How to Select Sensor Range (Part 1): Calculation Method and Key Factors

Sensor Range Selection (Part 1): How to Choose the Correct Capacity

Selecting the correct sensor range is essential for ensuring measurement accuracy, operational safety, and long service life. Choosing a sensor that is too large reduces measurement precision, while selecting one that is too small risks overload and damage.

Sensor range selection should be determined by evaluating multiple factors, including:

• Maximum weighing capacity
• Number of sensors used
• Dead weight of the scale structure
• Possible eccentric loading
• Dynamic loads and vibration

A comprehensive evaluation ensures both accuracy and durability.

Basic Principle of Sensor Range Selection

In general, the closer the sensor capacity is to the load assigned to each sensor, the higher the measurement accuracy. However, in real applications, the load on the sensor is not limited to the object being weighed.

Additional loads include:

• Scale structure weight
• Tare weight
• Eccentric loading
• Vibration and impact loads

Therefore, sensor range selection must consider safety margins to protect the sensor and extend its service life.

Sensor Range Calculation Formula

After considering various influencing factors, the following formula is commonly used:

C = K₀ × K₁ × K₂ × K₃ × (Wmax + W) / N

Where:

• C — Rated capacity of a single sensor
• W — Dead weight of the scale structure
• Wmax — Maximum net weight of the measured object
• N — Number of support points (number of sensors)
• K₀ — Safety factor (typically 1.2–1.3)
• K₁ — Impact factor
• K₂ — Center-of-gravity offset factor
• K₃ — Wind pressure factor

This formula helps determine the appropriate rated capacity for each sensor.

Explanation of Key Factors

Safety Factor (K₀)

The safety factor accounts for unexpected overload conditions. It is typically selected between 1.2 and 1.3 to ensure operational reliability.

Impact Factor (K₁)

This factor considers dynamic loads caused by sudden loading, mechanical movement, or shock forces.

Center-of-Gravity Offset Factor (K₂)

Uneven weight distribution can increase load on individual sensors. This coefficient compensates for load imbalance.

Wind Pressure Factor (K₃)

For outdoor installations, wind load may affect measurement stability and sensor loading.

Why Correct Range Selection Matters

Proper sensor range selection provides:

• Higher measurement accuracy
• Improved overload protection
• Longer sensor lifespan
• Stable weighing performance
• Reduced maintenance costs

Incorrect selection can lead to measurement errors, premature failure, or safety risks.

Conclusion

Sensor range selection requires careful evaluation of both static and dynamic loads. By applying the calculation formula and considering safety, impact, and environmental factors, users can select the most appropriate sensor capacity.

This ensures reliable performance, improved accuracy, and extended service life for weighing systems.