We are the largest Load Cell manufacturers In India ( Pune ).
As leading Load Cell manufacturers and exporters in India, Sharp Electronics takes pride in being an ISO 9001:2008 certified company. Established in the year 2002, we have established ourselves as a prominent name in the industry, specializing in a diverse array of Industrial Weighing Scales. Our product range includes Tabletop Scales, Platform Scales, Weight Controllers, and more, meticulously crafted to cater to a variety of specifications. This ensures that the distinct requirements of our esteemed customers are met with precision. Additionally, we provide Installation and Repair services to offer comprehensive solutions to our clientele.
Our offerings have garnered significant demand across various sectors, including sweet marts, hardware shops, poultry and fish markets, fruit stalls, market yards, and metal markets. At the core of our success is our robust infrastructure, equipped with cutting-edge machinery and tools that facilitate seamless operations. Backed by a team of experienced and skilled professionals, we work cohesively to achieve organizational objectives with the highest level of efficiency. Over the years, we have earned a commendable reputation within the industry, a testament to our unwavering commitment to excellence.
As we take immense pride in our role as prominent Load Cell manufacturers and exporters in India, our dedication to delivering top-notch products and services remains unwavering. Our reputation is further enhanced by the visionary leadership of Mr. Kailas Sithole, whose extensive industry experience and guidance have propelled us to a prominent position within the industry. Under his mentorship, we have cultivated a vast and loyal customer base, reflecting our dedication to excellence and customer satisfaction.
Understanding Load Cells: The Backbone of Weight Measurement
Imagine a world without load cells—precise measurements of weight would be virtually impossible. From industrial weighing to force measurement, load cells play a vital role in various applications. In this article, we’ll delve into the fundamentals of load cells, explore their working principles, discuss their applications, and provide valuable insights for choosing, installing, and maintaining these critical devices.
Load cells are transducers that convert force or weight into an electrical signal. They are commonly used in weighing scales, industrial equipment, and testing machines. Load cells have revolutionized the way weight is measured, offering accuracy, reliability, and versatility across numerous industries.
What is a Load Cell?
A load cell is a sensor designed to measure the force or load applied to it. It consists of a sensing element, which undergoes mechanical deformation when a force is exerted on it, and a mechanism to convert this deformation into an electrical signal. The electrical signal can then be calibrated and processed to provide an accurate measurement of the applied force or weight.
Types of Load Cells
Load cells come in various types, each designed to suit specific applications. Let’s explore some commonly used load cell types:
Strain Gauge Load Cells
Strain gauge load cells are the most common type and are based on the principle of strain measurement. They employ strain gauges, which are thin wires or foil strips that deform under load. As the strain gauges deform, their electrical resistance changes, providing a proportional electrical output.
Hydraulic load cells use hydraulic fluid to measure the applied force. They consist of a piston and cylinder arrangement connected to a Bourdon tube. When a force is applied, the hydraulic pressure increases, causing the tube to deform. This deformation is then measured and converted into an electrical signal.
Pneumatic load cells operate similarly to hydraulic load cells but use compressed air instead of hydraulic fluid. The force applied compresses the air, resulting in a pressure change that is converted into an electrical output.
Capacitive load cells utilize changes in capacitance to measure applied force. They consist of two plates separated by a small gap. When a force is applied, the plates move closer together, altering the capacitance between them. This change in capacitance is detected and converted into an electrical signal.
Piezoelectric load cells employ the piezoelectric effect, which is the generation of electrical charges in certain materials when subjected to mechanical stress. These load cells contain piezoelectric crystals or ceramics that generate an electrical signal proportional to the applied force. Piezoelectric load cells offer high accuracy and fast response times.
Working Principle of Load Cells
Understanding the working principle of load cells is crucial to comprehend their functionality. Let’s explore how different types of load cells work:
Strain Gauge Load Cell Working
Strain gauge load cells operate based on the principle of resistance change. When a force is applied, the strain gauge deforms, causing a change in its electrical resistance. This resistance change is measured using a Wheatstone bridge circuit, producing an electrical output proportional to the applied force.
Hydraulic Load Cell Working
Hydraulic load cells utilize the principle of fluid pressure. When a force is exerted, the pressure in the hydraulic system increases, causing the deformation of the Bourdon tube. This deformation is converted into an electrical signal using transducers or strain gauges.
