The load cell is a crucial component for a wide range of industries that rely on weighing systems. Whether you need it for manufacturing, warehousing, or commercial purposes, the load cell is the equipment for quality control, accurate calibration, and precise measurements. This is an essential tool, as improper calibration can affect safety, product quality, and regulatory compliance, which in turn can harm the reputation of the manufacturers. In this post, we will explore the effective tips that will optimize the load cell and lead to accurate readings.
What is a Load Cell?
It is equipment that converts mechanical force into an electrical signal, thus reflecting the measurement on the screen. When the load is placed on the equipment, the strain gauge attached to it deforms, which is then transformed into an electrical signal representing the reading.
It is used in manufacturing, the automobile, and pharmaceutical industries, where consistency in the products is of utmost importance. However, to ensure that they perform in a precise manner, it is important to check the calibration of the equipment. It ensures that the reading of the equipment is reliable and the readings it provides are accurate.
Why Is Calibration Important?
Now, you must be thinking why a load cell is important. The answer is that calibration is used for the measurement of a device's output to a certain standard and to reduce the chances of errors. If the calibration of the weighing machine is avoided:
- The measurement of the equipment will reduce over time
- The environmental changes can also hamper the accuracy of the output
- A manufacturing defect can impact the reliability
The regular calibration of equipment maintains its accuracy and ensures that it provides precise readings.
How to Calibrate the Load Cells for Accurate Readings?
Here are the tips that will ensure that the load cell is properly calibrated:
- Use Certified Calibration Weights:
To get an accurate calibration, you need to have certified reference weights. These weights are traceable to national and international measurement methods.
- Use weights appropriate to the load cell’s capacity.
- Avoid relying on the assumed weights.
- Store the weights in a cool and dry location to avoid any sort of contamination or corrosion.
It is best to use a weight of about 80- 100% of the load cell’s capacity in order to ensure precise calibration.
- Proper Load Cell Installation:
Calibration is of no use unless the load cells are of precise quality. Apart from that, it should also be installed properly.
- Ensure that the load cells are set up according to the manufacturer’s guidelines.
- Avoid the side or center loading as it will hamper the accuracy of the operations.
- Warm-Up the System:
- Put on the indicator and let it stabilize for 15 to 30 minutes.
- The temperature change can cause the resistance variation in the strain gauges, so the heat will help reach the right thermal equilibrium.
- Zero Load Cell:
Before applying any weight, you need to ensure that:
- There is no extra weight or external pressure
- Ensure that the reading on the screen is zero before you start the process of calibration.
- Exposure to the Operational Environment:
The environmental factors, like rain, humidity, and vibrations, can impact the performance of the load cell.
- Perform the operations under the exact conditions.
- Avoid calibrating in completely different locations, as the output will be ineffective.
You can also ensure a proper calibration environment through the software adjustments.
- Repeat Measurement for Consistency:
Do not rely on a single reading per weight point; instead, to achieve the apt calibration:
- Repeat each calibration up to 3-5 times
- Keep an eye out for the inconsistencies
- Document the Outcome:
- Date & time of the calibration
- Weight valves used
- Environmental conditions
- Measured outout valves
- Calibration techniques name
Verification and documentation may also include recording values to ensure that the system performance is not deteriorated.
Having said that, while calibration the load cells, these are some of the mistakes which should be avoided:
- Using incorrect weights
- Skipping the zeroing process
- Calibrating a different environment than the actual one
- Not recording the calibration results
- Speeding up the process without following the proper procedure.
Final Words….
By following all the above-mentioned techniques for calibration, you can ensure precise output with the load cell. So, if you want accurate readings during the production process, calibration is a process that must be followed.
At Optima Weightech PVT. LTD manufactures premium-quality load cells for increased productivity. Their cells are made from high-grade stainless steel, which can bear all the tensile stress, and are intended to meet the wide range of industrial requirements. They provide maximum accuracy, and the installation process is also easy. So, if you have to deal with measurement, it is only ideal to invest in the most reliable manufacturers and optimize your operations.
Frequently Asked Questions:
- What is the Purpose of a Load Cell?
It is a sensor device that converts the force or weight of an object. It is used widely in industries for maintaining the quality of products, material testing, and force measurement applications.
- What are the Applications of the Load Cell?
- Industrial weighing systems
- Production line for quality and quantity control
- Material testing
- Aerospace or automobile components weight testing
- Medical devices
- How Precise is the Measurement of the Load Cell?
On average, an industrial load cell can achieve between ±0.03% to ±0.1% on a scale of full accuracy.
- What leads to Inaccuracy in the Readings of the Load Cell?
- Temperature changes
- Electrical interference
- Mechanical misalignment
- Wrong installation
- Overloading more than the capacity
- Moisture or corrosion
- Can the Load Cell be Repaired?
It depends on the kind of damage that has occurred to the load cell. If the load cell is severely damaged, then it should be replaced. It is essential for accurate readings, or else the machine will malfunction.
- What is the Price of the Load Cell?
The price of the load cell can differ depending on specifications. A basic model will be cheaper compared model with advanced features.
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