~ Why toolkits are faster than screwdrivers for calibrating sensors ~
In industries where precision measurements are crucial — whether it’s monitoring weight in silo systems or measuring force and pressure in automotive testing — the accuracy of the instruments used can have a significant impact on operational efficiency and safety. Many engineers still rely on manual calibration methods to ensure their measurement tools are accurate. However, as technology advances and industries push for greater efficiency, it’s becoming clear that digital calibration tools offer a faster, more accurate alternative.
Engineers working with strain gauges, load cells and pressure transducers are now being introduced to the benefits of digital calibration. Whether it’s the challenge of achieving precise output or reducing time spent on repetitive tasks, the shift towards digital tools is transforming how these tasks are approached.
How it’s usually done
Manual calibration, often involving the use of screwdrivers to make fine adjustments, has long been the standard in industries where precise measurements are critical. Engineers familiar with this method know it inside out and there’s a level of control and hands-on involvement that comes with manually adjusting gain and offset settings. For many, it’s a process refined through years of experience.
However, manual calibration can be time-consuming. Adjustments need to be made incrementally, readings checked and rechecked and every small alteration must be verified before proceeding to the next step. While experienced engineers can manage this effectively, the process is not immune to human error and with increasing demands on time and resources, it’s becoming harder to justify this slower approach.
How it can be improved
As technology advances, digital calibration has emerged as a more efficient alternative. By using USB-connected devices and calibration software, engineers can now monitor and adjust settings in real time, with automated processes reducing the need for repetitive adjustments.
One key benefit of digital calibration is the ability to obtain instant feedback, allowing engineers to make accurate adjustments on the fly. Real-time data collection ensures that measurements are consistent and reliable, significantly reducing the chances of error that may occur with manual calibration. In industries where precision is critical, such as aerospace or automotive testing, these small improvements can lead to significant gains in both performance and cost savings.
Moreover, adopting digital tools enables engineers to future-proof their workflows. As more companies embrace digital solutions, keeping pace with these developments becomes essential for both efficiency and competitiveness.
Mantracourt’s In-Line Amplifier (ILA), which converts signals from strain gauges and load cells into a stable 4-20 mA output, offers a unique perspective on this evolution. As it supports both manual and digital calibration, we can compare the two methods side by side to see how each process differs.
In a manual calibration, engineers would typically use a screwdriver to adjust the gain and offset potentiometers while taking repeated measurements to ensure accuracy. The process involves trial and error, with each adjustment needing to be rechecked. Depending on the complexity of the system, this could take many hours, particularly for large-scale installations.
In contrast, digital calibration with the ILA is handled through a USB connection to a laptop using the ILA Toolkit. This allows engineers to monitor the calibration in real time, quickly making adjustments and applying automated calibration routines. The result is a process that is not only faster but also less prone to human error. Instead of making small manual tweaks and rechecking measurements, engineers can use the software to instantly apply and verify adjustments, saving both time and effort.
It’s not as hard as it seems
One common misconception is that switching to digital tools requires significant training or expertise. However, modern calibration software, like the ILA Toolkit, is designed to be user-friendly and intuitive, meaning engineers can quickly get up to speed. While digital gain and offset potentiometers operate in 256 defined steps—unlike the limitless adjustment of traditional potentiometers—this level of precision is sufficient for most use cases, enabling engineers to achieve highly accurate calibrations. Many digital tools are also designed to integrate smoothly into current workflows, offering flexibility and ease of use.
While manual calibration has served the engineering world well for decades, the shift towards digital methods is inevitable. By adopting digital calibration tools, engineers can streamline workflows, improve accuracy and significantly reduce operational costs.
You can find out more about the ILA at www.mantracourt.com and download the toolkit for free here.