Pneumatic Load Cell Working
Similar to hydraulic load cells, pneumatic load cells measure the pressure change resulting from the applied force. The force compresses the air within the cell, leading to a change in pressure. This pressure change is then converted into an electrical output.
Capacitive Load Cell Working
Capacitive load cells rely on changes in capacitance. When a force is applied, the separation between the plates of the load cell changes, altering the capacitance. This variation in capacitance is detected and converted into an electrical signal for weight measurement.
Piezoelectric Load Cell Working
Piezoelectric load cells utilize the piezoelectric effect. The applied force causes the piezoelectric material to generate electrical charges. These charges are measured and converted into electrical output, providing an accurate measurement of the applied force.
Applications of Load Cells
Load cells find applications in a wide range of industries due to their accuracy and reliability. Some common applications include:
Load cells are extensively used in industrial weighing scales, ensuring precise measurements in manufacturing, logistics, and material handling processes. They are crucial for monitoring product quantities, controlling inventory, and optimizing production efficiency.
Force and Torque Measurement
Load cells are employed in force and torque measurement devices, such as dynamometers and force transducers. They enable the accurate measurement of forces and torques in various applications, including material testing, robotics, and mechanical engineering.
Testing and Calibration
Load cells play a crucial role in testing and calibration processes across industries. They are utilized in materials testing machines, tensile testers, and calibration equipment to ensure the accuracy and compliance of products and instruments.
Aerospace and Defense
In the aerospace and defense sectors, load cells are used for aircraft weight and balance calculations, structural testing, and research and development. They provide essential data for aircraft design, maintenance, and safety.
Medical and Pharmaceutical
Load cells are utilized in medical and pharmaceutical equipment, such as infusion pumps, laboratory balances, and compression testers. They ensure accurate dosing, sample weighing, and quality control in medical and pharmaceutical applications.
Factors to Consider When Choosing a Load Cell
When selecting a load cell for a specific application, several factors should be considered:
The load capacity of the load cell should match the maximum force or weight that needs to be measured. It is essential to select a load cell with an appropriate capacity to ensure accurate and reliable measurements without the risk of overload or damage.
The accuracy of the load cell is crucial for precise weight measurements. Different load cells have varying levels of accuracy, typically expressed as a percentage of the full-scale output. It is important to choose a load cell with the required level of accuracy for the specific application.
Consider the environmental conditions in which the load cell will be used. Factors such as temperature, humidity, and exposure to chemicals or corrosive substances can affect the performance and longevity of the load cell. Select a load cell that is suitable for the specific environmental conditions of the application.
Size and Mounting Options
The physical size and mounting options of the load cell are important considerations, especially when space is limited. Ensure that the load cell can be conveniently integrated into the equipment or system without compromising functionality or accuracy.
Consider the cost-effectiveness of the load cell while ensuring it meets the required specifications. Compare different options based on their features, performance, and overall value for the investment.
Installation and Calibration of Load Cells
Proper installation and calibration of load cells are crucial for accurate measurements. Follow these steps for successful installation and calibration:
Ensure that the load cell is mounted securely and in a position that allows it to measure the force accurately. Follow the manufacturer’s guidelines for proper mounting techniques and avoid any external factors that could introduce errors or interference.
Wiring and Electrical Connections
Make sure to connect the load cell properly to the measurement system or indicator. Follow the wiring diagram provided by the manufacturer and ensure that all electrical connections are secure and free from any loose or damaged wires.
Calibrate the load cell according to the manufacturer’s instructions or industry standards. Calibration involves applying known forces or weights to the load cell and comparing the output with the expected values. Make adjustments if necessary to ensure accurate readings.
Troubleshooting Common Load Cell Issues
Even with proper installation and calibration, load cells may encounter issues. Here are some common problems and their possible solutions:
If the load cell’s zero reading deviates over time, it may indicate drift or mechanical issues. Perform zero calibration and check for any mechanical obstructions or misalignments. If the problem persists, consult the manufacturer or a professional technician.
Load cells are designed to operate within specific load limits. Exceeding these limits can cause permanent damage to the load cell. Ensure that the load applied to the load cell remains within its rated capacity to avoid overload damage.
Electrical Noise Interference
Electrical noise from nearby equipment or power sources can interfere with the load cell’s electrical signals, leading to inaccurate readings. Minimize electrical interference by properly grounding the load cell and using shielding techniques if required.
