How to install the weighing sensor on the silo

1. Choose the Right Weighing System

Most solid-material silos use compression load cells mounted under the support legs (typically 3 or 4 cells).

2. Pre-Installation Planning

Calculate total weight: Max material weight + silo empty weight. Choose load cells with 125–150% overload capacity.

Determine number of cells: 3 legs = 3 cells (self-leveling); 4 legs = 4 cells (may need corner adjustment).

Check structural integrity: The foundation and legs must support the concentrated point loads. Reinforce if needed.

Plan for mounting hardware: Each cell needs a top plate (to silo leg) and bottom plate (to foundation), plus check rods / stay rods to resist lateral forces (wind, seismic, filling impact).

3. Installation Steps (Compression Type)

Step 1: Prepare the foundation

Ensure each mounting point is flat, level, and rigid.

Grind or shim so all load cell bases are within ±1 mm of the same plane.

Anchor bottom mounting plates securely to the concrete/steel foundation.

Step 2: Lift the silo

Use jacks or a crane to raise the silo just enough to slide the load cells under each leg.

Lift evenly to avoid frame distortion.

Step 3: Mount the load cells

Place each load cell centered on its bottom plate, aligned with the leg's centerline.

Attach the top mounting plate to the silo leg.

Ensure load is applied axially (vertically) — no side load or torsion.

Use self-aligning mounting kits (cup-and-ball or rocker pins) if available; they compensate for minor misalignment and thermal expansion.

Step 4: Install restraint hardware

Fit horizontal check rods / tie rods between the silo frame and fixed ground points.

These absorb wind, seismic, and material-flow lateral forces without carrying vertical load.

Leave rods slightly loose (follow manufacturer specs) so they don't shunt weight away from the cells.

Step 5: Wire the system

Run shielded cable from each cell to a junction box (summation box).

In the junction box, cells are wired in parallel; use trimming resistors for corner (corner-adjust) balancing.

Run a single cable from the junction box to the weight indicator / transmitter.

Keep cabling away from power lines; use conduit for protection. Ground the shield at one end only to avoid ground loops.

Step 6: Calibrate

Zero calibration: With the silo empty, set the indicator to zero (tare the empty silo weight).

Span calibration:

Best: use known test weights placed on the silo.

Alternative: material calibration — weigh a known quantity (e.g., a truckload) on a certified scale, then add it to the silo and set the span.

Some systems support theoretical (calculated) calibration using cell rated output, but it's less accurate. Perform corner adjustment if one cell reads differently under equal load.

4. Critical Best Practices

Never weld on the silo structure with load cells installed — welding current can destroy strain gauges. Disconnect or remove cells first.

Protect cables from rodents, abrasion, and weather.

Allow for thermal expansion — use rocker mounts or slotted holes so the silo can expand/contract without side-loading the cells.

Avoid shock loading: Fill the silo gently; a free-falling material stream can generate dynamic overloads.

Regular maintenance: Check mounting bolts, rod tension, and cable condition; re-calibrate periodically (e.g., annually or after major maintenance).

5. Common Problems & Fixes

Safety Note

Silo weighing involves working under heavy suspended loads. Always follow lockout/tagout procedures, use proper lifting equipment, and have a qualified structural engineer verify the foundation and frame can support the concentrated loads before installation.