1、 Mechanical structural failure

1. Deformation or sinking of the weighing scale body

• phenomenonThe four corners of the scale body are uneven, causing significant fluctuations in data during weighing, or the scale body sinks after long-term use.
• reason：
  • The foundation construction is not standardized (such as the foundation is not compacted and the drainage is not smooth).
  • Overloading or long-term overloading of vehicles can cause deformation of the weighing body.
  • The sensor support point is loose or damaged.
• Solution：
  • Basic inspection: Use a spirit level to measure the height difference of the four corners of the scale body. If it exceeds 5mm, the foundation needs to be readjusted.
  • Repair the scale body: Correct the deformed parts or replace the structural components of the scale body.
  • Overload restriction: Set up load limit signs to prevent vehicles from driving overweight.

2. Limit device failure

• phenomenonWhen weighing, the scale body shakes, the data is unstable, or the instrument displays error codes such as "Err".
• reason：
  • Loose or worn limit bolts result in excessive clearance between the scale body and the foundation.
  • After long-term use, the limit block has aged and deformed.
• Solution：
  • Adjust the limit bolt to maintain a gap of 2-3mm between the scale body and the foundation.
  • Replace the limit block: Use wear-resistant materials (such as nylon) for the limit block and regularly inspect and replace it.

2、 Sensor malfunction

1. Sensor damage

• phenomenonData deviation during weighing (such as displaying non-zero values when unloaded), poor repeatability, or instrument display of "OL" (overload) alarm.
• reason：
  • Sensor overload damage caused by vehicle impact, overload, or unbalanced load.
  • Poor sealing of the sensor, water ingress or moisture.
  • The sensor wiring is loose or short circuited.
• Solution：
  • Replace sensor: Select a sensor that matches the prototype number (such as bridge or column) and recalibrate it.
  • Check wiring: Use a multimeter to detect the sensor output signal and confirm that the wiring is not loose or short circuited.
  • Waterproof treatment: Seal the sensor junction box to prevent water ingress.

2. Sensor signal interference

• phenomenonThe weighing data fluctuates greatly or the instrument display is unstable.
• reason：
  • There is a strong electromagnetic field nearby (such as frequency converters, high-voltage lines).
  • The sensor cable and power cable are laid in parallel, generating induced current.
• Solution：
  • Shielding interference: Lay the sensor cable through a metal tube or use shielded cables.
  • Stay away from interference sources: Adjust the position of the weighing scale to avoid getting close to strong electromagnetic equipment.
  • Grounding treatment: Ensure that sensors, instruments, and weighing scales are well grounded.

3、 Instrument display malfunction

1. No display or black screen on the instrument panel

• phenomenonAfter power on, the instrument panel shows no response or the screen goes black.
• reason：
  • Power failure (such as blown fuses or broken power lines).
  • Damage to the internal circuit board of the instrument (such as lightning strikes or unstable voltage).
  • The backlight of the display screen is damaged.
• Solution：
  • Check the power supply: Use a multimeter to check if the power supply voltage is normal, replace the fuse or power cord.
  • Repair instrument: Contact the manufacturer to replace the circuit board or display screen.
  • Install voltage regulator: Install UPS or stabilized power supply in areas with unstable voltage.

2. Inaccurate weighing data

• phenomenonThe deviation between the weighing value and the actual value is large, or the repeatability is poor.
• reason：
  • Instrument parameter settings are incorrect (such as mismatched range and division values).
  • Abnormal sensor signal (such as a damaged sensor or inconsistent signal).
  • Instrument calibration failure (such as failure to calibrate regularly or incorrect calibration methods).
• Solution：
  • Recalibration: Follow the instructions to perform angle and range calibration.
  • Check sensors: Use standard weights to test the sensor output signals one by one to confirm consistency.
  • Restore parameters: Restore instrument parameters to factory settings, reset range and division values.

4、 Electrical connection failure

1. Loose or disconnected wiring

• phenomenonSometimes there is no data during weighing, or the instrument displays error codes such as "Err".
• reason：
  • Loose or oxidized wiring inside the sensor junction box.
  • The cable between the instrument and the sensor is open or short circuited.
  • Corrosion or damage to the wiring terminals.
• Solution：
  • Check wiring: Open the junction box and tighten all wiring terminals with a screwdriver.
  • Testing cables: Use a multimeter to check for cable continuity and replace damaged cables.
  • Anti corrosion treatment: Apply anti rust oil to the wiring terminals to prevent oxidation.

2. Lightning protection grounding failure

• phenomenonAfter lightning strike, the weighing scale cannot function properly or the instrument is damaged.
• reason：
  • The lightning protection grounding device is not installed or the grounding resistance is too high.
  • The grounding wire is broken or poorly connected.
• Solution：
  • Install lightning protection device: Install lightning protection module (such as surge protector) at the power inlet.
  • Check grounding: Use a grounding resistance tester to measure the grounding resistance and ensure it is ≤ 4 Ω.
  • Repair grounding wire: Replace the broken grounding wire to ensure a secure connection.

5、 Environmental interference fault

1. Temperature/humidity impact

• phenomenonSlow instrument startup or data drift in low-temperature environments, and sensor signal attenuation in high-temperature environments.
• reason：
  • The internal components of the instrument are sensitive to temperature (such as changes in capacitance and resistance values).
  • Poor sealing of the sensor and humidity caused a short circuit in the internal circuit.
• Solution：
  • Temperature control measures: Install a heater (low temperature environment) or a cooling fan (high temperature environment) inside the instrument box.
  • Moisture proof treatment: Fill the sensor junction box with moisture-proof agent or select waterproof sensors.

2. Vibration/shock interference

• phenomenonThe weighing data fluctuates greatly while the vehicle is in motion, or the instrument display is unstable.
• reason：
  • The foundation of the weighing scale is not isolated from vibration (such as being installed directly on a hard ground).
  • Frequent starting/braking of the vehicle generates impact.
• Solution：
  • Shock absorption treatment: Install shock absorbers (such as rubber pads) between the foundation of the weighing scale and the ground.
  • Speed limit: Set speed limit signs and require vehicles to drive at low speeds (≤ 5km/h).

6、 Daily maintenance suggestions

1. periodic calibrationConduct a comprehensive calibration every 6 months to ensure weighing accuracy.
2. Cleaning and maintenanceClean the surface debris of the scale body every week to prevent foreign objects from getting stuck in the sensor.
3. Check the wiringCheck the junction box and cable connections monthly, and tighten loose terminals.
4. Lightning protection testingInspect lightning protection grounding devices annually to ensure that the grounding resistance is qualified.
5. backup dataRegularly backup instrument parameters and weighing records to prevent data loss.