Preparation Before Calibration
1. Empty the material rack and remove all paper rolls to ensure the tension roller is completely unloaded.
2. Prepare a standard weight of known weight, approximately 50%-80% of the sensor's full-scale range.
3. Power on the equipment and keep the control system in standby mode; do not start paper feeding.
Step 1: Zero-Point Calibration (Eliminate zero-point drift and resolve no-load tension deviation)
This is the most common calibration. Most tension instability issues only require zero-point calibration:
1. Enter the "Tension Calibration" menu in the control system and select "Zero-Point Calibration."
2. Confirm that there is no load on the tension roller and keep it in a relaxed, stationary state.
3. Wait for the system to automatically collect the current no-load signal. After collection, save the zero-point parameters.
4. After calibration, observe the tension display on the touchscreen. It should normally be within ±1% of the range. Excessive deviation requires recalibration.
Step 2: Full-Scale Calibration (Ensuring tension accuracy across the entire range and resolving overall tension inaccuracies) If the tension deviation is still large after zero-point calibration, perform full-scale calibration:
1. After zero-point calibration, select "Full-Scale Calibration" from the menu;
2. Suspend the prepared standard weight at the stress point of the tension roller, keeping it stationary and stable;
3. Enter the actual weight of the weight/corresponding tension value into the system and wait for the system to acquire the full-scale signal;
4. After acquisition, save the full-scale parameters. Calibration is complete;
5. After removing the weight, the tension display should return to near zero (deviation not exceeding 2%) to be considered合格 (qualified).
Special Instructions for Different Equipment
1. Offline Calibration: If the sensor needs to be removed for maintenance, it can be calibrated point-by-point using a standard tension gauge on the calibration bench. Confirm that the output error at each tension point is within the allowable range before reinstalling it into the equipment.
2. Production Process Calibration: If tension deviations are found in finished products during daily production, it is not necessary to disassemble the equipment. Only a zero-point calibration needs to be performed again. It is generally recommended to calibrate the zero point once a month.
3. Original Factory Calibration: If a brand new tension sensor is being replaced, it is recommended to follow the original manufacturer's calibration procedure first. The menu paths for different brands of control systems may vary slightly.
Post-Calibration Verification: After calibration, start the no-load paper feed and observe the tension value on the touchscreen. If the value fluctuates by no more than 2% of the full scale during paper feed, the calibration is considered successful. After producing finished products, check the paper roll tightness. Consistent tightness indicates effective calibration.
