A wire rope load cell system is a specialized force measurement solution designed to monitor tension or load in wire ropes (also called steel wire cables) used in cranes, hoists, elevators, suspension bridges, mooring systems, and other lifting or tensioning applications. Unlike traditional load cells that measure compression or tension in a single direction, wire rope load cells are clamped or integrated directly onto the wire rope to measure real-time tensile forces without cutting or terminating the rope.
Key Components of a Wire Rope Load Cell System
Component
Description

1. Clamp-on Load Sensor (Load Pin or Saddle-Type)
The core sensing element. It clamps around the wire rope and uses strain gauges to detect deformation caused by tension.
2. Wire Rope
The load-bearing cable (6×19, 6×36, rotation-resistant, etc.). Diameter typically 8–60 mm.
3. Signal Conditioning Unit
Amplifies and converts the sensor’s mV signal into 4–20 mA, 0–10 V, or digital output (RS485, CAN, Modbus).
4. Display/Indicator
Local or remote digital display showing real-time load in kg, tons, or kN.
5. Data Logger / PLC Integration
For overload alarms, data recording, and integration with SCADA or crane control systems.
6. Overload Protection Relay
Triggers alarms or stops operation if safe working load (SWL) is exceeded.
Types of Wire Rope Load Cells

Mechanism
Best For
Clamp-on Saddle Type
Two half-shells clamp around rope; strain gauges on saddle
Easy retrofit, non-intrusive
Load Pin (Sheave Pin)
Replaces existing pulley pin with instrumented pin
High accuracy, permanent install
Running Line Tensiometer
Rope passes through three pulleys; middle pulley measures force
Dynamic lines, winches
Dead-End Socket Sensor
Sensor at rope termination (socket or wedge)
Fixed-end applications
How It Works (Clamp-on Type Example)

The load cell is clamped around the live section of the wire rope.
As tension increases, the rope slightly deforms the sensor body.
Bonded strain gauges in a Wheatstone bridge configuration detect micro-strains.
Output: ~2 mV/V at full load → amplified to standard signal.
System displays actual load and can trigger overload cutoff.
Accuracy: ±1% to ±2% of full scale (FS)
Capacity Range: 1 ton to 200+ tons per rope
Rope Diameter Compatibility: 8 mm to 90 mm (custom available)
Advantages

✅ Benefit
Description
Non-intrusive
No need to cut or replace rope
Easy Installation
10–15 minutes with basic tools
Real-time Monitoring
Prevents overload, extends rope life
Safety Compliance
Meets ISO 4309, ASME B30, LOLER, EN 13889
Retrofit Friendly
Ideal for older cranes without built-in load sensing
Typical Applications

Industry
Use Case
Cranes
Tower, mobile, overhead cranes (anti-two-block, SWL monitoring)
Elevators
Rope tension balancing, overload detection
Marine
Anchor winches, mooring lines, davit cranes
Mining
Hoist ropes, draglines
Construction
Pile driving, material lifts
Entertainment
Stage rigging, flying systems
Installation Tips (Clamp-on Type)
Select correct model for rope diameter and construction.
Clean rope surface (remove grease, rust).
Position sensor on straight section (avoid bends or sheaves).
Torque clamp bolts evenly to manufacturer specs.
Calibrate using known test weight or shunt calibration.
Route cable away from moving parts.
Warning: Never install on rotating or spinning rope sections.
Standards & Safety Factors
Parameter
Typical Value
Safety Factor (SF)
5:1 to 10:1 (depending on application)
Proof Load
200% of rated capacity
IP Rating
IP67/IP68 (waterproof, dustproof)
Temperature Range
-20°C to +80°C (standard), -40°C to +120°C (optional)
Example System Specification (10-ton Crane Rope)
Item
Spec
Rope Diameter
16 mm
Load Cell Type
Clamp-on saddle
Capacity
0–15 tons
Output
4–20 mA
Accuracy
±1% FS
Display
Digital panel meter with relay output
Alarm Setpoint
90% SWL (9 tons) → Warning110% SWL → Shutdown
Leading Manufacturers (India & Global)
Brand
Country
Notes
Eilon Engineering (Ron Crane Scales)
Israel
High accuracy, wireless options
Straightpoint (Crosby)
UK
Radiolink plus, Bluetooth app
Magtrol
Switzerland
High-end systems
Sensy
Belgium
ATEX versions for hazardous areas
Load Cell Systems
USA
Custom clamp-on designs
Inland Industrial (India)
India
Cost-effective, IS-certified
Sushma Industries (India)
India
OEM supplier, good support
Cost Estimate (India, 2025)
Capacity
Type
Approx. Price (INR)
5–10 tons
Clamp-on
₹45,000 – ₹75,000
20–50 tons
Load pin
₹1,20,000 – ₹2,50,000
Full System (with display + relay)
—
₹80,000 – ₹3,50,000
Prices vary by brand, certification, and wireless features.
Maintenance & Calibration
Visual inspection: Monthly (check clamps, cable damage)
Zero check: Before each shift
Full calibration: Annually or after overload event
Use certified test weights or shunt calibration
Need a Custom Solution?
If you’re in India, local suppliers like Sushma, Load Master, or Interface Force can provide:
On-site installation
Integration with PLC/HMI
Wireless data transmission
NABL traceable calibration
Want a datasheet or supplier recommendation for your specific rope diameter and crane type?
Reply with:
Rope diameter (mm)
Max load (tons)
Crane type (tower/mobile/overhead)
Output needed (analog/digital/wireless)
I’ll give you a ready-to-buy system config.