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Common Load Cell Errors Explained

The document discusses various factors that can cause errors in load cell measurements, including total combined error, temperature changes, creep, load cell response, and others. It emphasizes the importance of proper installation, maintenance, and calibration to minimize inaccuracies. Additionally, it highlights that multiple issues occurring simultaneously can lead to significant measurement errors.

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kieubichson
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16 views3 pages

Common Load Cell Errors Explained

The document discusses various factors that can cause errors in load cell measurements, including total combined error, temperature changes, creep, load cell response, and others. It emphasizes the importance of proper installation, maintenance, and calibration to minimize inaccuracies. Additionally, it highlights that multiple issues occurring simultaneously can lead to significant measurement errors.

Uploaded by

kieubichson
Copyright
© All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd

Load cell error

1. Total Combined Error


All measurement devices will have some degree of error that is not preventable. In load cells, this is
shown through non-linearity and hysteresis. Since some level of error is unavoidable, there aren’t
load cell troubleshooting strategies for this. However, this is acceptable as long as the error is less
than the error tolerance of any ingredient. Additionally, non-linearity and hysteresis are less
problematic in particular situations.
Non-linearity describes the weighing error over the entire load cell range. Smaller changes will
create less error due to non-linearity, while a change from zero to maximum capacity will cause the
greatest effect. Hysteresis is the difference in the results between increasing the load from zero and
decreasing from maximum. Similar to non-linearity, error due to hysteresis is more noticeable when
dealing with larger loads. So, when working with batching, this inevitable error is generally less of
a problem compared to larger loading operations.

2. Temperature Changes
Dramatic temperature changes cause metal to warp. Traditional load cells are built using strain
gauges, which are delicate metal pieces. Dramatic temperature changes will affect the function of
the strain gauge, and therefore the load cell. If the load cell is exposed to cold nights and then hot,
direct sunlight, or surrounding equipment heats up the area, this can cause inaccuracy. To
troublehshoot this load cell problem, you might take temperature readings at different times, and
shield the equipment from the sun if it causing dramatic temperature shifts.

3. Creep
If a load cell remains under pressure for a long period, it becomes susceptible to creep. This isn’t a
problem in batching operations at two or three minute intervals, but load cells measuring storage
silos or other containment units for extended periods will need to account for creep.

4. Load Cell Response


All load cells require a set time to return to zero before they can accurately measure a new load. If
the process begins to refill the vessel before the load cell(s) return to zero, the measurement won’t
be accurate within the error tolerance. Allow enough time between measurements for the load cells
to stabilize and response time will not be an issue. To troubleshoot this load cell problem, test the
load cell response upon installation and with calibration, to ensure it remains stable.

5. Balanced Load
The load must be properly balanced on the load cell, or the load cells must be arranged to
accommodate for unbalanced loads. Where multiple load cells are used, they must be mounted so
no other part of the vessel or container takes on a part of the load. For a sitting vessel, this generally
means the load cells must be situated between the vessel and the floor. For a mounted load, bumpers
and checkrods used to stabilize the load cannot also support its weight.

6. Vibration
Excessive vibration, usually from other nearby processes or sometimes from passing trucks or
heavy equipment, can disrupt the reading. Troubleshooting this load cell problem might involve
moving the source of the vibration or moving the load cells and attached equipment. Dampening
devices such as layers of rubber or cork can also absorb the vibration. If the vibration is cyclical, it
can also be electronically filtered out by a weight controller.

7. Windforce
Air currents exert force on a load cell that can disrupt the weight of the load alone. Usually, this is
not enough to cause significant inaccuracy, but strong, consistent windforce can disrupt the reading.
This might come from intense winds outdoors, or from strong air currents used to prevent dust
buildup.

8. Noise
When the load cell transmits its electrical signal to the weight controller, interference, or noise, can
disrupt it. Radio signals and electromagnetic signals both cause noise, which includes electrical
currents, other data transmission signals, even strong wireless signals. Proper shielding around the
load cell cables and grounding of the shield can prevent interference from noise. Using a capacitive
digital load cell can also help to prevent signal loss due to noise. In a capacitive digital load cell, the
signal is converted to digital locally within the load cell, so there is no loss of signal across the cable
length or at bad connection point.

9. Moisture
Moisture can also inhibit the signal from the load cell to the weight controller. Moisture, perhaps
from steam, excessive humidity, or equipment washing, most often enters the load cell through the
cable entry area. Hermetic sealing will prevent moisture from damaging the load cell and internal
components.

10. Signal Jitter


A number of factors can cause the weight signal from a load cell to “jitter;” moving unsteadily
upward (or downward, as in a loss-of-weight feeder) instead of in a smooth line. The hopper’s or
vessel’s movement while weighing, material entering the vessel unevenly, an agitator preventing
sticking, or unshielded noise can all cause the signal to fluctuate. A weight controller averages the
fluctuation and creates a smooth analog signal, then converts the signal to digital. However, if the
weight controller isn’t working properly or isn’t installed properly, signal jitter will disrupt the
measurement.

11. Damaged Load Cell Connections


Often, multiple load cells are used to measure a load. When these load cell signals are not combined
and summed properly at the weighing instrument, it can cause noticeable error. This can occur due
to faulty connections between the load cells and the instrument. Corrosion from acids or salts can
cause connections to corrode, thereby disrupting the signal.

