To ensure accurate and reliable performance of your weighing system, it's essential to follow best practices during the installation and maintenance of load cells. Here are key considerations:
1. Use structural components with automatic positioning (reset) as much as possible, such as spherical bearings, joint bearings, or positioning fasteners. These help prevent lateral forces from affecting the sensor. Keep in mind that not all lateral forces come from mechanical installation—thermal expansion, wind, or vibrations from agitators on container scales can also contribute. If the scale is mounted directly onto a container’s pipe, ensure that the connection allows for flexibility in the direction of the sensor’s loading axis to avoid "eating" the true load and causing errors.
2. Although load cells have some overload capacity, it's crucial to avoid overloading them during installation. Even brief overloads can cause permanent damage. If necessary, temporarily replace the sensor with a height block, then reinstall the correct one later. In normal operation, always include mechanical overload protection. If using screws to fix the sensor, apply the proper torque and ensure sufficient screw depth. High-strength screws are typically recommended.
3. Level adjustment is critical. First, level the mounting base for each individual sensor. For systems with multiple sensors, ensure all mounting surfaces are perfectly horizontal. This helps distribute the load evenly across all sensors. Each load cell should be loaded in its designated direction, avoiding lateral forces, bending moments, and torsional stress.
4. Handle sensors with care, especially small ones made of aluminum alloy. Any impact or drop can severely affect their accuracy. For larger load cells, use appropriate lifting equipment like chain hoists or electric hoists. The mounting surface must be clean, flat, and free of oil or debris. The base itself should be strong and rigid, ideally stronger than the sensor to prevent deformation.
5. Install protective barriers or cover the sensor with a thin metal plate to prevent dust or debris from interfering with moving parts. To check if the movable parts are obstructed, add or subtract about 0.1% of the rated load and observe the display. If the reading changes, it may indicate contamination.
6. Protect the sensor from electrical interference by connecting hinged copper wires (about 50 mm² cross-section). Avoid strong thermal radiation, especially on one side of the sensor. Electrical connections should be carefully managed: do not run signal cables parallel to power or control lines. If they must be close, maintain a distance of at least 50 cm and use metal conduits for the signal cables.
7. Twist power and control cables to at least 50 rpm. If extending the signal cable, use a sealed junction box. If soldering is necessary, ensure proper sealing and moisture resistance. After connection, check the insulation resistance and aim for 2000–5000 MΩ. Recalibrate the sensor if needed. For long cables requiring high precision, consider using a relay amplifier with a compensation circuit.
8. Use shielded cables for all signal connections. Ensure proper grounding—either through the mechanical frame or an external ground. Avoid floating shields. If three sensors are connected, a 6-wire configuration might be used in the junction box instead of the standard 4-wire setup. Place the signal readout circuit away from devices that generate interference, such as thyristors or contactors. If heat is a concern, isolate the area and install a fan. Finally, provide a separate power supply for the sensor circuit to minimize noise from shared power sources.
By following these guidelines, you can ensure more accurate measurements, easier installation, and longer sensor life.
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