A load cell is a transducer that is used to create an electrical signal whose magnitude is directly proportional to the force being measured. The various types of load cells include hydraulic load cells, pneumatic load cells and strain gauge load cells.
Strain gauge load cell
Through a mechanical construction, the force being sensed deforms a strain gauge. The strain gauge measures the deformation (strain) as a change in electrical resistance, which is a measure of the strain and hence the applied forces. A load cell usually consists of four strain gauges in a Wheatstone bridge configuration. Load cells of one strain gauge (quarter bridge) or two strain gauges (half bridge) are also available. The electrical signal output is typically in the order of a few millivolts and requires amplification by an instrumentation amplifier before it can be used. The output of the transducer can be scaled to calculate the force applied to the transducer.
Strain gauge load cells are the most common in industry. These load cells are particularly stiff, have very good resonance values, and tend to have long life cycles in application. Strain gauge load cells work on the principle that the strain gauge (a planar resistor) deforms/stretches/contracts when the material of the load cells deforms appropriately. These values are extremely small and are relational to the stress and/or strain that the material load cell is undergoing at the time. The change in resistance of the strain gauge provides an electrical value change that is calibrated to the load placed on the load cell.
Strain gauge load cells convert the load acting on them into electrical signals. The gauges themselves are bonded onto a beam or structural member that deforms when weight is applied. In most cases, four strain gauges are used to obtain maximum sensitivity and temperature compensation. Two of the gauges are usually in tension, and two in compression, and are wired with compensation adjustments. The strain gauge load cell is fundamentally a spring optimized for strain measurement. Gauges are mounted in areas that exhibit strain in compression or tension. The gauges are mounted in a differential bridge to enhance measurement accuracy. When weight is applied, the strain changes the electrical resistance of the gauges in proportion to the load. Other load cells are fading into obscurity, as strain gauge load cells continue to increase their accuracy and lower their unit costs.
Piezoelectric load cell
Piezoelectric load cells work on the same principle of deformation as the strain gauge load cells, but a voltage output is generated by the basic piezoelectric material - proportional to the deformation of load cell. Useful for dynamic/frequent measurements of force. Most applications for piezo-based load cells are in the dynamic loading conditions, where strain gauge load cells can fail with high dynamic loading cycles.
Hydraulic load cell
The cell uses conventional piston and cylinder arrangement. The piston is placed in a thin elastic diaphragm. The piston doesn't actually come in contact with the load cell. Mechanical stops are placed to prevent over strain of the diaphragm when the loads exceed certain limit. The load cell is completely filled with oil. When the load is applied on the piston, the movement of the piston and the diaphragm results in an increase of oil pressure which in turn produces a change in the pressure on a Bourdon tube connected with the load cells. Because this sensor has no electrical components, it is ideal for use in hazardous areas. Typical hydraulic load cell applications include tank, bin, and hopper weighing. By example, a hydraulic load cell is immune to transient voltages (lightning) so these type of load cells might be a more effective device in outdoor environments. This technology is more expensive than other types of load cells. It is a more costly technology and thus cannot effectively compete on a cost of purchase basis.
Pneumatic load cell
The load cell is designed to automatically regulate the balancing pressure. Air pressure is applied to one end of the diaphragm and it escapes through the nozzle placed at the bottom of the load cell. A pressure gauge is attached with the load cell to measure the pressure inside the cell. The deflection of the diaphragm affects the airflow through the nozzle as well as the pressure inside the chamber.
Other types include vibrating wire load cells, which are useful in geomechanical applications due to low amounts of drift, and capacitive load cells where the capacitance of a capacitor changes as the load presses the two plates of a capacitor closer together.
Every load cell is subject to "ringing" when subjected to abrupt load changes. This stems from the spring-like behavior of load cells. In order to measure the loads, they have to deform. As such, a load cell of finite stiffness must have spring-like behavior, exhibiting vibrations at its natural frequency. An oscillating data pattern can be the result of ringing. Ringing can be suppressed in a limited fashion by passive means. Alternatively, a control system can use an actuator to actively damp out the ringing of a load cell. This method offers better performance at a cost of significant increase in complexity.
Load cells are used in several types of measuring instruments such as laboratory balances, industrial scales, platform scales and universal testing machines. From 1993 the British Antarctic Survey installed load cells in glass fibre nests to weigh albatross chicks. Load Cells are used in a wide variety of items such as the seven-post shaker which is often used to setup race cars.
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- "Load cell testing gets straight to the point". Maritime Journal (Mercator Media). 20 December 2010.
- Highfield, Roger. Antarctic's birds thrive on warmth, The Daily Telegraph 18 August 1993
- ASTM E4 - Practices for Force Verification of Testing Machines
- ASTM E74 - Practice for Calibration of Force Measuring Instruments for Verifying the Force Indication of Testing Machines
- NTEP - National Conference on Weights and Measures (Certificate of Conformance)