Extreme temperatures can affect the performance of load cells, especially those with strain gauge elements. Consider temperature compensation techniques or choose load cells specifically designed for the intended temperature range to minimize temperature-related errors.
If the load cell consistently provides inaccurate readings, check for issues such as loose wiring, damaged cables, or faulty signal conditioning equipment. Perform calibration checks and verify that the load cell is compatible with the measurement system.
Maintenance and Care of Load Cells
Proper maintenance and care can extend the lifespan and performance of load cells. Follow these guidelines:
Periodically inspect the load cell for any signs of damage, wear, or contamination. Check the mounting, wiring, and electrical connections. Clean the load cell if necessary, following the manufacturer’s recommendations.
Cleaning and Protection
Clean the load cell using a non-abrasive cleaning solution and a soft cloth. Avoid harsh chemicals that may damage the load cell. Protect the load cell from dust, moisture, and corrosive substances by using appropriate covers or enclosures.
Proper Handling and Usage
Handle the load cell with care, avoiding excessive force or impact. Follow the manufacturer’s guidelines for proper usage, including load application and operating conditions. Avoid subjecting the load cell to shocks or vibrations that may affect its performance.
Regularly verify the calibration of the load cell to ensure accurate measurements. Perform calibration checks using known weights or forces and compare the readings with the expected values. Adjust the load cell if necessary or consult a professional calibration service.
Advancements in Load Cell Technology
Load cell technology continues to evolve, introducing new features and capabilities. Here are some advancements that have improved load cell performance:
Wireless Load Cells
Wireless load cells eliminate the need for cumbersome cables, providing more flexibility in installation and usage. They use wireless communication technology to transmit the measurement data to a receiver or monitoring system.
Digital Load Cells
Digital load cells offer enhanced accuracy, resolution, and communication capabilities. They utilize digital signal processing to provide precise measurements and often feature built-in diagnostics for easier troubleshooting.
Smart Load Cells
Smart load cells incorporate advanced features such as self-calibration, temperature compensation, and data-logging capabilities. They can communicate directly with computer systems or controllers, allowing for real-time monitoring and data analysis.
Miniature Load Cells
Miniature load cells are compact and lightweight, making them suitable for applications with limited space or weight constraints. Despite their small size, they maintain high accuracy and reliability.
Integrated Load Cell Systems
Integrated load cell systems combine multiple load cells, amplifiers, and signal conditioning equipment into a single unit. These systems provide a convenient and integrated solution for weight measurement in complex applications.
Load cells are essential devices for accurate weight measurement in various industries. Understanding their types, working principles, applications, and factors for selection and maintenance is crucial for achieving reliable and precise results. As technology advances, load cells continue to evolve, offering improved features and capabilities to meet the ever-growing demands of modern industries.
FAQs (Frequently Asked Questions)
Q: What is the lifespan of a load cell? A: The lifespan of a load cell can vary depending on factors such as usage, environmental conditions, and maintenance. With proper care and regular calibration, load cells can last for many years.
Q: Can load cells be used in hazardous environments? A: Yes, there are load cells specifically designed for use in hazardous environments. These load cells are built to withstand potentially explosive atmospheres and meet specific safety standards.
Q: Can load cells measure both compression and tension forces? A: Yes, load cells are capable of measuring both compression and tension forces. The type and design of the load cell determine its ability to measure different force directions.
Q: Can load cells be repaired if they become damaged? A: In some cases, load cells can be repaired if the damage is minor. However, significant damage may require replacement of the load cell. Consult the manufacturer or a professional technician for assessment and guidance.
Q: Are load cells affected by temperature variations? A: Temperature variations can affect the performance of load cells, particularly those with strain gauge elements. It is important to choose load cells with appropriate temperature compensation or consider environmental factors in the application.
A load cell is a transducer that is used to convert a mechanical force or weight into an electrical signal. It is a type of sensor that is commonly used in weighing scales, industrial equipment, and scientific applications where force or weight needs to be measured accurately.
Load cells are typically made up of a metal structure, strain gauges, and electrical wiring. The metal structure is designed to deform under the application of force or weight, and the strain gauges are bonded to the metal structure to measure the deformation. The electrical wiring is used to transmit the electrical signal produced by the strain gauges to a readout device, such as a computer or a digital display.
