load cell failure

Drift in the zero balance, random noise on the signal, or readings that won’t stabilize under a known weight. Sometimes the output just locks at a fixed value. If you tap the cell and the reading jumps, that’s often a sign of a broken bond layer or internal damage.

Yes. Exceeding the safe overload limit—usually 150% of rated capacity for good designs—can permanently deform the metal, shifting the calibration. The cell might still output something, but accuracy and linearity are gone. In critical applications, that’s as bad as total failure.

Look for IP68 or IP69K ratings if the sensor will be submerged or pressure-washed. Even then, cable entries are the weak spot. Kingmach seals cable glands with potting compound and uses vent tubes with Gore membranes to equalize pressure without letting water in. Site practices matter too: never leave a cable junction sitting in a puddle.

Usually a latent issue that finally propagates. A small crack in the strain gauge bond grows, a moisture film slowly corrodes a connection until resistance spikes trigger erratic readings. In some cases, fatigue from cyclic loading causes a fracture. A sudden failure often has a slow, hidden start.

Check the mounting hardware first—loose bolts or binding on the mount can mimic sensor failure. Verify the excitation voltage at the cell and look for damaged cable insulation. Swap the indicator with a known good cell if possible. Many returns we see at Kingmach aren’t sensor failures at all, just installation issues that a simple field check would catch.