How to Select Sensor Range (Part 2): Working Load Ratio and Accuracy Considerations

Sensor Range Selection (Part 2): Working Range and Accuracy Considerations

In addition to calculation formulas, practical experience also plays an important role in selecting the appropriate sensor range. Proper working load distribution not only improves measurement accuracy but also ensures sensor safety and longevity.

Recommended Sensor Working Range

Based on industry experience, sensors should generally operate within 30% to 70% of their rated capacity. This range provides:

• Optimal measurement accuracy
• Stable performance
• Reduced measurement error
• Extended service life

Operating within this range ensures that the sensor maintains good sensitivity while avoiding overload risks.

Special Cases with High Impact Loads

For weighing systems exposed to large dynamic or impact loads, such as:

• Dynamic rail scales
• Dynamic truck scales
• Steel weighing systems
• Heavy material handling equipment

It is recommended to increase the selected sensor range. In these cases, sensors typically operate within 20% to 30% of their rated capacity.

This approach provides:

• Larger load reserve
• Improved overload protection
• Better resistance to shock forces
• Longer sensor lifespan

Considering Sensor Application Range

Different sensor types are designed for specific applications. When selecting a sensor, it is important to consider its suitability for the operating environment and load conditions.

Key performance parameters include:

• Non-linearity
• Creep
• Creep recovery
• Hysteresis
• Repeatability
• Sensitivity

These technical indicators collectively determine the sensor's accuracy grade.

Accuracy Grade vs. Cost Consideration

When choosing a sensor, it is not always necessary to select the highest accuracy grade. Instead, selection should balance:

• Measurement accuracy requirements
• Application environment
• Budget constraints
• System design requirements

Choosing excessively high accuracy sensors may increase cost without providing meaningful performance benefits.

Best Practices for Sensor Selection

To ensure optimal performance:

• Keep working load between 30%–70% when possible
• Use 20%–30% working range for high-impact applications
• Select appropriate accuracy grade based on needs
• Consider environmental and dynamic load factors
• Balance performance and cost

Conclusion

Proper sensor range selection involves more than calculation formulas. By considering working load ratios, impact conditions, and accuracy requirements, users can achieve reliable performance and cost-effective system design.

A well-chosen sensor ensures measurement stability, improves safety, and extends operational life.