{"id":19326,"date":"2026-02-25T13:12:29","date_gmt":"2026-02-25T18:12:29","guid":{"rendered":"https:\/\/blog.wika.com\/us\/?p=19326"},"modified":"2026-02-25T13:12:29","modified_gmt":"2026-02-25T18:12:29","slug":"load-cell-problems-why-some-load-cells-fail","status":"publish","type":"post","link":"https:\/\/blog.wika.com\/us\/products\/force-products\/load-cell-problems-why-some-load-cells-fail\/","title":{"rendered":"Load Cell Problems: Why Some Load Cells Fail"},"content":{"rendered":"

Learn the common causes of load cell problems in industrial weighing technologies, and how WIKA engineers can customize sensors \u2014 even in small quantities \u2014 to reduce the chances of load cell failure.<\/strong><\/p>\n

Load cells and other industrial force transducers are sensitive yet robust measuring instruments. However, they will fail under certain conditions.<\/p>\n

What is the main cause of load cell failures?<\/h2>\n

Most load cell problems occur due to operator misuse, namely overloading. End users might drop a load onto the weighing platform, which subjects the load cell to dynamic forces that exceed its designed parameters. Or they might not center the load properly; this creates side loads and off-axis loading that can lead to inaccuracy and physical deformation of the sensor.<\/p>\n

SOLUTION: <\/strong>Because human errors are inevitable, system engineers and equipment manufacturers should always factor that in when choosing load cells. The right load cells should have:<\/p>\n

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  1. A sufficiently high force range for an application<\/li>\n
  2. Built-in buffers for safe overload and ultimate overload<\/li>\n<\/ol>\n

    Safe overload is the range over the rated capacity where the load cell can function outside of accuracy specifications without suffering permanent damage. Ultimate overload is the maximum force that can be applied to a load cell; above this percentage, the load cell is very likely to experience structural failure.<\/p>\n

    Once a load cell begins to suffer from accuracy issues, that usually means its strain gauges<\/a> have been damaged. Sometimes it\u2019s possible to replace just the strain gauges and recalibrate the sensor. But for the greatest reliability and accuracy, our recommendation is to replace the entire load cell.<\/p>\n

    WIKA load cells<\/a> are typically designed with a safe overload up to 150% and an ultimate overload of 150% to 300%. Determining the overload is a balance between output and the size of the load cell.<\/p>\n

    What are some other causes of load cell failure?<\/h2>\n

    Besides overloading, common reasons for load cell problems include<\/p>\n