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The ADI CONTROLS Custom Load Cell Manufacturing Protocol

Standard load cells often fail to meet the unique demands of specialized industries, from aerospace and medical devices to high-speed automation. At ADI CONTROLS, we engineer precise force measurement solutions built to specification.

We follow a rigorous 7-Stage Manufacturing Protocol to transform your requirement into a reliable, high-precision instrument.

Phase 1: 📝 Consultation and Requirement Definition (The Blueprint)

This is the most critical initial step. Our engineers work directly with your team to deeply understand the complete application environment and performance needs.

  • •Application Analysis: Understanding the specific load type (tension, compression, torque, shear), expected cycle life, and measurement frequency.
  • •Capacity & Overload: Defining the maximum operating load, safe overload limits, and ultimate destruction limits for robust operation.
  • •Environmental Factors: Specifying critical elements like operating temperature range, chemical exposure, vibration, and the required Ingress Protection (IP) rating (e.g., IP68 for submersible use).
  • •Output Specification: Determining the required sensitivity ($\text{mV/V}$), accuracy class, and electrical connection requirements (cable length, connector type).
  • •Form Factor Constraints: Defining the physical dimensions, mounting hole locations, and material requirements (e.g., stainless steel, alloy steel).

Our Action: We meticulously assess your input against engineering feasibility. We then assign a specific Type Number, prepare initial drawings, decide the optimal Construction Material, and recommend the best Protection Sealing, dimensions, and appropriate installation methods.

Phase 2: 💻 Design Optimization and Modeling (CAD/FEA)

Once requirements are finalised, our design team translates them into a mathematically verified, viable engineering model using in-house state-of-the-art computer-aided design (CAD) software.

  • •3D CAD Modeling: Creating a detailed digital model of the load cell, including all mechanical features and stress points.
  • •Material Selection: Choosing the optimal high-grade material (e.g., 17-4 PH Stainless Steel) for the required capacity, environmental durability, and fatigue life.
  • •Strain Gauge Placement Design: Precisely mapping the location and orientation of the strain gauges for maximum signal output and inherent temperature compensation.
  • •Finite Element Analysis (FEA): This crucial virtual testing simulates real-world forces and stresses on the model. FEA allows us to predict performance, confirm structural integrity, and optimize the design for maximum accuracy and durability before physical machining begins.
Phase 3: ✅ Customer Approval – Committing to the Design

Your involvement is essential. We present the detailed engineering drawings, material specifications, and predicted performance data (derived from FEA) for your review and final technical sign-off.

  • •Manufacturing commences only after you approve our custom load cell design, ensuring total alignment with your operational expectations.
Phase 4: 🛠️ Fabrication and Machining (Precision Manufacturing)

The approved digital design is brought to life using our state-of-the-art machinery and manufacturing expertise.

  • •CNC Machining: The sensor body (or spring element) is precisely cut and shaped from the selected raw material using Computer Numerical Control (CNC) machines, ensuring micro-level dimensional accuracy.
  • •Heat Treatment: Critical structural elements may undergo specialised heat treatment to achieve the required strength, hardness, and thermal stability.
  • •Surface Preparation: The housing is cleaned, deburred, and prepared for the sensitive process of strain gauging.
Phase 5: 🔗 Strain Gauging and Wiring (The Core Technology)

This is the most specialized and delicate part of the manufacturing process, often performed in a clean environment to guarantee reliability.

  • •Strain Gauge Bonding: High-precision foil strain gauges are meticulously positioned and bonded to the sensor body using specialised adhesives.
  • •Wheatstone Bridge Assembly: The individual strain gauges are wired together to form a Wheatstone bridge circuit, the essential configuration for converting mechanical strain into a stable electrical signal.
  • •Sealing and Protection: The gauges and internal wiring are hermetically sealed and protected against contaminants. This sealing technique (e.g., potting, welding) determines the final IP rating.
Phase 6: ✅ Calibration and Quality Assurance (Testing and Certification)

The finished load cell is rigorously tested and calibrated to guarantee it meets or exceeds your precise specifications.

  • •Multi-Point Calibration: The sensor is connected to a high-accuracy reference standard and loaded repeatedly at various points to generate a precise calibration curve.
  • •Compensating Circuits: Internal circuits are adjusted to correct for temperature effects (drift and shift) and ensure consistent output across the operating temperature range.
  • •Traceability and Certification: A calibration certificate is generated, detailing the load cell's performance specifications (non-linearity, hysteresis, creep, etc.) and confirming traceability to national standards.
Phase 7: 📦 Delivery – On Time, On Spec

Your final, custom-engineered load cell or sensor will be delivered to you precisely within the agreed period. Each shipment includes the detailed calibration certificate and full technical documentation to ensure seamless integration into your system.

Beyond Customization: We can also convert your machine components (Bolts, Shafts, Plates) into fully functional sensors, offering an integrated measurement solution.

Ready to initiate your custom sensor project? Would you like to schedule a consultation with our engineering team?

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