PAYLOAD SENSING IN HEAVY EQUIPMENT WITH LOAD CELLS

Where: Load cells are typically integrated into the suspension systems of mining haul trucks.

How: These load cells continuously measure the load weight by detecting force exerted on truck suspensions as material is loaded. As the payload increases, the force on the suspension changes proportionally, causing deformation in load cells embedded with strain gauges. This deformation generates electrical signals interpreted as accurate weight readings, preventing overloading and optimizing haul cycles by enabling smarter payload management.

Where: Load pins are integrated into excavators and loaders help operators achieve precise load management.

How: Strain gauge load pins connecting hydraulic cylinders to the chassis or bucket linkage are a common and effective approach. These load pins measure the force exerted during material lifting operations. As the bucket scoops or lifts, the applied force causes deformation in the load pins. The resulting electrical resistance change in the strain gauges translates into precise payload measurements, guiding operators to maintain optimal loading capacities and prevent mechanical strain due to excessive payloads.

Where: Load cells are typically mounted within the crane hook assembly, at the load block, or along the tension cables.

How: As cranes lift and move payloads, load cells measure the tensile forces on lifting cables or hooks. The strain gauges within the load cell convert mechanical strain into measurable electrical signals, giving crane operators immediate, real-time data about load weight. This information ensures lifts remain within safe working limits, triggering automatic safety shutdowns if predetermined thresholds are exceeded.

Where: Load cells are often integrated into the axles or chassis of harvesters, grain carts, or spreader bins.

How: As harvested material accumulates, load cells sense increased forces exerted on the equipment’s frame or axles. Strain gauges within the load cell measure the subtle deformation under load and produce electrical outputs proportional to the weight. This real-time feedback allows operators and automated systems to precisely track harvest yield, manage distribution, and prevent machinery overload.

Where: Load pins are embedded beneath the container platform or integrated into the hydraulic lift mechanism of refuse collection vehicles.

How: Load pins precisely measure payload weight as refuse bins are lifted and emptied into collection vehicles. During the lifting process, mechanical stress creates measurable strain on these load pins. The integrated strain gauges convert this mechanical strain into electrical signals, accurately capturing payload weights. This ensures compliance with legal road limits, optimizes collection routes by providing operators real-time payload data, and reduces unnecessary vehicle wear and fuel consumption.

Where: Load cells are typically mounted beneath the basket of aerial work platforms used in firetrucks, utility trucks, and construction equipment.

How: Load cells measure payload weight as workers, tools, and equipment are loaded into the basket. Strain gauges within the load cells detect mechanical strain caused by the weight, converting it into electrical signals for accurate real-time monitoring. This data ensures basket loads remain within safe operational limits, enhancing worker safety, preventing structural overload, and optimizing the operational efficiency of aerial equipment.