Weighing Silos, Hoppers, Tanks, and Bins with Strain Gauge Sensors
Load & Level Monitoring with Retrofit Strain Gauge Sensors
Inventory Weight & Level Measurement for Industry and Agriculture
Weight and level monitoring of silos, hoppers, tanks, and bins is vital to many sectors including agriculture, manufacturing, mining, construction, chemicals, oil, water and waste management. In bulk storage systems where volume estimates can be unreliable, weight measurement provides accurate inventory data, improving stock control, batching, and process efficiency. These insights can prevent overfilling, reduce waste, enhance safety, and support automation.
Load Cells
While load cells can provide a well-established solution, they are often unviable due to a range of factors. Installation requires lifting or modifying the existing structure, which can be costly, disruptive, and impractical. Servicing load cells for recalibration, replacements, or repairs also causes downtime and likely loss of revenue.
Strain Gauge Sensors
By contrast, strain gauge sensors offer a reliable and cost-effective alternative to load cells without intrusive modifications or downtime.
This retrofit method can be adapted to a wide range of containers, working within space or budgetary constraints.
Visualisation of Bolt-On Strain Gauge Sensors being fitted to a Silo leg
Installation
Strain Gauge Sensors are bolted onto the load-bearing structures such as legs, beams, or support frames of the storage container.
These sensors are connected to a Local Control Unit or Indicator.
Depending on the Indicator and the number of sensors, a junction box, and signal conditioners or amplifiers may be required.
Working Principle
As the container fills and empties, the weight fluctuations apply strain (deformation) to the support structures.
Strain Gauge Sensors detect these deformations and converts them into electrical signals proportional to the load.
Datum Electronics Bolt-On Strain Gauge Sensors Installed on a Grain Silo
SignalOutput
Typical strain gauges output an analog signal measured in millivolts (mV).
Conditioners, Amplifiers, and Analog-to-Digital Chips (ADCs) within advanced Indicators or Control Units convert the signal into the desired format for PLC, HMI, or SCADA systems.
Our Strain Gauge Sensors can be configured for a variety of analog and digital outputs including: 0-10VDC, 4-20mA, CANopen, RS323 & RS485.
Calibration
The system is calibrated to account for the container’s inherent weight, ensuring that readings accurately reflect changes to load.
Depending on the structure, calibration may involve balancing the strain readings across all support points, compensating for asymmetries or uneven load distribution.
Our Strain Gauge Sensors offer reliable storage weighing in an adaptable form factor, well-suited to a wide range of systems.
Easy to install and designed to withstand harsh environments and high-stress levels, they deliver consistent performance even in demanding applications.
Our client, a South American inventory solutions provider, needed a safe and efficient way to measure raw material silo stock levels. Our sensors enabled effective level monitoring without modification or downtime.
Whether you’re developing a new prototype or upgrading an existing setup, our experts are here to guide you. Complete the form below and a member of our team will contact you shortly.
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