LOAD CELL
• A load cell converts a force such as tension, compression, pressure, or
torque into a signal (electrical, pneumatic or hydraulic pressure, or
mechanical displacement indicator) that can be measured and
standardized. It is a force transducer.
• As the force applied to the load cell increases, the signal changes
proportionally. The most common types of load cells are pneumatic,
hydraulic, and strain gauge types for industrial applications.
Diagram :-
Construction :-
• A typical load cell consists of two parts: the main body and an attached
electrical circuit. The main body is what bears the weight or force and
accounts for most of the load cell’s size. Typically, it is made from high-
grade steel or aluminium, which ensures mechanical reliability, and
predictable and uniform strain distribution.
• The electrical circuit is housed within the load cell, tightly bonded to the
main body. The circuit includes strain-gauges which are specialised parts
of the circuit designed to sense the deformations of the main body.
Working :-
• When we use load cells, one end is usually secured to a frame or base,
while the other end is free to attach the weight or weight-bearing element.
• When force is applied to the body of the load cell, it exes slightly under
the strain. This is similar to what happens to a shing rod when a sherman
hooks a sh.
• Deformation is very subtle and not visible to the naked eye. To measure the
deformation, strain gages are tightly bonded to the body of the load cell at
pre-determined points, causing them to deform in unison with the body.
The resulting movement alters the electrical resistance of the strain gages
in proportion to the amount of deformation caused by the applied load.
• Using signal conditioning electronics, the electrical resistance of the strain
gages can be measured with the resulting signal being output as a weight
or force reading.
Load Cell circuit :-
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Explanation :-
• Let us assume that a load cell sensor has four internal strain gauges i.e. A,
B, C, and D as shown in the image above.
• The input voltage supplied by a signal conditioner or digital display is
attached to the two opposite corners of the bridge i.e. C and D whereas,
the output voltage is measured by joining the A and B resistors to the
signal side of the digital display.
• When no load is applied to the load cell (Load=0), the circuit is said to be
balanced. As soon as the load is applied to it, the strain gauge resistors will
witness a change in its resistance, thereby altering the voltage owing
through the circuit.
• Hence, the voltage across A and B will change which will be displayed as
the weight on the readout unit or the digital display.
• The output of the Wheatstone bridge or a load cell is analog data which is
converted to readable units using an interpreter.
Types Of Load Cells :-
1. Hydraulic Load Cell
• Hydraulic load cells measure weight based on the change in pressure
placed on an internal uid. With a diaphragm hydraulic force sensor, the
load acts on a loading head that causes a piston to compress uid in a
con ned elastomeric diaphragm chamber. As the force increases, pressure
on the uid rises. The output is linear and una ected by the amount of uid
or the uid’s temperature.
2. Pneumatic Load Cells
• Pneumatic load cells operate on a force balance principle and use multiple
dampener chambers that provide highly accurate readings. They have an
elastic diaphragm that is attached to a platform surface. When an object is
placed on the load cell, pressurized air or gas balances its weight. The air
needed to balance the weight determines the weight of the object.
• Pneumatic load cells are used in industries where small weights are
measured and cleanliness and safety are important. They are explosion
proof, una ected by changes in temperature, and do not have any uids
that would contaminate a process if the diaphragm of the load cell
ruptured.
3. Strain Gauge Load Cells
• Strain gauge Load Cells are the most common type of load cell with a
capacity rating between 5 N to more than 50 MN. They have high-res
digital indicators with ideal force transfer standards. Strain gauge load cells
are transducers that change electrical resistance when under stress or
strain with the resistance proportional to the strain placed on the cell. The
readings from a strain gauge load cell are linear and can be converted to
force and weight.
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Advantages :-
• High accuracy and precision in force measurement.
• Wide range of capacities available to suit various applications.
• Can be easily integrated into di erent systems and machinery.
• Relatively low maintenance requirements.
• Durable construction for long-term use in harsh environments.
• Inherently explosion proof
• Insensitive to temperature variations
• They do not contain uids, therefore, there is no possibility of
contamination of the process if the diaphragm breaks.
• The load cells of the voltage meter can be used for both expansion and
compression.
• Strain gauge load cells are less costly so mostly used in the industry.
Disadvantages :-
• Susceptible to damage from overloading or shock loading.
• Temperature variations can a ect accuracy if not compensated for.
• Initial cost can be relatively high, especially for high-capacity load cells.
• Requires calibration and periodic maintenance to ensure accuracy.
Applications :-
• Industrial Weighing Scales: Load cells are commonly used in industrial
weighing scales for accurate measurement of weights in factories,
warehouses, and shipping facilities.
• Material Testing: Load cells are used in material testing machines to
measure the strength, elasticity, and other mechanical properties of
materials such as metals, plastics, and composites.
• Tank and Hopper Weighing: Load cells are employed in tank and hopper
weighing systems to measure the weight of bulk materials such as liquids,
powders, and granules in industrial processes like food processing,
chemical production, and agriculture.
• Force Measurement in Manufacturing: Load cells are integrated into
manufacturing equipment and machinery to measure forces during various
processes such as stamping, pressing, molding, and forming.
• Automotive Testing: Load cells are used in automotive testing applications
to measure forces during crash testing, durability testing, and performance
testing of vehicle components and systems.
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• Aerospace and Defense: Load cells are utilized in aerospace and defense
applications for testing and monitoring structural integrity, load distribution,
and performance of aircraft, spacecraft, and military equipment.
• Medical Devices: Load cells are incorporated into medical devices such as
patient lifts, hospital beds, and rehabilitation equipment for precise
measurement of forces and weights, ensuring patient safety and comfort.
• Material Handling Equipment: Load cells are integrated into material
handling equipment such as cranes, hoists, and forklifts to monitor and
control loads, prevent overloading, and ensure safe lifting and
transportation of materials.
