Batch Weighing & Control

APPLICATION: In many factories that batch blend bulk products, weigh batching is a manual, time-consuming process in which ingredients are weighed individually before being emptied into a blender or other process vessel. A large number of these factories could benefit from the installation of an automated batch weighing and control system.

For both small and large operations a batch weighing system can pay for itself within a short space of time through increased productivity and more accurate measurement of ingredients. This results in reduced product losses due to overages and a higher quality product being produced as the correct ratio of ingredients is supplied every time. 

Batch weighing and control systems generally comprise of a central vessel or tank mounted on a load cell weigh frame. One or more feeders are positioned around the vessel and are used to automatically deliver materials in the vessel in accordance with the specified recipe. After each deposit, the load cells verify that the correct amount of product has been delivered before the next ingredient is added to the mix. Alerts can be set up to inform controllers when there are instances of either too little or too much product delivered to the central vessel.

LCM Systems supply load cells and instrumentation for use with weigh frames and have a range of accessories including weighing mounts that allow for movement of the vessel or tank, whilst still maintaining high accuracy weight measurement.

Beam Proof Testing

APPLICATION: All lifting operations involving lifting equipment such as lifting, lift shaft and runway beams, must be marked to indicate their SWL (safe working load), which is the maximum load the equipment can safely lift when in use. Load testing ensures that lifting equipment has been installed correctly and is strong enough to resist the bending and shear forces generated during lifting operations. 

Beam proof testing should be carried out after installation on-site and before first use, if there has been a potential overload instance that could have caused damage/fatigue or if it has been out of use for a long period of time. Some companies also include regular retesting as part of their quality procedures.

LCM Systems manufacture a selection of products that are suitable for beam proof testing and can supply just the load cells or additional instrumentation and displays to provide a compete load monitoring system. For this particular application we are often asked for wireless systems that eliminate the need for long lengths of cable that is prone to snagging and damage. We have a range of wireless load pins, load shackles and load links that are all simple to install and set up, and can be supplied with wireless instrumentation and displays.

Boat Lifting & Weighing

APPLICATION: Boats routinely need to be lifted out of the water for checks and maintenance, repairs, anti-fouling work, moving to another location or for winter storage. Boat hoists and cranes are predominantly used for to do this, and the installation of a load monitoring system can ensure that a safe lift is achieved every time.

Load bearing pins in the hoist block can be substituted for load measuring pins, and when combined with a display can provide real-time monitoring of loading during the lift. This data can be used to monitor the load distribution between the lifting points to check that it is spread evenly. If unevenly loaded there is a danger of individual strops or cables becoming overloaded, potentially resulting in failure that can cause extensive and costly damage to the boat, as well as putting the safety of nearby personnel at risk. The system can also be used to provide an accurate weight of the boat that can be used to check dry dock supports are suitable or to verify weight for transportation purposes.

For instances where a non-permanent or portable load monitoring system is required, load shackles or load links can be used instead, which are normally fitted in the lifting points. Wireless systems are also particularly suitable for this application, and we have a comprehensive range of both wireless and cabled products. Whatever your requirements when it comes to boat lifting and weighing, LCM Systems can supply a system tailored to your needs.

Bolt Tensioning Systems

APPLICATION: Most industrial environments contain hundreds of bolts that hold equipment and machinery in place. Some of these bolts are critical for the safe operation of the machinery, and consequently the safety of the workers that operate them. Should these crucial bolts fail it may lead to equipment damage, production downtime, and even injury to personnel. Therefore, ensuring correct bolt tensioning is essential, as over tightening that can lead to premature fatigue and the breakdown of joints, and if under tensioned the joints could come apart. In most instances tightening to the correct tension relies on the skill of the operator and so is subject to errors.

LCM Systems manufacture washer/bolt tensioning load cells that can be used to improve the accuracy of the bolt tensioning process, and as a result improve infrastructure reliability and safety. Monitoring over time for tightness becomes a simple exercise and removes the need for a physical inspection and a mechanical torque reading of each bolt. This is particularly useful for bolts that are difficult to access.

Our WAS load cells are simple and quick to install and can provide continuous tension monitoring. We can provide just the load cell and a handheld display for periodic checks, or a more comprehensive system that includes instrumentation with alarms to alert asset owners when tensions exceed or fall below predefined limits. 

In addition to our WAS bolt tensioning load cell, we also supply several other load cells that can be used for bolt tension monitoring. See below for further details on these and our WAS load cell.

Bridge Lifting & Positioning

APPLICATION: Newly built bridges need to be lifted and carefully positioned in their final position following construction and transportation to site. They may also have to be lifted during their service life for bearing replacement or structural repairs. This requires the use of jacking systems or cranes, both of which can benefit from the use of a load monitoring system to improve safety and efficiency.

If a hydraulic jacking system is being used, our load cells can be incorporated to provide real time information to engineers of the jacking forces being applied to the bridge structure, allowing them to be either increased or reduced to achieve optimal lift and performance. 

When using cranes to lift bridge structures, our crane safe load monitoring systems provides the operator with lifting load data so they can continually monitor the lift to ensure that it stays within the cranes maximum safe load limit.

