Ocs crane load cell

Types of OCS crane load cell

OCS crane load cells are broadly categorized according to the types of cranes they are designed for. These load cells offer precise weight measurement for the safety and efficiency of heavy lifting operations.

Beam or Girder Type Load Cells

Often found in overhead bridge cranes, beam or girder-type load cells are mounted on the crane's lifting components, such as the hook or the girder. This helps to measure the weight of the load being lifted. Their structural incorporation enhances safety by continually providing real-time data on weight capacity. This early reporting allows users to take proactive measures when needed.

Hook Type Load Cells

A hook-type load cell is easy to use because it resembles a traditional hook. It converts the force exerted by the load into electrical signals. This type of load cell can be added to existing cranes without significant modifications. For this reason, they are often used in rental fleets. Despite their [hook-type load cell] lightweight design, they are highly accurate and durable.

Compression Load Cells

Unlike tension load cells, compression load cells are used in cranes such as scissor lifts and stacker cranes, where the load-carrying part is compressed rather than elongated. These load cells provide reliable data on weight and help improve stability and control during lifting operations. Companies in logistics and warehousing industries frequently use compression load cells.

Wireless Load Cells

Wireless load cells have emerged in industries where frequent mobility and quick data access are important. Motion control cranes, for instance, use wireless load cells to send load data to dashboards and mobile devices. These load cells are especially valued for their quick load feedback and easy mobility, giving them an edge for operations in various locations.

How to Choose OCS Crane Load Cell

Selecting the right OCS crane load cell is important for precise measurements and operational safety. Here are some points to consider when selecting an OCS crane load cell.

Weight and Load Capacity

Measuring the weight and load capacity against the maximum load that will be lifted is a key factor in choosing a crane load cell. Overloading a load cell can cause failure and inaccurate readings. However, undercapacity may lead to safety issues during heavy lifts. It is also prudent to select a load cell with a higher capacity than the: maximum load to provide a safety margin.

Customization Options

Customization can range from dimensional alterations to integration with specific control systems. It is common when there are unique operating conditions. For instance, extreme temperatures or exposure to corrosive substances. Optional load cells can address such situations to meet operational demands and ensure longevity.

Precision and Accuracy

Consider the load cell's sensitivity and error margin. High precision and accuracy reduce the risk of overloading or underloading. This, in turn, guarantees operational safety and efficiency. Selecting a load cell with a low tolerance for error is critical in tasks where weight distribution must be controlled.

Material and Durability

Durability will be determined by the material of the load cell, especially where lifting is involved. Common materials are aluminum and hardened steel. The former is corrosion-resistant and lighter but cannot support as much weight as the latter. Steel has better rigidity and weight support.

Specifications and industrial uses of OCS crane load cells

OCS load cells have certain specifications that make them suitable for a variety of applications. One such application is the lifting or moving of very large and heavy objects, primarily in construction and shipping.

Key Specifications

• Rated capacity: The rated capacity is the maximum load or weight the crane can lift and move safely. OCS crane load cells have a large rated capacity to suit large loads that are often found in industrial environments.
• Output signal: A load cell is normally connected to a power supply through a Wheatstone bridge arrangement, a voltage or electrical signal output is obtained whenever a load is applied. This signal is proportional to the load weight, so the heavy the load, the higher the output signal. Load cells, therefore, have a tiny output signal that has to be amplified using signal conditioners before processing to eliminate noise.
• Linearity: Load cells are ideally characterized by a single straight output as the load is increased, making them easy to model mathematically. However, in reality, load cells often exhibit nonlinear behaviors because they are normally subjected to different extreme loads. For this reason, load cells need to be characterized for their linearity over a wide load range.
• Temperature sensitivity: The performance or behavior of load cells is affected by temperature, thus resulting in changes in their output signal. This temperature effect has to be minimized by using materials with different thermal expansion coefficients or built-in compensating resistors.
• Mechanical stiffness: Load cells experience lateral loads, attachment misalignment, and mechanical resonance in a working environment. These factors affect the cell behavior by inducing unwanted deflection or movement. The mechanical stiffness of the loading cell has to be maximized, especially in dynamic environments.

