Load Cell Mounting and Installation Best Practices

tacunasystems.com/knowledge-base/load-cell-mounting-and-installation-best-practices

< All Topics

While selecting the appropriate load cell model for an application is important, its
measurement output could be meaningless if the load cell is not properly mounted and
installed. Proper installation is critical to obtaining high-quality, accurate readings. It also
guarantees ease of use and safe operations.

This article will give helpful load cell installation tips but does not replace an installation
guide. For best results, always follow the manufacturer’s installation instructions and
ensure that installers are properly trained. We encourage you to contact Tacuna Systems to
discuss any design or implementation issues specific to your project.

1) Choose The Right Frame and Fixture

Every load cell has a design for a specific environment, set of conditions, and mechanical
orientation. Setting up the proper fixture (or load cell mount) and frame is critical to
maximize load cell performance and maintain safe operating conditions. The article A
Comparison of Tacuna Systems Load Cell Mounts summarizes the features of each such
mount sold by Tacuna Systems, to help simplify the selection process.

An optimal frame design should maximize stiffness but minimize weight and costs. The
frame must be sturdy enough to support the maximum weight borne by the measuring
device (including overload), and rigid enough to withstand deformation and flexing. The
supporting features to the structure should be rigid.

1/10
The fixture design should minimize unintended inputs from the surrounding environment.
Vibrations, thermal expansion, mechanical deformation, and stray electrical current can
cause false readings and damage to or failure of the load cell.

Mitigating Vibration
A variety of sources can introduce vibrations that affect the fixture, including compressors,
pumps, actuators, and engines. Additionally, ground vibrations from seismic activity can
skew measurement results. Securing the frame to a hard, flat surface will reduce vibrations
from passing vehicles and local equipment.

Accounting for Thermal Expansion/Mechanical Deformation

Design the mounting frame to allow for unhindered thermal expansion or contraction.
Load cell mounts that do not allow for mechanical expansion can cause permanent damage
to the load cell or frame. To maintain a safe operating environment, always design for the
appropriate amount of expansion clearance. Also build a frame that avoids the intrusion of
ice, moisture and other weather-related factors that can cause corrosion or mechanical
deformation.

Avoiding Rotation
For suspended loads, the mounting frame should limit the amount of rotation to prevent
hardware from loosening over time.

Accounting for Other Forces

Particularly in outdoor environments, the support frame should account for other forces
that can add loads to the system, such as wind.

2/10
Avoiding Electrical Interference
The fixture and frame should not cause unintentional ground paths. Avoid welding of the
frame, fixture or mounts in the presence of installed load cells. Stray currents from welding
can damage these sensitive components.

2) Align Loads in the Proper Direction

3/10
Ideally, in a measuring system all of the load or force will be transmitted through the load
cell. If the measured force is not fully applied through the intended axial direction of the
load cell, the measurement system cannot capture the correct reading. This axis is often
clearly marked or labeled on the device and is ideally perpendicular to the loading surface.

This can happen in two ways: when the frame and mounts improperly guide the load, and
when any attached structures (such as supports, safety cables, pipes and hoses) create
“force shunts.”

Correctly Distributing and Guiding the Load

The most common reason for inaccurate load cell measurements is improper axial loading.
Since loads can be compressive, tensile, or torsional, properly guiding the load direction
depends on the application. Section 4 describes mounting best practices to mitigate
improper loading.

Compressive Load Applications

Place load cells at all corners of the supporting structure to maintain the full weight or load.
While some manufacturers recommend placing “dummy” cells on supports and deriving
the total load, dummy cells can prevent proper calibration. When using load cells under
structural supports, always arrange them symmetrically around the plane perpendicular to
the force flow, and level to this plane.

When installing shear beams, single-point, platform, canister, and disk load cells, keep the
lower mount plate level and flat. The top plate that will translate the load should always
maintain a parallel position to the bottom plate. Also, the load path should be
perpendicular to the plates. This will keep a predominately axial loading.