Load cells are available in a wide range of sizes and capacities, from small load cells used in laboratory equipment to large load cells used in industrial applications. They can be used to measure tension, compression, and shear forces, and are commonly used in applications such as material testing, aerospace testing, and structural monitoring.
Overall, load cells are an essential component in many modern measurement systems and are used in a wide range of industries to provide accurate and reliable force and weight measurements.
A pancake load cell is a type of load cell that is designed to measure compressive forces in a flat, pancake-like form factor. This type of load cell is often used in applications where space is limited, and a low profile is required.
Pancake load cells typically consist of a flat, circular sensing element made of metal, such as stainless steel. Strain gauges are bonded to the sensing element to detect changes in resistance caused by deformation under load. The sensing element is usually mounted between two flat, circular plates that distribute the load evenly over the sensing element.
Pancake load cells are commonly used in applications such as weighing scales, material testing, and force measurement in robotics and automation. They are also used in industries such as aerospace, automotive, and medical devices where precise force measurement is essential.
One advantage of pancake load cells is their low profile, which makes them well-suited for applications where space is limited. They are also easy to install and can provide accurate and reliable measurements with minimal maintenance. However, pancake load cells may not be suitable for applications where high accuracy or precision is required, as their flat shape can make them more susceptible to non-axial loading and bending moments.
|Capacity||100 -170 Ton|
|Features||Easy to install|
|Creep Error (30 minutes)||+/-0.03% FS|
|Temperature Effect on Zero||+/-0.05% FS/DegC|
|Temperature Effect on Output||+/-0.03% FS/DegC|
|Zero balance||+/- 1% FS|
|Maximum Safe Overload||150% FS|
|Ultimate Safe Overload||200% FS|
|Recommended Excitation Voltage||9 to 12V DC|
|Input Resistance||750 +/- 10 Ohm|
|Output Resistance||700 +/- 2 Ohm|
|Insulation resistance at 50V DC||>= 1000 M Ohm|
|Compensated Temperature Range||-10 to +40 Deg C|
|Operating Temperatue Range||-20 to +70 Deg C|
- Precisely designed
- Require less maintenance
- Optimum quality
|200kg to 5000kg||105||90||6.2*8||M16*1.5||32||36|
|20T to 30T||155||125||16.5*8||M39*2||50||52|
- Alloy steel & Stainless steel structure
- Nickel plated
- Suitable for multiform environments
- Easy to Install & Use
- Electronic Truck Scales
- Truck Scales, Hooper Scales
- Other Electronic Weighing Devices
A high-capacity compression load cell is a type of load cell designed to measure compressive forces in high-capacity applications. These load cells are used in a variety of industries, including construction, heavy equipment, and materials testing.
High capacity compression load cells are typically made of durable materials such as stainless steel, and they are designed to withstand high loads without distortion or damage. They typically consist of a cylindrical or rectangular sensing element with strain gauges bonded to it to measure changes in resistance caused by deformation under load. The sensing element is often surrounded by a protective housing that helps to protect it from environmental factors such as dust, moisture, and temperature fluctuations.
High capacity compression load cells can be used in a wide range of applications, from simple weighing scales to large industrial processes that require accurate measurement of large compressive forces. These load cells can be used in conjunction with other sensors and instruments to provide precise measurements of force, torque, pressure, and other variables.
One advantage of high capacity compression load cells is their ability to provide accurate and reliable measurements even in harsh environments. They are also easy to install and can be integrated into existing systems with minimal modification. However, they can be relatively expensive compared to other types of load cells, and they may require periodic calibration to maintain their accuracy over time.
