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Load Cell Word

Load cells convert applied force into an electrical signal that can be measured. They consist of a main body that deforms under strain and electrical circuits with strain gauges bonded to the body. When force is applied, the strain gauges' resistance changes proportionally. Common types are pneumatic, hydraulic, and strain gauge load cells. Strain gauge load cells are most widely used in industries to accurately measure applied forces and weights.

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65 views

Load Cell Word

Load cells convert applied force into an electrical signal that can be measured. They consist of a main body that deforms under strain and electrical circuits with strain gauges bonded to the body. When force is applied, the strain gauges' resistance changes proportionally. Common types are pneumatic, hydraulic, and strain gauge load cells. Strain gauge load cells are most widely used in industries to accurately measure applied forces and weights.

Uploaded by

amkslade101
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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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 in-
dicator) 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 distribu-
tion.
• 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 flexes slightly under the strain.
This is similar to what happens to a fishing rod when a fisherman hooks a fish.
• Deformation is very subtle and not visible to the naked eye. To measure the defor-
mation, strain gages are tightly bonded to the body of the load cell at pre-deter-
mined points, causing them to deform in unison with the body. The resulting move-
ment 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 :-


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 flowing 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 con-
verted 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 fluid. With a diaphragm hydraulic force sensor, the load acts on a loading
head that causes a piston to compress fluid in a confined elastomeric diaphragm
chamber. As the force increases, pressure on the fluid rises. The output is linear and
unaffected by the amount of fluid or the fluid’s temperature.
2. Pneumatic Load Cells
• Pneumatic load cells operate on a force balance principle and use multiple damp-
ener chambers that provide highly accurate readings. They have an elastic di-
aphragm 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, unaffected by
changes in temperature, and do not have any fluids 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 rat-
ing 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.

Advantages :-
• High accuracy and precision in force measurement.
• Wide range of capacities available to suit various applications.
• Can be easily integrated into different 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 fluids, 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 compres-
sion.
• 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 affect 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 gran-
ules in industrial processes like food processing, chemical production, and agricul-
ture.
• 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 mea-
sure forces during crash testing, durability testing, and performance testing of vehi-
cle components and systems.
• Aerospace and Defense: Load cells are utilized in aerospace and defense applica-
tions for testing and monitoring structural integrity, load distribution, and perfor-
mance 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.

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