the logics and interlocks in the bulk solid
feeder;
- a digital input circuitry (6) to read and ascertain from the bulk
solid feeder the logical potential free output and the potential
output used in the circuits for indication, protection, and interlock
of the bulk solid feeder;
- an ADC circuitry (5) to measure and feed the simulated signals to
the timer / counter circuitry (9) to generate proportional speed
signal of the drive mechanism, and to measure and display the
feedback from the bulk solid feeder equivalent to the feedrate
output; and
- a microcontroller (10) to process and control all the arithmetic and
logical operation via transmitting and receiving the processed signal
data pertaining to the bulk solid feeder mechanism.
2. The apparatus as claimed in claim 1, wherein a data transfer circuitry (11)
is provided to link and transfer data between the computer system (PC; 1)
and the control module (3).

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3. The apparatus as claimed in claim 1, wherein the computer system is
enabled to generate pop-up notes, attention, warning tags during testing
and calibration.
4. The apparatus as claimed in claim 1 or 3, wherein the computer system is
enabled to generate documentation including storage in the memory in
respect of test and calibration results.
5. An apparatus for testing and calibrating a feed control system for bulk
solid feeders as substantially described and illustrated herein with
reference to the accompanying drawings.
Dated this 29th Day of APRIL 2008.

The invention relates to an apparatus for testing and calibrating a feed control
system (DUT) for bulk solid feeders, the bulk solid feeder at least having a centralized controller for the purpose, a weight sensing device, and a drive mechanism, the apparatus comprising; a computer system comprising a
computer device (PC) and a software structure (1) incorporated in the device (PC);a data connecting cable (2) interfaced to the computer device (PC) at a first end, and to a control module (3) at a second end to allow functioning of the control module (3);the control module (3) acting as a signal generator and receiving unit, comprising a DAC circuitry (7) to feed simulated signals corresponding to feedrate demand, and the mass of the material being fed, the
respective data being generated by the centralized controller a timer / counter
circuitry (9) to feed simulated signals corresponding to the speed signal from the
drive mechanism including calibration probe pulse signals and belt-movement
sense pulse signal generated in the bulk solid feeder; a digital output circuitry (8)
to feed simulated logical interlocks and switches corresponding to the logics and
interlocks in the bulk solid feeder; a digital input circuitry (6) to read and
ascertain from the bulk solid feeder the logical potential free output and the
potential output used in the circuits for indication, protection, and interlock of the
bulk solid feeder; an ADC circuitry (5) to measure and feed the simulated signals
to the timer / counter circuitry (9) to generate proportional speed signal of the
drive mechanism, and to measure and display the feedback from the bulk solid
feeder equivalent to the feedrate output; and a microcontroller (10) to process
and control all the arithmetic and logical operation via transmitting and receiving
the processed signal data pertaining to the bulk solid feeder mechanism.