A failure to maintain axial loading could result in bending moments. As described in

Section 4, install rod-end bearings and clevis mounts to prevent this.

Likewise, when using double-end shear beams, align the load vertically through the center,
avoiding twisting or torsion. The load should not shift relative to the cell body. Double-
ended shear beams have higher load capacity ratings than single-end. When supporting
these greater loads with size constraints, implement double-end beams. Canister or disk
load cells also handle higher capacities, but can be larger and bulkier.

Tension and Suspension Applications

For tension applications such as pulleys, hoists or cranes, and fork lifts, fewer suspended
supports will deliver more accurate results. Install suspension systems with adjustable
linkages to maintain the ability to evenly distribute loads among load cells.

4/10
S-beam load cells can be used in both tension and compression. They are susceptible to
large bending moments; to prevent this, install with rod-end bearings. Also, since the
internal strain gauge usually sits on a specific end of S-beam load cells; take particular
notice of its correct orientation relative to the mounts and load.

Avoiding Force Shunts

A force shunt is any device or path through which a portion of the force flow or load is
diverted. While the term “shunt” typically describes electrical current, the concept remains
true for the “flow” of force. The force being considered is mechanical, and can be created
by a physical load, weight, or pressure. Avoiding force shunts is critical for weighed objects
such as tanks, platforms, or scales. Failure to set up the fixture in this way will interfere
with accurate measurements. For a more in-depth explanation of force shunts, see
Measuring Forces in the Force Shunt .

If attachments to the measured fixture are present due to process connections, (i.e., piping,
hosing, ducts per Figure 1) they should remain flexible to reduce force shunting. Small
diameter piping, or long segments without significant supporting structures, can also cause
significant force shunting. If possible, use larger diameter connections at all times. Connect
piping with hoses or accordion tubing for best results.

Figure 1. Weighed Vessel with Force Shunt

Ladders, pipes, rods, and catwalks can all improperly load, or shunt, a portion of the
measured structure. Remove these when measuring or compensate for the errors they
introduce to the output measurement.

Despite these advisories safety is a high priority; therefore use safety features even if they
create force shunts. Choose flexible over rigid structures, such as cables or chains, to help
reduce force shunts while assuring high levels of safety for operators. If load cell
5/10
component failure would cause injury (such as load pins in suspension applications), have
the proper structural backup in place. Secure the fixture with cables or stops to prevent
harm to operators and equipment.

3) Consider Environmental Factors Affecting Load Cells

Every load cell will perform differently depending on the environment. Before installing
the measuring system, planners should do a thorough analysis of the environmental
factors influencing the load cell and fixture (the latter being discussed in Section 1). Keep
the load cell application in a controlled environment and when possible use devices
indoors to reduce environmental effects. When the load cell application must be outdoors,
the measuring system’s design (including calibration) will need to mitigate the effects of
debris buildup, temperature, wind, precipitation, ice, sunlight, humidity, electrical systems
and ground conditions to derive accurate readings.

Temperature
If ambient temperatures fluctuate, use load cells that are temperature compensated. This
information appears on the load cell model datasheet. Uncompensated devices will behave
poorly at extreme temperatures. Therefore, shielding them from radiant heat and cooling
systems is important. Installing a shield or insulation around the device can provide
protection from extreme temperatures.

Moisture
If the operating environment includes moisture or precipitation, discuss with the
manufacturer how well the load cell performs and compensates for moisture. Moisture can
lead to shorting in the electrical current causing errors in measurements, and can often
damage the load cell.

Take precautions to avoid corrosion of both the load cell device and the mount, and inspect
them frequently. Use non-corrosive metals such as stainless steel when the device may
experience moisture exposure. Also, keep the load cell and surrounding surfaces dry. Check
for cracks caused by corrosion pitting that could lead to damage of the load cell and
equipment failure.

