Overload limiter with load cell

Types of Overload Limiters With Load Cells

Overload limiters with load cells have great significance in preventing the overloading of hoisting equipment. They operate by applying a pre-set load to generate an output signal indicating the state of the load. The operator can use this signal to take appropriate decisions. This ensures that the optimum load-carrying capacity is never threatened.

The types of overload limiters, differentiated by function, construction, operating principle, integration level, and application, are as follows:

• Mechanical Overload Limiters

  Mechanical overload limiters employ gears, levers, and springs to fabricate a shut-off mechanism in case of overload. The main working principle is the helical spring tension, the main load and force-exerting components. The Load cell calibrates the overload by deforming under the applied weight. A mechanical overload limiter is used in simple applications or where electrical devices may be positively affected by environmental factors such as dust or moisture.

• Hydraulic Overload Limiters

  Hydraulic overload limiters use fluid. These limiters particularly suit the heavy-duty field and construction work where high loads are encountered. The working principle of hydraulic overload limiters is the pressure of a hydraulic fluid inside a chamber. The Load cell applied load is also converted into hydraulic pressure. In case of overloading, a safety valve is opened or a pressure release mechanism is actuated. These limiters have high accuracy and are very reliable under severe working conditions. They also find applications in large cranes and hoists tipper trucks.

• Electromechanical Overload Limiters

  Electromechanical overload limiters integrate electrical components and mechanical principles. This makes their working principle unique and different. It operates by electric signal processing of mechanical load cell deformation. These limiters have digital displays and are capable of transmitting remote signals. This is done by converting the load cell output into an electric signal. They find their way into sophisticated industries where instant data measurement, remote monitoring, and high accuracy are desired.

• Digital Overload Limiters

  Digital overload limiters have Load cells and microcontrollers to measure the load and analyze the data. The Working principle constitutes an A/D converter that converts analog voltage output from the Load cell into digital signals. In addition, these limiters have data storage capabilities and are very accurate. They can display real-time load information and trend histories on load. These limiters are well placed in industries such as manufacturing, shipping, and construction with demand for greater accuracy, data logging, and detailed monitoring. The limiters are light in weight and compact, making them convenient to work with.

Materials Used To Make Overload Limiters With Load Cells

Overload limiters with load cells use components made from different materials. The manufacturing materials are critical to ensure these limiters maintain strength and durability and give accurate readings.

• Stainless Steel

  Stainless steel is used extensively in the manufacture of the main frames and body parts of the overload limiters. This steel offers immense tensile strength, preventing deformation or breaking under heavy loads. It also resists corrosion, making it ideal for outdoor and moisture-laden conditions such as construction sites and marine environments. In terms of accuracy, stainless steel is non-magnetic and prevents unwanted interference that would otherwise affect the Load cell.

• Aluminium Alloys

  Aluminium alloys are another commonly used material for constructing overload limiters. aluminium is lighter but still stringer compared to other metals. It does not corrode at all like steel. Instead, it forms a protective structure of oxidized aluminium over the surface that is more resistant to environmental elements. The use of aluminium alloys where the limiters have to be mobile reduces weight without compromising on the strength. Apart from these, aluminium alloys are very machinable and thus have smooth finishes that enhance accuracy in Load cell readings.

• Brass

  Brass usually makes the electrical components of overload limiters. It is an alloy of copper and zinc, one of which is the cheapest electrical conductive material. Apart from the conductivity, copper makes brass very resistant to corrosion, while zinc provides the required rigidity. It is specifically applied in connectors, terminals, and sensors where optimum conductivity and resistance to oxidation are required.

• Rubber and Polymeric Composites

  Rubber and polymer composites are used as insulation. They are also used to make seals and gaskets for the limiters. Though metals give out electrical signals, these materials have low or no electrical conduction; thus, the chances of electric interference are eliminated. Seals made of rubber prevent dust, water, or any liquid from entering internal spaces, providing adequate protection for devices stationed in severe working conditions. In addition, these materials are flexible and help reduce any impact or vibration that would affect the readings of the Load cell.

Commercial Uses of Overload Limiters With Load Cells

Overload limiters with Load cells are important in the health and transport sector.

• Cranes

  Cranes are notorious for being operated with overload limiters for their safety and stability. These limiters prevent the crane from lifting heavier weights than it can carry, which would cause an accident or damage property. They give feedback to the operator by stopping further lifting or lowering of the load when a specific weight limit is reached. This helps prevent the slings from breaking, load falling off, or structural collapse. Limiters have been used in construction, where safety is of the utmost importance and operations involve heavy lifting.

• Hoisting Systems

  In the hoisting system found in mining and industrial applications, overload limiters play a central role in ensuring operational safety. They prevent the hoist mechanism from being overloaded, which may cause wear and damage or endanger the employees. These limiters send back load information that is often employed in real-time monitoring to control the hoist operations. This is critical in underground mining or heavy industries where the hoisted materials are most often very massive.

• Mobile and Industrial Power Sources

  Overload limiters are significant in mobile and stationary power sources such as generators and motors. They prevent electrical or mechanical overloads, which may cause system failure or reduce efficiency. These limiters also protect machinery by cutting off power or reducing load levels when maximum capacity is reached. This is essential for managing operations in various industries such as manufacturing, construction, and service delivery, where the unavailability of power sources translates to a loss of time and reduction in effectiveness.

• Tippper Trucks

  Tipper trucks widely use overload limiters to keep them safe when transporting bulk materials such as sand or gravel. These limiters stop the truck from lifting an unsafe load as it would cause the vehicle instability, over strain, and accidents. Trucks with Load cells apply the load to measure the weight inside the cargo area and give real-time data that ensures even distribution of load and compliance with road safety rules. They are important in civil engineering and construction since they affect efficiency and safety in the transportation of materials.

