Tension load cells are often overlooked but are actually very important in many industries for safety and efficiency in lifting, towing, and load testing. They measure the forces applied to an object by detecting tension, which is necessary for structural integrity and overload prevention.
At the heart of a tension load cell is a sensing beam that bends or deflects when a force is applied. Strain gauges attached to the beam measure this deflection. As the beam bends, the strain gauges detect tiny changes in electrical resistance, which are then converted into an electrical signal. This signal is directly proportional to the force applied, so you get precise measurements.
Whether in manufacturing, construction or transportation, knowing how tension load cells work allows you to measure loads better, improve safety and operate more efficiently.
Now, let’s get into the mechanics and applications.
What is a Tension Load Cell?
A tension load cell is a type of load cell that measures strain or force. Used in industries like manufacturing and converting, they measure the tension or pulling force on web, wire, cable, composite filament or laminate materials.
Made from metals like steel or aluminum, tension load cells have a body or “load sensor” attached to a roller or pulley system.
How Does a Tension Load Cell Work?
In a tension load cell, the strain gauges are placed along the same direction as the force being measured. When a pulling force (tension) is applied, the wires in the strain gauge stretch and become thinner. As this happens, the electrical resistance in the wires increases. The change in resistance is directly related to the amount of force, which allows the load cell to calculate how much force is being applied.
Understanding how tension load cells work involves examining the load cell’s internal electronics, which process the change in resistance. These electronics are built to handle tough environments, making sure the device works reliably in places like construction sites or factories. The signal from the strain gauge is converted into a readable format, either as a number on display or as data that can be analyzed.
In simple terms, a tension load cell turns pulling force into an electrical signal that can be measured, providing important information to keep operations safe and efficient.
Tension Load Cell Types
Tension load cells come in many shapes:
- Tension Link Load Cells: Lifting and weighing applications, 2.2K lbs to 1.1M lbs (5 to 500 metric tons).
- S-Type Load Cells: Overhead crane applications, no headroom.
- Clamp Sensors (e.g., DLWS): Load at the dead-end of crane wire ropes, in tight spaces.
- Load Shackles: Weight sensor applications where there is no dead end for efficient performance in restricted headroom.
- Load Links: Tension link load cells for lifting and weighing applications, rugged design, various capacities, customisable for harsh environments.
- Load Pins: Lifting and weighing across various capacities, custom designs, and rugged construction. They are compatible with load shackles for accurate force measurement.
- Wireless Tension Links, Load pins and Load Shackles: Compact design, easy installation, reduced overall weight. Can transmit data over long distances while keeping internal electronics sealed for harsh environments.
How Are Tension Load Cells Used in Industrial Settings?
Tension load cells are used in many industries for many applications. These scales measure strain and tension in many industries, including construction and manufacturing. Here are some of the most common:
- Lifting and Hoisting: Tension load cells are used in cranes and hoists to measure the weight of the load being lifted for safe operation. Crane scales are often used in these applications as a traditional and simple way to measure weight. Multiple applications in hoisting intensive industries such as mining.
- Vehicle Recovery: In towing, the tension on the cables must be measured for safe vehicle recovery.
- Web Tension Control: In manufacturing processes such as printing and packaging, tension on the webs of material is maintained, slippage is prevented, and quality is ensured.
- Cable and Wire Testing: Test the strength and tension of cables and wires in many applications, including construction and telecommunications.
- Mooring and Towing: In marine operations, tension on mooring lines and towing cables is measured for safe operation in marine environments.
- Material Testing: In laboratories, tensile testing of materials is done to determine their strength and elasticity.
- Agricultural Applications: To measure tension on ropes and cables in equipment such as balers and harvesters.
These applications show how important tension load cells are for safety, efficiency, and accuracy in industry.
Reasons to Consider Tension Load Cells for Your Operations
Here are 5 reasons to consider a tension load cell for your industrial operations:
1. Accurate Measurement
Tension load cells measure tensile forces accurately, so your operations are based on real data. This accuracy will improve quality control and reduce errors.
2. Safety
By measuring loads accurately, tension prevent overloading of equipment which can cause accidents and expensive damage. This is critical in lifting and towing.
3. Flexibility
Tension load cells can be used in many applications, from lifting and hoisting to towing and material testing. They are nice to have in many industries.
4. Durability and Reliability
Many tension load cells are designed to withstand harsh industrial environments, so they will last longer. Buying robust equipment reduces maintenance costs and extends life.
5. Cost Effective
Although there may be an upfront cost, the long-term savings from safety, efficiency, and reduced errors will pay for it, so tension load cells are a good investment.
Having a tension load cell in your business will improve safety, efficiency and accuracy and ultimately your bottom line.
Get in Touch with Our Load Cell Specialists
As industries evolve, the demand for accuracy and reliability in measurement has never been greater. Tension load cells offer a perfect blend of technology and practicality for measuring forces and loads in your operations.
By integrating tension load cells into your processes, you’re not just investing in technology; you’re investing in safety, efficiency, and the future of your operations. Be precise with tension load cells and level up your performance.
To request a quote or to learn more about our load cells, contact Massload today!