LCM Systems have provided many load monitoring solutions for bridge lifting and positioning applications and have a range of load cells to suit. Below is a selection of the most commonly used load cell types, with both cabled and wireless options. 

Cable Stay Tension Monitoring

APPLICATION: Structural cables (cable-stayed bridges, suspension bridges, suspended roofs) are complex civil engineering structures in which the stay cable system is a vital structural element. To achieve their design service life, stay cables require regular monitoring in addition to detailed inspections following certain events, such as strong winds, earthquakes, accidental impacts etc. The use of tension monitoring can reduce the need for time consuming individual cable stay monitoring/inspections by providing asset owners with continuous tension data that can be used to warn them of any under or over tensioning instances.

For long-span cable bridges, it is particularly important to monitor cable tension when the bridge is in use and subject to traffic loading. A cable stay tension monitoring system facilitates the safe operation of the bridge and can reduce both the cost of maintenance and disruption due to traffic closures by alerting bridge operators to any potential issues with cable stay over/under tensioning, allowing targeted remedial action to be taken before it becomes a safety concern.

LCM Systems provide a wide range of tension monitoring solutions that include tension load cells, load links and load shackles. These can be installed in the anchor block or cable stay load path to provide continuous load monitoring. Instrumentation and displays can also be provided with alarms that are triggered when pre-set over or under tensioning limits are detected.

Cable Tension Monitoring

APPLICATION: Cables are used in many industries to support and secure many different types of structures, from bridges to stage rigging, sailing yachts to architecture. The life of these cables can be significantly shortened when they are over tensioned, resulting in fatigue and possible failure. Conversely, under tensioning can have severe safety implications, as the stability of the structure can become compromised.

LCM Systems provide a range of products that can monitor cable tension through the use of load cells and digital read outs. This can be achieved using various types of load cells, including load shackles, load links and load pins, the selection of which will depend on several factors including space available, cable configuration and accuracy required. Our sales team and engineers are always on hand to offer advice on the best type of load cell to use for a specific application.

Our cable tension monitoring systems provide real time load data on cable tension and can be set up to include alarms that warn operators and asset owners when cable tensions have either fallen below or exceeded specified levels. This allows preventative action to be taken before any problems and potentially dangerous safety issues occur.

Centre of Gravity Weighing Systems

APPLICATION: When a load is lifted by a crane, the load is free to tilt and move. It will continue to do so until the centre of gravity is directly under the crane hook. If the centre of gravity of the load is known, the exact angle of tilt can be predicted before the lift. This is critical when planning the lift and working out whether or not the lift will be stable. If the load is unstable because the centre of gravity is not centralised, the integrity of the lift and the safety of nearby personnel is put at risk.

LCM Systems centre of gravity systems both weigh and calculate the centre of gravity of any large structure, including offshore oil rigs, boats, turbines and reactors. A typical system comprises of compression load cells and custom designed software that displays individual load cell readings, the total load and the centre of gravity of the module being weighed. The total number of load cells needed will depend on the number of lifting points and the size of the structure.

Our systems facilitate both safe lifting and transportation, as well as determining the type of crane required and the best position of the lifting points to keep the structure stable during the lift.

Crane Load Monitoring & Control

APPLICATION: Crane load monitoring and control systems are installed on all types of cranes to provide continuous data to operators and asset owners that allows them to increase productivity and improve safety. Monitoring of lifted loads enables the operator to move the maximum amount of product safely, resulting in fewer lifts and faster completion of duties. Additionally, as overload instances are eliminated, safety is improved and damage to the cane avoided. Information on crane usage and loads lifted also provides information to asset owners on integrity, life expectancy and required scheduling of maintenance and repairs.

LCM Systems offer a comprehensive range of weighing and overload systems to suit most applications. Our crane load monitoring and control systems can be fitted either to new cranes as original equipment or retrofitted to existing cranes. The type of load cell used in a system will depend on many factors including crane design, amount of headroom available and the level of accuracy needed, and so could comprise of a load link, load shackle or load pin. 

Each system requires a load cell to sense the load and an indicator to display the load and provide any control outputs that may be required. We can supply just the load sensing component or the complete system with a display. For customers who already have a display or PLC system that they would like to integrate the load cell into, we offer various signal outputs for simple connection. 

Crane Proof Testing

APPLICATION: Crane proof load testing involves a crane lifting a known load in line with its rated load capacity to verify its strength and ability to safely lift that load. The proof load test is normally expressed as a percentage of the working load limit (WLL) or safe working load (SWL) that the crane is designed to withstand. Typically, a crane proof load test will be carried out following manufacture, repair, refurbishment, modification or an overload incident. Periodic testing may also be specified as part of the asset owner’s quality procedures.

Every load cell that LCM Systems manufactures is designed to operate to the highest accuracy and in the toughest of environments. We offer a variety of products suitable for crane proof testing applications and can supply the load cell only or a complete load monitoring system that incorporates instrumentation and/or a display. 

For this application, wireless systems are often preferred, as the requirement for long lengths of trailing cable is eliminated, making installation much faster and simpler. In addition to our cabled products, we also have a comprehensive range of wireless load links and load shackles, which when combined with Mantracourt’s renowned T24 wireless instrumentation products, provide a reliable, out of the box wireless solution.