|Type||Pan Cake Type Loadcell|
|Load Capacity||100 kg to 100 Ton|
|Cable Length||3 meter|
- Compact design
- Accurate fitting
- Light weight
- 5 Tf to 100 Tf
- Multicolumn Construction
- Hermetically Sealed – IP 68. on request
- Linearised version – available with accuracy better than 0.025% of full span
- Truck Scale
- Tank Weighing
- Hopper Weighing
- Compressive force Testing
- Industrial Automation
- Protection to IP67
- Explosion proof version (Ex ib ll Ct4)
- Low Profile, High anti-interface
- Suitable for motion weighing
|Related Load (kg.) 100kg to 100Ton|
|Composition Error0.03||Excitation Voltage (V)9~12 (DC)|
|Rated Output (mv/v)2.0 ±10%||Compensated temp. Range (°C)-10~+40|
|Non-Linearity (%FS)0.03 / 0.017||Use Temp. Range (°C)-35~+65|
|Hysteresis (%FS)0.03 / 0.02||Temp. Effect on Zero (%FS/10°C)0.03 / 0.017|
|Repeatability (%FS)0.01||Temp. Effect on Zero (%FS/10°C)0.03 / 0.017|
|Creep (%FS/30min)0.02||Safe Overload (%FS)120|
|Zero Balance (%FS)± 1||Ultimate Overload (%FS)150|
|Input Resistance (Ω)750 ± 10||Defend GradeIP66|
|Output Resistance (Ω)700 ± 2||Cable6mm, 5mtr|
A button type load cell is a type of load cell that is designed to measure compressive forces in a small, compact form factor. It is also known as a “compression button” or “button compression load cell.”
Button type load cells are typically small and cylindrical in shape, with a threaded mounting hole in the center that allows them to be easily installed in tight spaces. They are often used in applications where space is limited, such as in robotics and automation, medical devices, and laboratory equipment.
Button type load cells typically consist of a small cylindrical sensing element made of metal, such as stainless steel, with strain gauges bonded to it to detect changes in resistance caused by deformation under load. The sensing element is usually mounted between two flat plates that distribute the load evenly over the sensing element.
Button type load cells can be used to measure compressive forces in a wide range of applications, such as in materials testing, component testing, and force monitoring. They can be integrated into existing systems easily and can provide accurate and reliable measurements with minimal maintenance.
One advantage of button type load cells is their small size and low profile, which makes them ideal for applications where space is limited. They are also relatively inexpensive compared to other types of load cells and can provide accurate and reliable measurements even in harsh environments. However, they may not be suitable for applications where high accuracy or precision is required, as their small size can make them more susceptible to non-axial loading and bending moments.
|Output Sensitivity(FS)||2.0 +/- 0.1 mV/V|
|Creep Error (30 minutes)||+/-0.01% FS|
|Temperature Effect on Zero||+/-0.017% FS/DegC|
|Temperature Effect on Output||+/-0.0015% FS/DegC|
|Zero balance||+/- 1% FS|
|Maximum Safe Overload||120% FS|
|Recommended Excitation Voltage||9 to 12V DC|
|Input Resistance||750 +/- 10 Ohm|
|Output Resistance||750 +/- 2 Ohm|
|Insulation resistance at 50V DC||>= 1000 M Ohm|
|Compensated Temperature Range||-10 to +40 Deg C|
|Operating Temperatue Range||-35 to +65 Deg C|
|Cable Length||5 m|
- 50Kg to 1000 Kg Capacities.
- Complete environmental protection IP65 class.
- Hardened stainless steel construction.
- Miniature and low profile.
- Easy for installation.
- Custom built design available on request
- Tensile testing
- Force and impact test
- Test Bench
- Industrial Force Measurement
- Delivery Time: 7 Days
A shackle type load cell is a type of load cell that is designed to measure tension or pulling forces in a variety of applications. It is often used in industries such as construction, mining, and oil and gas, where heavy loads need to be lifted, moved or suspended.
Shackle type load cells are typically made of high-strength materials such as alloy steel or stainless steel and consist of a shackle, a load sensor, and electrical wiring. The load sensor is usually located between the shackle pin and the bow of the shackle, where it can detect changes in tension caused by a load. The electrical wiring is used to transmit the electrical signal produced by the load sensor to a readout device, such as a computer or a digital display.
Shackle type load cells are available in a wide range of sizes and capacities, from small load cells used in laboratory equipment to large load cells used in heavy-duty industrial applications. They can be used to measure tension or pulling forces in a variety of applications, such as in crane and hoist systems, load testing, and marine applications.
One advantage of shackle type load cells is their ability to provide accurate and reliable measurements even in harsh environments. They are designed to withstand high loads, shock, and vibration, and they can provide real-time data on the load being measured, which can be used to improve safety and efficiency in lifting and moving operations.
Overall, shackle-type load cells are an essential component in many modern lifting and suspension systems, and they are used in a wide range of industries to provide accurate and reliable tension measurements.