Electrical and Magnetic

Stray electrical currents could interfere with load cell readings and are another possible
source of damage to the device. Properly cover and secure all wiring and lighting. Ground
the load cell fixture to the specifications outlined by the manufacturer. Avoid welding near
load cells as stray currents from welding can significantly damage components.

6/10
Magnetic and electrical fields can create interference with weighing system signaling. To
avoid this, place the load cell, connection cabling, and electronics in a shielded housing.

4) Properly Prepare the Mounting Frame

The load cell mount’s surface and structure is critical for accurate measuring. When
installing mounts, surfaces should always be clean, even, and level. Mount the load cell to
heavy plates attached to the fixture. These plates should be rigid and non-deformable. This
transfers the total load through the bottom mount to the supporting structure.

Drill and tap holes in the mounting plates based on the dimensions in the load cell’s
installation drawing or data sheet. Maintain tight tolerances when drilling. Loose
tolerances could cause improper installation of, or unwanted stress in, the device and
hardware.

Single point load cells are rated for a specific loading area; therefore design top plates and
scales with these limits in mind. Likewise install load stops where the possibility exists for a
load to exceed a load cell’s rated capacity (for example, due to accidental shock loading or
extreme winds).

a) When Mounting Accessories Are Helpful

As stated before, the load cell should always be the intermediate point between a fixed
surface and the introduced load path. The load direction should always comply with the
load cell manufacturer’s installation manual. Mounting accessories mitigate misalignment,
side loads or bending moments. Rod ends or clevises (Figure 2) can also help reduce
bending moments.

7/10
Limit lateral deflection, if needed, with end
stops. If the load cell design requires self-
centering, a self-checking load cell mount
automatically returns the support structure to
the correct position. The installation of
elastomeric bearings regulates heat between
the tank and load cells in a tank weighing
system.

Figure 2. S-Beam Load Cell Mounted to Rod

End and Clevis Assembly

b) When the Mounting Frame is Not the Only Consideration

There are situations where the mounting frame or mounting accessories cannot fully
compensate for conditions that can alter measurements. In these cases the choice of load
cell is critical.
8/10
If side loading or torsion is unavoidable, use load cells designed to capture these inputs.

Also, the dimensions of the load cell will affect clearances of the fixture when it is loaded to
capacity. Select a size and capacity of the load cell appropriate for the application without
significant oversizing.

5) Choose the Right Hardware

Properly securing the load cell to the support plates will limit unintended movement in the
device. This keeps the load cell aligned with the load path, maximizing accuracy and
preventing damage to the component.

Always use the provided device hardware or other standard hardware approved by the
manufacturer. Install all hardware to the specifications outlined in the installation manual.
Engage the full threaded section of bolts connecting the support plates. Next, apply the
proper preload before allowing the system to support the full weight of the measured
entity. If bolts are not preloaded or preload is not maintained, the hardware could
experience joint-separation or a fatigue failure. This can also lead to the bolts self-
loosening, ultimately causing a failure in the bolted joints.

The attachment plate used to mount the load cell should be thick enough to have a
significant thread engagement with attaching hardware. If the plate is thin it will prevent
the component from being properly secured.

Apply torque to the hardware per specifications. Use jam nuts and other locking hardware
to prevent connections from loosening or separating. Lastly, do not allow suspended
systems to rotate, as this might also loosen hardware.

Standard hardware should not be the weak point in the load path. Yielding, shearing, or
fatigue failures could cause damage to the load cell device. If standard hardware is
potentially inadequate for the load cell application, upgrade hardware before beginning
installation.

Conclusion
As this article demonstrates, the accuracy of a measuring system depends greatly on its
proper installation. Each system is unique and often has specific considerations to ensure
best results. Tacuna Systems engineers are always available to answer your installation or
application questions regarding our load cell products.

References
Measurement and Instrumentation Principles, 3rd Edition, Alan S. Morris

9/10
Introduction to Instrumentation and Measurements, 3rd Edition, Robert B. Northrop
Elements of Electronic Instrumentation and Measurements, Joseph J. Carr

10/10