Dual Sensor Load Cell for High Resolution Force Measurement

The measurement system is segmented into two independent load cells: a high-capacity load cell for measuring large loads with acceptable resolution, and a low-capacity load cell for measuring small loads with high resolution. Each load cell is optimized for its specific capacity range, and the system selectively uses the appropriate cell based on the applied load magnitude, thereby resolving the contradiction between load capacity and measurement resolution.

The system dynamically switches between two different measurement configurations based on the applied load. A switch mechanism automatically connects either the high-capacity load cell or the low-capacity load cell to the measurement circuit depending on whether the applied load exceeds a predetermined threshold. This dynamic adaptation allows the system to maintain high measurement resolution across the entire load range from light to heavy loads.

The system incorporates a protective switching mechanism that anticipates heavy loads and prevents them from reaching the high-resolution low-capacity load cell. The switch is configured to automatically disconnect the delicate high-resolution cell before excessive force can damage it, thereby cushioning the system against potential harm while preserving the high-resolution measurement capability for appropriate load conditions.

A mechanical switch or intermediary device is introduced between the applied load and the high-resolution load cell. This intermediary automatically engages the high-capacity load cell when heavy loads are detected, acting as a protective mediator that redirects excessive force away from the fragile high-resolution sensor, thus preventing damage while maintaining system functionality.

The system uses two relatively simple, cost-effective load cells instead of one expensive high-resolution load cell that would need to handle all load ranges. The low-capacity load cell, while delicate, provides high-resolution measurements for light loads at low cost, and the high-capacity load cell handles heavy loads affordably. This approach of using multiple simpler components is more economical than deploying expensive instrumentation across the entire measurement range.

The system changes the operational parameters by selecting different load cells based on the load magnitude. Instead of using a single expensive high-resolution load cell for all conditions, the system switches between two load cells with different capacity parameters. This parameter-based selection allows the use of more affordable instrumentation for each specific measurement task, reducing overall system cost while maintaining high measurement precision where needed.