Published: 2026-08-21 Article source:
Welcome to the General Measure's channel. In this video, we will explain the key factors that affect weighing system accuracy and the corresponding solutions.
The accuracy of an industrial weighing system depends not only on the load cells, but also on the mechanical structure, installation method, environmental conditions, electrical signals, and maintenance.
In practical applications, many weighing errors are not caused by insufficient accuracy, but by external factors that affect overall system performance.
Now, let us look at the main factors affecting weighing accuracy and how to address them.
① Select an appropriate load cell capacity. A capacity too high or too low can compromise performance. In general, the actual load should remain within 20%–80% of the rated capacity, with 30%–70% being the optimum operating range.
(Example: Total weighing load: 10 t (supported by four load cells)
Recommended load cell capacity: 4 t per load cell
Actual load on each load cell: approximately 2.5 t
equivalent to 62.5% of its rated capacity
which falls within the optimum operating range of 30%–70%.
Calculation:
10 t × (1.3–1.5) ÷ 4 ≈ 4 t
Total load Safety factor Number of load cells)
Except special applications, such as truck scales with a particularly high dead load.
② If accuracy class, creep, temperature drift, or zero drift do not meet the operating requirements, select a more suitable load cell.
③ Aging or faulty load cells and damaged cables can reduce weighing stability. Replace the load cell or cable promptly.
④ Mixing load cells from different brand or with different capacities in the same weighing system can compromise performance. Use load cells of the same brand, model, and capacity.
2. Mechanical Installation Structure:
① If the scale foundation lacks sufficient rigidity, it may deform under load and reduce weighing stability. The foundation should be properly reinforced. For indoor steel structures, supports should be secured to load-bearing beams to improve overall rigidity and stability.
② Limit stops or linkage devices that are too tight or too loose can create friction or lateral restraint forces. Readjust these mechanical connections; if necessary, temporarily remove them for diagnostic testing.
③ If the load cells are not level or have significant height differences, readjust the mounting surfaces to the same level.
④ Uneven loading at the support points can cause severe off-center loading. Distribute the load as evenly as possible across all support points.
3. Connections and Accessories:
① Water ingress, oxidation, poor contacts, or an open-circuit shield terminal in the junction box can affect signal integrity. Replace the junction box if necessary.
② Arbitrarily extending load cell cables, poor extension connections, low-quality extension cables, or missing/improper shield grounding can impair performance. Use the original factory-supplied load cell cables.
③ Ensure that a 4-wire load cell is correctly connected to a 6-wire weighing indicator. For example, when connecting a 4-wire load cell to the General Measure GMT-P1, jumper EX+ to SN+ and EX− to SN−.
④ Air hoses, corrugated hoses, flexible connections, or rigidly connected pipes can pull on the scale structure. Use suitable flexible connections between the scale and external equipment to prevent mechanical interference.
Rapid temperature changes can cause temperature drift. High temperatures accelerate equipment aging, while low temperatures may affect the stability of electronic components.
2. Vibration and Shock:
Vibration and shock from nearby equipment can cause unstable or fluctuating weight readings.
3. Wind Disturbance:
Wind can cause weight fluctuations in outdoor silos, while airflow from air-condition or fans can affect high-precision scales.
4. Dust, Moisture, and Corrosion:
These conditions can damage components or circuits in electronic weighing instruments.
To minimize environmental interference, consider these factors during the system design. Measures may include maintaining constant indoor temperature and humidity, locating the system away from heavy machinery, installing vibration isolators, properly sealing and waterproofing equipment, and selecting load cells and indicators with higher ingress-protection ratings.
If the supply voltage is unstable, use a regulated power supply or a suitable power module.
2. Electromagnetic Interference
Variable-frequency drives and high-power equipment may generate electromagnetic interference. Ensure that the load cell cable shield is properly grounded.
3. No Separation Between Power and Signal Cables
Do not route load cell signal cables and high-voltage power cables in the same cable tray. Keep power and signal wiring properly separated.
4. Poor Shield Connection:
If the cable shield is not properly grounded, inspect and restore the grounding connection.
5. Signal Transmission Loss
Excessive cable length can attenuate the load cell signal. Install the weighing indicator closer to the load cells where practical.