Load cells are force measurement devices that are crucial components in many industrial and commercial applications. Choosing the right load cell design is important to ensure accurate and reliable force measurements for your specific needs. Here are some key considerations when selecting a load cell design:
The load range or capacity refers to the minimum and maximum forces the load cell can accurately measure. Consider the peak loads and safety factors to determine the ideal capacity. A higher capacity load cell may reduce sensitivity for lower loads.
How will force be applied to the load cell? Common loading types include tension, compression, and beam bending. This determines if you need a strain gauge or piezoelectric load cell. Strain gauges are suitable for tension and compression loads. Beam load cells work for bending loads.
Consider the temperature, humidity, vibration, and other conditions the load cell will operate in. Load cells designed specifically for harsh environments will perform better in demanding applications. Hermetically sealed load cells prevent moisture damage.
Load cell electrical outputs are usually millivolt or amplified voltage outputs. Millivolt cells require less power but need specialized signal conditioning. Voltage output load cells simplify connectivity to data acquisition systems.
Higher accuracies and sensitivities require premium load cells. Accuracy is how close force measurements are to the true value. Sensitivity is the minimum change in force to produce a measurable signal change.
The available space for the load cell and method of integration impacts the optimal design. Miniature load cells offer high performance in tight spaces. Consider if you need a compact compression style or low profile pancake design.
Wired load cells directly connect to monitoring systems but may have distance limitations. Wireless options transmit force data to remote receivers, allowing greater flexibility. Wireless adds complexity and the need for power at the cell.
Shear beam load cells measure loads on a bending element. Double-ended designs enhance load introduction and performance but occupy more space. Single-ended styles simplify installation for limited spaces.
Stainless steel alloy provides excellent performance and corrosion resistance. Aluminum and alloy steel offer high capacities at lower cost but have reduced outputs and lower corrosion resistance.
Choose load cells that meet necessary safety and performance standards for your industry and region. Common certifications include ATEX rating for explosion-proof needs and OIML/NIST standards for legal weighing applications.
Established manufacturers with strong application engineering resources offer the widest selection and ability to customize designs. Look for ISO 9001 certified manufacturers with decades of proven field reliability.
Look beyond just purchase price. Superior load cells provide better performance, longer service life, and lower maintenance costs over time. Quality load cells improve productivity, reduce downtime, and enhance safety.
Proper validation and calibration of your chosen load cell design is critical after installation. Follow manufacturer guidelines to validate the load cell's accuracy over the intended load range. Calibrate the electrical signal output to match the load applied. Periodic recalibration may be required for consistent accuracy. Invest in calibration equipment or hire certified services to verify precision. Validated and calibrated load cells provide reliable data for sensitive processes and applications.
Carefully evaluating your specific application requirements and load cell design options using these criteria will lead you to the optimal solution. Load cells impact accuracy, performance, and safety, so it pays to take the time to make the right choice. Consulting with load cell experts is highly recommended for best results.
