I. Pre-processing
Set up a digital multimeter, a standard gauge block, a grade 0 feeler gauge, and debugging software for the host computer. To guarantee a consistent output signal, activate the sensor 15 minutes in advance.
Verify that the hot runner has cool completely to room temperature (25°C), the sensor is securely installed, and the wiring is tight. Bypass the conventional installation and re-inspection procedures.
II. Cold-State One-Click Two-Point Calibration:
Rapid zero-point calibration: Apply pressure to the hot runner plate to achieve the initial zero position. Utilise a feeler gauge to verify that there is no gap between the hot runner plate and the probe. To set the current displacement value to 0mm, select the "Recalibrate" button on the host computer directly.
Rapid full-scale calibration: Insert the standard gauge block that corresponds to the full-scale thickness. Select the "Read Data" option. The current displacement value is automatically recorded by the system, which also generates coefficients of calibration.
Verify linearity promptly by selecting a single point in the center. Verify that the error is less than 0.1mm. The operation steps are significantly reduced by eliminating the necessity for repeated potentiometer adjustments.
III. Rapid Hot-State Dynamic Calibration
The hot runner is rapidly heated to operating temperature and maintained for 10 minutes, while the measured displacement value and the theoretically calculated thermal expansion value of the sensor are simultaneously recorded.
The calibration is immediately declared qualified if the deviation is ≤0.2mm, which eliminates the necessity for repeated fine-tuning of installation coaxiality and bypasses the redundant multi-temperature point-by-point verification process.
IV. Rapid Alarm Verification
Manually simulate a displacement error scenario. Ensure that the system generates an audible and visual alarm within one second, save the calibration coefficients directly, and reboot the connection. The new calibration coefficients are effective immediately.
In order to confirm repeatability, only one forward and reverse movement is executed, thereby omitting the numerous repetitive tests that are conducted throughout the entire stroke. The calibration process is concluded when no errors are identified.
The rapid calibration process is seamlessly integrated with the low-cost Hall effect displacement sensor that you have selected for domestic production. Ordinary maintenance engineers can rapidly acquire and operate it; professional calibration personnel are not necessary.