• Shipping and Handling

  Shipping and handling process uses overload limiters during the handling and transport stages to maintain safety in the operations. In this case, limiters protect the equipment such as forklifts, conveyor belts, and ships from being overloaded, which would cause equipment breakdown or accidents. They provide Load cell readings that are used to assess and track the weight of packages and ensure that time limit capacities are not exceeded. It is important in logistic services and freight management, where efficiency, safety, and cost control are vital in ensuring business success.

How To Choose Overload Limiters With Load Cells

Different overload limiters with Load cells are designed for various working purposes and operating conditions. The type of industry in which they are employed, the expected loading, and the environmental elements that are to be encountered dictate the sort of limiter that is to be used.

• Load Capacity and Range

  The primary consideration in determining the correct overload limiter is the load-carrying capacity that is to be monitored. The chosen limiter should be able to accommodate the entire range of loads in order to achieve accuracy and efficiency. One risk is that inaccuracy occurs if the overload limiter gets overloaded or is underloaded. On the other hand, underloading leads to sensitivity loss, which translates to overload meant to be detected going undetected. Excess load causes mechanical damage, while insufficient load causes operational risks. Determine the minimum and maximum load range of applications and select limiters that cover these limits.

• Industry Specific Application

  Overload limiters have been specially designed and manufactured for individual applications and industries. For instance, cranes and hoists require limiters that are extremely robust and waterproof due to the harsh working environment. Construction and mining limiters should resist dust and moisture and possess a high degree of mechanical strength. In manufacturing, shipping, and logistics, digital limiters with data-logging capabilities ensure a high degree of accuracy. Understand the specific application of the limiters and the conditions they might undergo and select the one best suited for the environment.

• Sensitivity and Accuracy

  Accuracy depends on how sensitive limiters are to load changes. High accuracy and sensitivity in limiters have become imperative in industries where small load variations can bring large operational consequences. In such cases, limiters with fine resolution and quick response are preferred. Construction and heavy industries may afford themselves lower accuracy limiters since the load volumes are massive; in delicate operations like laboratory experiments or precision engineering, a highly accurate and sensitive limiter would be required. Weighing the accuracy versus the load-carrying capacity is a key determining factor in selecting an appropriate overload limiter.

• Durability and Material Construction

  The degree of robustness required is the other key consideration in selecting overload limiters. Mechanical and hydraulic limiters are designed to be more robust than their digital and electromechanical counterparts. This is useful in industries with massive loads and open-air operations such as construction and mining. In indoor and controlled conditions industries, less strong materials could suffice. These include the materials of which the limiter is constructed and the environmental factors the vehicle is likely to encounter, which is liable to dictate how durable the limiter is.

• Ease of installation

  Easy installation involves simplicity in operation and maintenance. Some limiters require special tools for installation, while others can be easily fitted with basic tools. Look for limiters with simple interfaces and operating controls. Choosing the right limiters is important for their maintenance because some come with parts that can be maintained or replaced, while others require the entire system to be replaced once a particular part develops a fault. Check how the previous limiters in the system have been replaced and the time and cost involved in doing that. This drastically reduces operating downtimes.

Q & A

Q1: Will an overload limiter go off when a load is excessive?

A1: Overload limiters prevent mechanical overloads in equipment by using pre-set load values to control operation. They are integrated into systems such as cranes, hoists, and conveyers to stop further movement or lifting when maximum load capacity is reached. Mechanical limiters employ mechanical shut-off mechanisms, while hydraulic limiters release pressure through valves. Electronic limiters use sensors to detect loads and send signals to stop operation. Often, limiters have built-in safety margins that increase the degree of protection.

Q2: What load limiters do truck drivers use?

A2: Load limiters are used by truck drivers to ensure that cargo is not overloaded. These limiters control the amount of weight carried by individual axles to keep trucks stable while driving and reduce wear and tear on the truck. It is done by distributing the weight evenly across all the axles, ensuring no single axle is excessively burdened. This maintains ease of control while traveling and loads are transported without exceeding legal weight standards. Tipper trucks employ overload limiters and Load cells during the transportation of bulk materials for safety and stability.

Q3: Are overload limiters necessary for beaters?

A3: Yes, overload limiters are important for beaters and other machines operating in heavy load conditions. Just like other machines, beaters face the challenge of motor burning out, machinery breaking down, or even safety risks when overloaded. By preventing these overloads, limiters enhance the lifespan of machines and minimize repair costs. Also, they help maintain work efficiency by limiting machine downtime.The advantages of overload limiters are efficiency, safety, increased durability of machines, and cost reduction.

Q4: Are overload limiters waterproof?

A4: Overload limiters, especially those used in outdoor and harsh conditions, are often designed to be waterproof. These limiters use seals, gaskets, and corrosion-resistant materials to prevent moisture, dust, and other debris from entering the internal electronic components. Limiters applied in marine, construction, and outdoor mining are usually housed in waterproof casings or have special coatings to fend off humidity, salt, and other environmental elements that may cause corrosion or damage to the device. Indoor limiters, which are not exposed to hostile environments, may not be waterproof but could have protective enclosures.

Q5: What are overload limiters used for?

A5: Overload limiters protect machines and equipment from being overloaded and suffering mechanical strain. They are used in hoisting systems, cranes, and other heavy industries to ensure lifting operations remain within safe weight limits. They prevent accidents, protect personnel, and reduce expensive repairs. Shipping and handling industries apply limiters to monitor and control loads during the transporting process to ensure equipment safety. They are also used in mobile and stationary power sources to prevent electrical overloads that would hinder operations.