How Do You Know if a Load Cell Is Damaged?

Load cells act as the pillar of trade scales that provide precise measurements. But when they don’t give the exact result, it can affect the business. It is therefore vital to know whether the load cell is damaged or not.

However, here in the article, we have mentioned some of the signs and potential causes that can help you know about the problem early on.

What is a load cell?

A load cell is a dynamometer of a transducer used to create an electrical signal whose amplitude is directly proportional to the measured force. It functions by altering mechanical force into digital values, making it easy to read and record. Keep in mind that the internal mechanisms of a load cell differ depending on which type of load cell technology you choose for your job. However, there are four different types of these sensors, including:

• Pneumatic

• Hydraulic

• Strain gauge

• Capacitance

Causes of Load Cell Damage

Load cells are the most vulnerable part of a weighing or balance system, so there is a chance that they will frequently fail as they undergo many events that can reduce their functionality. Hence, it is very important to understand the problem and resolve it in time because if you knew what happened, you could hopefully mitigate the risk of it happening again in the future. Here we’ve listed some common causes of load cell damage, including:

1. Dropped or mishandled

If the load cells are abandoned or mishandled, it can change the final results. Some load cells are sensitive and require careful handling by operators. If you unintentionally drop the load cell, it can damage the body and the interior of the load cell.

2. Moisture damage

It is one of the most common problems that you can easily find in warehouses with a high water level or in outdoor industrial areas. Therefore, water can cause the load cell to short circuit and tend to rust interior parts.

3. Sudden electrical damage

Lightning can create problems, and these unexpected energy outbreaks can eternally damage the load cells. Also, it is better to identify your cable connections, as a cut, damaged, or crimped cable can also affect the load cell connections, causing damage to the cell.

4. Overload capacity

One of the most common causes of load cell damage is overloading the capacity of the balance. Scales are rated based on what their load cells can withstand, and exceeding this limit can result in significant deformation of the load cell itself. It could do anything, from making it less precise to making it unusable.

5. Chemical Ingress

Chemicals can cause roughly the same damage as water if they enter a load cell environment or container. Additionally, they can also corrode a load cell more strongly and ruin its components and overall structure.

6. Environmental forces

Other forces, including environmental forces such as wind loads, shock loads, vibrations, large temperature changes, and pressure differences, can also produce problems in the load cell signal.

Signs that your load cell is damaged

Red flags indicate that your load cell is not working properly. Here we have listed some signs that your load cell is damaged, including:

Inconsistency: If the cell shows different results for the same weighed item, it means the load cell is acting.

Zero balance: Load cells are reset to zero after each measurement to maintain accuracy; otherwise, the results will be incorrect.

Overload error: In some cases, load cells warn you of an overload when there is none. But in reality, there is no weight on it.

However, there are several checks you can try to determine if you are experiencing any of the above signs with your load cell measurement system.

How to check the load cell problem

When load cells start to malfunction, now is a good time to identify what is causing them, physical damage to the wrong type or the wrong voltage range. To help you here, we’ve listed some methods to check for load cell issues, including:

1. Visual Check

A visual check concerns the load cell and the entire measuring system to determine the possible location of the fault. It can reveal physical damage that could affect the results. Sometimes the obvious signs will lead to the answer.

So, while using this method, make sure your load cell is disconnected from any power source and then check if there are any cracks, distortions, wear, or tears on the body or load cell cables.

2. Zero Balance Check

Zero balance is the output reading of an empty load cell. For a multi-sensor measuring system, you must check each sensor individually. So before starting this test, make sure that there is no weight on the load cell and that it is not connected to the cell; disconnect signal leads and measure the voltage between the negative and positive signal leads. When measuring, the output should be similar or close to the manufacturer’s specifications.

Finally, make sure you have connected the wires to the digital weight indicator, which would supply the excitation voltage to the wires.

3. Insulation Check

Insulation is the other cause of having inaccurate readings on the load cell. To check the problem, perform an insulation resistance test when there are unstable readings or unexpected changes in the zero-balance point of the load cell. It measures the resistance between the body of the load cell and all of its connected wires.

Closing Words

Are you suspicious that your load cells are not working properly or are damaged? It could be due to several common issues, including overload, strong electrical surges, chemical or moisture ingress, improper handling, etc. 

However, to diagnose your problem with high-quality load cells, first, examine the causes individually and then call an industry expert. They will be able to assess your entire machine and identify problems. Then, whether you are in manufacturing, food processing, agricultural, farming, or any other similar industry, make sure you have the right load cell solution for your business.