Modeling and Selection of Rational Parameters for Sensors Installation Assemblies on Coal Charging Car Hoppers

This study presents a comprehensive analysis of the modeling and optimization of sensor installation nodes for weight measurement in the hoppers of a charging car utilized in coke production. The research highlights the critical role of precise load monitoring in preventing technological disruptions, minimizing equipment degradation, and optimizing energy consumption. Conventional sensor technologies, including capacitive, ultrasonic, and laser-based systems, are evaluated, with weight sensors mounted on hopper supports identified as the most robust solution for real-time mass determination under industrial conditions characterized by high dust levels, temperature fluctuations, and mechanical vibrations. A finite element analysis (FEA) was conducted to assess the structural behavior of sensor installation nodes under three distinct loading scenarios, corresponding to different operational conditions of the charging car. The four-point support structure of the hopper experienced the highest loads and non-uniformities. A stress–strain analysis of the sensor mounting assembly, performed using the Ansys software package, confirmed that both the sensor and its support structure maintain a sufficient safety margin (version 2024 R1, Ansys Inc., Canonsburg, PA, USA, the academic license provided to Wrocław University of Science and Technology). The findings validate the structural integrity and operational reliability of the proposed sensor configuration, contributing to the advancement of automated monitoring and control systems in coke production.