12. Scale Instrument


Both the load cell and the scale instrument are important in determining accurate measurements.
The scale instrument, or the scale head, must be able to integrate effectively with the load cell. A
typical load cell is accurate with 5,000 divisions, which might not be accurate enough for the
application. However, a finely-tuned scale instrument can divide by 10,000 or even 20,000. This
would allow a 100 lb load cell to show increments of .01 or even .005 lbs, respectively. Though this
would not be considered standard, the ingredient or application could call for additional accuracy.
13. Conductive Dust
Most load cells use a strain gauge, layers of very thin, conductive metal, to measure weight. Just as
moisture can disrupt the load cell’s function, so can conductive metal dust and debris. If a load cell
is not properly sealed and environmental metal dust or even salt. Capacitive load cells do not use a
strain gauge, but can also be disrupted by conductive dust. However, capacitive load cells are easier
to hermetically seal and prevent disruption.

14. Damaged Components


Though a load cell can be reinforced to withstand difficult environments, the internal components
are delicate. A heavy impact, as well as corrosive chemicals or salts, can damage the inner workings
of the load cell and cause it to malfunction. If you notice intermittent misreadings, or if there is
more error than usual, the strain gauge or capacitor within the load cell may be damaged.

15. Calibration
To stay accurate, load cells require regular calibration. A regular maintenance schedule is the best
way to stay on top of necessary maintenance. If the load cell is not calibrated, it is more susceptible
to every form of disruption. When making repairs to the load cell, remember to recalibrate
afterwards.
One of these load cell problems alone will probably not create a noticeable problem, unless it is
extreme. However, several of them occurring at once can cause measurements to be noticeably
inaccurate. Careful attention to the environment around the load cell and the equipment, as well as
the installation and use of the load cell itself, can prevent many load cell problems.

Common questions

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Environmental contamination like conductive dust and moisture affects load cells by disrupting signal transmission through metal strain gauges. Conductive environments or moisture intrusion through cable entry points are primary concerns. Employing hermetically sealed load cells minimizes these impacts by providing a robust barrier against contaminants. Capacitive load cells, less reliant on strain gauges, also offer improved resilience against such disruptions .

Signal jitter in load cells can be caused by several factors including vessel movement during weighing, uneven material ingress, or agitators preventing material sticking. Additionally, unshielded electrical noise can contribute to this phenomenon. A weight controller can mitigate these issues by averaging fluctuations to smooth out the signal and converting it to digital form, ensuring accurate readings. Proper installation and functioning of the weight controller are crucial for minimizing jitter effects .

Creep in load cells becomes relevant in scenarios where the load cell is under pressure for extended periods, such as when measuring weights in storage silos. The impact of creep is determined by the duration the load is applied; short durations, as in batching operations with intervals of a few minutes, typically do not suffer from significant creep effects. The extent of creep is directly related to the time and consistency of the pressure on the load cell .

Electrical noise can significantly disrupt load cell signal transmission, primarily through interference from radio and electromagnetic signals or electrical currents. To minimize these effects, proper shielding around load cell cables and grounding of the shields is essential. Utilizing capacitive digital load cells, which convert signals to digital form locally, helps prevent signal disruption across the cable length .

Vibration can disrupt load cell readings by resonating with the equipment, often caused by nearby machinery or vehicles. Adequate measures include relocating the vibration source or using vibration-dampening materials like rubber. Windforce can affect load cell readings by exerting additional force on the load cell, especially with strong, consistent wind. To address windforce, shielding or environmental adjustments can be employed to minimize airflow impact .

Improperly balanced loads can cause inaccurate measurements as the load may not evenly distribute across multiple load cells, possibly leading some cells to bear excessive or insufficient weight. To ensure balance, load cells should be positioned directly between the vessel and supporting structures, using strategically placed bumpers and checkrods that stabilize rather than support weight. This maintains consistent and accurate pressure on all load cells, essential for precision in weight distribution applications .

The integration capability of a scale instrument with a load cell directly affects measurement precision by determining how accurately the scale instrument can interpret the load cell's output. Key considerations include the instrument's division capability, which ideally exceeds that of the load cell to enhance precision (e.g., dividing by 10,000 or 20,000). A finely tuned scale instrument can significantly ameliorate the inherent resolution limits of a standard load cell, improving measurement accuracy even in demanding applications .

Non-linearity and hysteresis contribute to load cell inaccuracies by affecting measurements across different load ranges. Non-linearity refers to the error distribution over the entire capacity of a load cell, becoming more pronounced with larger changes, such as from zero to maximum capacity. Hysteresis involves differences in readings when load is increased from zero load or decreased from full load capacity. These factors are more significant when dealing with larger loads or ranges. However, they pose less of an issue in operations involving smaller, incremental changes, such as batching, where their impact is minimized .

Temperature changes can cause metal strain gauges in load cells to warp, leading to inaccurate readings. This is particularly problematic with dramatic temperature shifts, such as exposure to both cold nights and hot sunlight. To mitigate these effects, it is advisable to monitor temperature variations and shield the equipment from direct sunlight or ambient heat that causes these fluctuations .

Calibration is crucial to maintaining the accuracy of load cells by ensuring they provide correct readings in various operational conditions. Neglecting calibration increases susceptibility to errors from environmental factors and technical issues. Regular maintenance and recalibration after repairs help maintain measurement integrity. Without calibration, even minimal issues can accumulate, leading to significant inaccuracies .

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