Introduction
Force measurement systems are designed to deliver precise, repeatable results. However, environmental conditions can significantly influence a sensor’s performance if not properly accounted for.
From temperature swings to moisture ingress and vibration, external factors can introduce drift, noise, and mechanical errors.
This article outlines the key environmental variables that affect load cells and force sensors—and how to mitigate their impact for accurate, reliable measurements.
1. Temperature Effects
Problem:
Changes in temperature cause expansion or contraction of materials, altering strain gauge resistance and shifting the sensor’s output.
Impacts:
Zero-point drift
Span sensitivity changes
Hysteresis errors (especially in wide temperature swings)
Solutions:
Use temperature-compensated sensors
Allow system to thermally stabilize before measurement
Install thermal shields or enclosures for outdoor systems
Avoid direct exposure to heat sources like sunlight or machinery
2. Humidity and Moisture Exposure
Problem:
Moisture can penetrate load cells, signal cables, or junction boxes, degrading insulation resistance and causing short circuits or ground loops.
Impacts:
Signal instability and drift
Long-term corrosion of sensitive components
Increased noise in output signals
Solutions:
Choose sensors with IP67 or IP68 ratings for wet environments
Use sealed connectors, cable glands, and waterproof junction boxes
Apply desiccants or moisture barriers in critical installations
3. Mechanical Vibration and Shock
Problem:
Force sensors subjected to vibration, impact, or oscillation can produce unstable or erratic signals, even when the load is static.
Impacts:
Noise in measurement
False peak loads
Mechanical fatigue leading to early failure
Solutions:
Use anti-vibration mounts or elastomeric bases
Implement signal filtering or moving average smoothing in software
Choose shock-resistant load cells for high-impact applications
4. Electromagnetic Interference (EMI)
Problem:
Nearby motors, drives, welders, or radio equipment can induce unwanted voltages in the sensor wiring.
Impacts:
Noise spikes
Signal drift
Communication errors (especially with digital signals like RS485)
Solutions:
Use shielded, twisted-pair cables grounded at one point
Install ferrite filters or EMI suppressors
Physically separate sensor wiring from power or RF lines
5. Structural Movement or Settling
Problem:
Buildings, tanks, and mechanical structures can shift or settle over time, introducing unintended side loads or misalignment forces on the sensor.
Impacts:
Zero-point shift
Increased measurement error
Premature sensor wear or damage
Solutions:
Use self-aligning mounting systems
Regularly inspect structural supports
Allow for thermal expansion and mechanical movement in system design
Summary Table
| Environmental Factor | Impact on Measurement | Mitigation Strategy |
|---|---|---|
| Temperature | Drift, sensitivity change | Compensation, shielding, stabilization |
| Humidity / Moisture | Instability, corrosion | Sealed sensors, IP-rated protection |
| Vibration / Shock | Signal noise, mechanical fatigue | Damping mounts, filtering |
| Electromagnetic Interference (EMI) | Noise, drift, comms errors | Shielded cabling, EMI filters |
| Structural Movement | Misalignment, zero drift | Floating mounts, regular inspection |
Conclusion
Environmental conditions are often overlooked when designing force measurement systems—but they can make or break your measurement reliability.
By proactively considering temperature, moisture, vibration, EMI, and structural dynamics, you can achieve more stable, accurate, and long-lasting performance.
Smart environment management = better data = better decisions.