Troubleshooting Your Scale
When counting thousands of pieces or parts, accuracy is a key component that cannot be compromised. Even the smallest mistake can translate into significant expenses, missed production cycles, and wasted components. Using a counting scale is an effective and efficient way to determine the number of parts in receiving, warehousing, production or shipping. Whatever components your operation needs to count, it requires keeping the counting scale clean and well maintained. This article will cover basic troubleshooting tips as you get used to your new counting scale.
Human Error
The technical level of the scale plays a major part in defining a scale's capability to weigh accurately. But no matter how advanced your weighing technology, when counting manually, the major sources of counting error are operator mistakes and piece-weight variance. Those operator errors are caused not only by misreading scale results or incorrect handling.
Miscounting often starts one step earlier, namely when taking the reference weight. Take the correct reference To start a counting operation, you must first determine the average piece weight. Because even highly standardized parts have small deviations in weight, you have to calculate an average weight per piece to then count the bulk quantity.
When taking a sample of 10 pieces, for example, you can calculate the complete batch. Logically, the greater the sample quantity, the greater the likelihood that the sample will represent the bulk quantity. But more counting leads to more errors. Efficiency pressure, shift change or lacking operator concentration are common reasons for even this small number of reference pieces to be miscounted.
Not Reading Weight:
A common issue with any scale is when you have weight on the scale but it is giving a reading of zero. There are a few reasons for this. Sometimes it is as simple as checking the power source or ensuring that it is receiving power. Other times you may need to repair or replace the scale. Some ways to troubleshoot this issue are:
Make sure all the supports of the scale are in direct and solid contact with the floor and that the scale is level.
Make sure you have removed all the shipping screws from the platform.
Make sure the feet are screwed in properly and not screwed in too high where a stud may be blocking the load sensor from flexing.
Reading Fluctuations:
You have weight on the scale, but the reading never settles down to a consistent number, jumping back and forth. If you experience this issue, your scale most likely needs service, repair or adjustment. Professionals can help you determine the issue and decide whether the scale needs calibration once it works properly again. Some ways to troubleshoot this problem are:
Make sure the scale is not on a vibrating surface or being buffeted by winds.
Make sure the scale is plugged in with a clean power source.
Make sure any devices that might cause RF interference, like two-way radios or heavy industrial electric motors, are not interfering with the scale.
Make sure no pins are missing from the load cell cable.
Inconsistent Readings
Depending on where you place the weight, you get a different measurement. Sometimes in our environments, we won’t realize that some surfaces may not be suitable for the counting scale. Environments and surfaces matter and could be the factor to causing you inconsistent readings. These tips below can help ensure a more consistent measurement.
Make sure you did not screw in one of the feet so tightly that it prevents the load sensor from flexing.
Make sure all feet are on the floor.
Make sure nothing is interfering with the platform.
Honorable Mention
Error Codes Manufacturers typically use error codes in their software to help diagnose issues with their scales. Error codes are usually clearly documented in the scale's manual. The code could mean anything from the scale needing calibration or that a particular component is malfunctioning. Referring to the manual is always the first step if an error code is displayed.
Drifting
Drifting is another common problem scale users may face. Drifting occurs when a scale's display continuously fluctuates and is generally caused by water exposure. Water in the scale's indicator, junction box, load cells, cables, or internal components can cause erratic readings. If you discover water in the system, immediately shut it down. Allow the scale to completely dry. You may be able to use it again if there is no permanent damage.
Closing words
Owning an industrial scale is pretty straightforward, but like any piece of equipment will have its own issues throughout the duration of the ownership. These tips will serve as a good quick reference guide to help when you experience the aforementioned issues. For more information concerning counting scales, then check out our Counting Scale Basics article.