NEWS

Column compression force sensors are widely used in heavy-duty industrial applications such as press machines, structural testing, load monitoring, and weighing systems. Field calibration is essential to ensure accurate force measurement, especially after installation, maintenance, or long-term operation. Unlike laboratory calibration, field calibration must account for real operating conditions while minimizing downtime. This article explains how to calibrate a column compression force sensor in the field using practical and reliable methods.

 

Understand Sensor Specifications and Calibration Requirements

 

Before starting calibration, review the sensor’s rated capacity, sensitivity, and allowable overload. Confirm that the applied calibration force will not exceed the sensor’s maximum rating. Understanding the output signal type and calibration procedure recommended by the manufacturer helps avoid errors during the process.

 

It is also important to identify the measurement system used, such as an indicator, data logger, or control unit, as calibration settings may vary depending on the equipment.

 

Prepare the Installation and Load Path

 

Accurate calibration depends on a stable and well-aligned load path. Inspect the column compression force sensor to ensure it is installed concentrically and that the applied force is purely axial. Any side load, bending moment, or misalignment can lead to inaccurate calibration results.

 

Clean all contact surfaces and verify that the sensor is firmly seated between loading plates or structural components. If necessary, use hardened load distribution plates to ensure even force transfer.

 

Perform Zero Calibration

 

Zero calibration is the first and most critical step. With no external force applied, allow the sensor output to stabilize and set the zero point on the measuring instrument. This establishes a baseline reference for all subsequent measurements.

 

Ensure that no residual loads, friction, or mechanical constraints are present during this step, as they can cause zero drift.

 

Apply Known Calibration Forces

 

Field calibration typically involves applying known forces using calibrated reference equipment such as hydraulic jacks with load gauges, proving rings, or certified test weights. Apply the force gradually in increments to avoid shock loading and allow the sensor output to stabilize at each step.

 

Record the sensor output at multiple force levels, including both increasing and decreasing loads. This helps verify linearity and detect hysteresis effects.

 

Adjust Span and Verify Accuracy

 

Based on the recorded data, adjust the span or gain settings of the indicator or control system so that the sensor output matches the applied reference force. Repeat the loading and unloading process to confirm accuracy and repeatability across the operating range.

 

If significant deviations are observed, recheck alignment, load distribution, and electrical connections before repeating the calibration.

 

Consider Environmental Conditions

 

Temperature, vibration, and humidity can influence field calibration results. Whenever possible, perform calibration under normal operating conditions to ensure that the sensor behaves consistently during actual use.

 

Allow the sensor to reach thermal equilibrium before finalizing calibration to minimize temperature-related drift.

 

Document Calibration Results

 

Proper documentation is essential for quality control and traceability. Record calibration dates, applied forces, reference equipment used, environmental conditions, and final calibration settings. These records support maintenance planning and compliance with industry standards.

 

Conclusion

 

Calibrating a column compression force sensor in the field requires careful preparation, accurate reference forces, and attention to alignment and environmental factors. By following a structured calibration process, operators can achieve reliable force measurements, improve system performance, and extend sensor service life. Regular field calibration ensures that column compression force sensors continue to deliver precise and trustworthy data in demanding industrial applications.