Choosing Load Cells for Harsh Environments - Considerations and Solutions 📰

4^th Jul 2024

In industrial settings where extreme temperatures, moisture, chemicals and mechanical stresses are prevalent, selecting the right load cells for measurement applications is crucial for ensuring accuracy, reliability and longevity. Load cells designed for harsh environments are engineered to withstand challenging conditions while maintaining optimal performance. This article explores the key considerations and solutions for choosing load cells suited for harsh environments, highlighting factors such as environmental factors, material selection and protective measures.

Environmental Considerations:

Harsh environments pose unique challenges for load cells, including exposure to high or low temperatures, humidity, corrosive chemicals and mechanical shock or vibration. When selecting load cells for harsh environments, it's essential to consider the specific environmental conditions the load cells will be exposed to and choose models with suitable environmental ratings and protection levels. Load cells designed for harsh environments often feature rugged construction, corrosion-resistant materials and sealing mechanisms to prevent ingress of moisture, dust and contaminants.

Material Selection:

The choice of materials plays a critical role in determining the durability and performance of load cells in harsh environments. Stainless steel and alloy steel are commonly used for load cell construction due to their excellent corrosion resistance, mechanical strength, and durability. In applications where exposure to corrosive chemicals or saltwater is a concern, load cells may incorporate special coatings or treatments or be manufactured from specific grades of stainless steel, to provide additional protection against chemical corrosion and abrasion.

Protective Measures:

Load cells for harsh environments may incorporate various protective measures to enhance their resilience and longevity. These measures may include:

Hermetic Sealing: Load cells may feature hermetically sealed enclosures to protect sensitive internal components from moisture, dust and contaminants. Hermetic sealing ensures long-term reliability and prevents degradation of performance in challenging environments.

IP (Ingress Protection) Rating: Load cells are often rated according to IP standards, which specify the degree of protection provided against ingress of solid particles and moisture. Higher IP ratings indicate greater resistance to environmental hazards, with IP67 or IP68 ratings being suitable for harsh industrial environments, including permanently submersed applications.

Overload Protection: Load cells may incorporate overload protection mechanisms such as mechanical stops, overload stops or instrumentation with alarms and system shutdown facilities to prevent damage from excessive loads or shock loads. Most load cells are also calibrated to 150% of their rated load, which is the maximum force the load cell can measure without sustaining any damage. These features help extend the service life of load cells and maintain measurement accuracy under challenging operating conditions.

Choosing the right load cells for harsh environments requires careful consideration of environmental factors, material selection and protective measures. By selecting load cells specifically designed and engineered to withstand extreme temperatures, moisture, chemicals, and mechanical stresses, operators can ensure reliable and accurate measurement performance in challenging industrial applications. Collaborating with reputable load cell manufacturers and suppliers and consulting with experienced engineers can help identify the most suitable load cell solutions tailored to the specific requirements of harsh environment applications. With proper selection and installation, load cells equipped to handle harsh environments contribute to improved operational efficiency, reduced downtime and enhanced reliability in industrial processes.