Industrial Applications

OCS crane load cells find applications in multiple industries, including construction, manufacturing, shipping, and event management, experiencing heavy lifting and requiring precise weight measurements. The construction industry relies heavily on OCS load cells in overhead cranes, and this is primarily to lift structural steel beams, concrete blocks, and high-weight construction materials. The shipping industry has also been known to implement OCS load cells in both container cranes and mobile harbor cranes to lift shipping containers and bulky goods. Manufacturing plants also employ load cells to lift machines or large parts during assembly or transport. Finally, OCS load cells are used to lift lighting, staging, and sound equipment in event management theatres or convention centers.

How to DIY and maintenance of OCS crane load cells

Load cells can be maintained and sometimes even repaired without professional help. The same thing goes for the replacement of even a single part. However, this depends on the damage types and the availability of replacement parts.

DIY Steps for Maintenance and Repair

• Calibration: Calibration is a relatively easy process. First, one must ensure that an appropriately sized load is available. Next, attach the load to the crane and record the output. Compare the output with the expected value to identify the error. Apply the adjustable parameter for the load cell as per the manufacturer's guidelines, repeating the calibration process until the output matches the expected value. Calibration helps get accurate readings and is often done manually after a certain period.
• Signal Conditioning: Conditioning the output signal will also require very rudimentary equipment. Start by building a Wheatstone bridge circuit configuration using operational amplifiers to sense the tiny signal output from the load cell. Then, an amplifier will be used to increase the signal output. Finally, filters will be employed to eliminate unwanted noise from the output signal, if any, to process a clean and stable signal.
• Greasing: The first maintenance procedure that can be implemented in a DIY manner is greasing. Regular cleaning and occasional greasing of the cells will minimize the wear and tear of internal components like gears and chains. It will also minimize the chances of signal wire disruption. The tired vehicle parts will occasionally need to be cleaned and re-greased to make them functional again.
• Inspecting: The physical inspection of load cells and other hardware components to check for wear and tear, loose connectors, worn-out wires, or damaged parts will also be necessary. Here, a multimeter is used to check for continuity or breaks in the wiring. Moreover, during inspections, one should ensure that the load cell is not exposed to external elements such as water, dust, or extreme temperatures. Use a weatherproof cover where necessary to protect the load cell from external elements.

Maintenance Tips

• Keep the area clean: Maintaining cleanliness will prevent dust or debris accumulation on the load cell, leading to inaccuracy.
• Temperature control: The temperature effect can also be minimized by keeping the cell in a temperature-stable environment to minimize thermal expansion and condensation exposure.
• Regularly inspect: A regular inspection of the load cells and cables will prevent small issues from becoming large ones.
• Shielding wires: Exposed cell wires should be shielded to prevent them from electromechanical interference, which would disrupt their functionality.
• Weatherproofing: Covering a load cell will prevent exposure to dust, moisture, or extreme temperatures and enhance durability.

Q&A

Q1: What is a wireless load cell?

A1: Wireless load cells measure and transmit load data without cables, providing flexibility and quick access to weight data.

Q2: What industries frequently use load cells?

A2: Load cells are commonly used in construction, shipping, manufacturing, and event management to lift heavy objects.

Q3: How do compression load cells work?

A3: Compression load cells measure weights by sensing the force of a load pressing down on them, commonly used in lifted equipment.

Q4: What is the function of a crane load cell?

A4: An OCS crane load cell measures the weight of a load being lifted by a crane and sends this data for display or control.

Q5: Why is calibration important for maintaining load cells?

A5: Calibration ensures load cells provide accurate measurements by aligning them with known weight standards.