Did a sudden failure of the CHLET-1 sensor cause abnormal tension and compression measurement? As the core monitoring equipment of a reaction copper mixing station, the accuracy of the column-type force sensor directly affects production safety. In this article, Xi'an Shenghongchuang technical experts share a 3-step rapid diagnosis method, covering key troubleshooting points for common models such as CKY-118 and EX302B, helping you quickly restore the measurement accuracy of load cells such as ET-2 and BLR-ZSA.

I. The impact of sensor failures on production safety

In industrial scenarios such as reaction copper mixing stations, column-type force sensors such as CHLET-1, ET-2, and CKY-118 undertake critical tension and compression measurement tasks. The accuracy of these sensors is directly related to the stability and safety of the production process. Once a sensor fails, it may lead to the following problems:

• Measurement data deviation, affecting process control accuracy
• Increased risk of equipment overload, possibly causing mechanical damage
• Fluctuations in production quality, reducing product qualification rates
• Safety hazards, potentially triggering safety accidents

According to industry statistics, about 35% of industrial accidents are related to sensor failures, among which abnormal tension and compression measurement accounts for the highest proportion. Therefore, rapidly and accurately diagnosing sensor failures is of vital importance.

II. Detailed explanation of the 3-step rapid diagnosis method

1. Preliminary inspection and appearance diagnosis

For column-type force sensors such as CHLET-1 and EX302B, a visual inspection should first be carried out:

• Check whether the sensor housing has obvious deformation or damage
• Confirm whether the wiring terminals are loose or oxidized
• Observe the sealing performance to prevent media infiltration from affecting measurement
• Check whether the installation position is correct to avoid the influence of lateral force

For models such as BLR-ZSA and YY-L103, special attention should also be paid to the waterproof performance of cable connections. According to the GB/T 7551-2008 standard, the enclosure protection rating of the sensor should reach IP65 or above.

2. Electrical performance testing

Use a multimeter to perform basic electrical tests:

For models such as NR-LB2 and CZL-3, it is also necessary to check whether the excitation voltage is stable（usually 10V DC）. If any abnormality is found, it is recommended to stop using it immediately and contact professional technicians.

3. Load characteristic verification

Conduct load testing using standard weights or a force testing machine:

1. Start from zero load and gradually increase to the rated load（such as 150%FS of LK-1016）
2. Record the output signal at each load point and plot the characteristic curve
3. Check key indicators such as nonlinearity and repeatability

According to the JJG 391-2009 verification regulation, the nonlinearity error of load cells such as XL-G2 should be ≤0.05%FS. If the test result exceeds this range, it indicates that the sensor needs calibration or replacement.

III. Common failure types and solutions

Based on Xi'an Shenghongchuang's 15 years of industry experience, the typical failures of column-type force sensors are summarized as follows:

• Zero drift: Common in models such as ET-2 and BLR-ZSA, mostly caused by temperature changes or mechanical stress, requiring rezeroing or temperature compensation
• Unstable output: CKY-118 and EX302B may encounter this problem; check the stability of the power supply and grounding conditions
• Overload damage: If sensors such as CHLET-1 and YY-L103 are overloaded for a long time, the strain gauge may be permanently deformed, and the core component needs to be replaced
• Signal interference: NR-LB2 and CZL-3 are easily affected in strong electromagnetic environments; it is recommended to use shielded cables and keep away from interference sources

IV. Maintenance recommendations and professional support

To ensure the long-term stable operation of sensors such as LK-1016 and XL-G2, it is recommended to:

• Carry out one preventive maintenance inspection every 6 months
• Establish sensor usage records to log historical data and maintenance status
• Use original factory parts for repair and replacement
• Regularly participate in professional technical training

As a national high-tech enterprise, Xi'an Shenghongchuang provides technical support, calibration services, and spare parts supply for the full range of sensors such as CHLET-1. Our technical team has 20 years of industry experience and can provide customized solutions according to your specific working conditions.

V. Summary and action recommendations

Through the 3-step diagnosis method introduced in this article, you can quickly identify the causes of failures in column-type force sensors such as ET-2, CKY-118, and EX302B. Remember:

• Regular inspection is the best way to prevent failures
• Professional calibration can extend sensor service life
• Timely maintenance prevents minor issues from developing into major failures

If you encounter complex failures in sensors such as BLR-ZSA and YY-L103, or need professional technical support for the CHLET-1 sensor, please contact Xi'an Shenghongchuang Instrument Co., Ltd. immediately. Call our service hotline 400-XXX-XXXX, or visit our official website www.xxxxxx.com for more solutions.