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電阻應變式稱重傳感器是基于這樣一個原理：彈性體(彈性元件，敏感梁)在外力作用下產生彈性變形，使粘貼在他表面的電阻應變片(轉換元件)也隨同產生變形，電阻應變片變形后，它的阻值將發生變化(增大或減小)，再經相應的測量電路把這一電阻變化轉換為電信號(電壓或電流)，從而完成了將外力變換為電信號的過程。
由此可見，電阻應變片、彈性體和檢測電路是電阻應變式稱重傳感器中不可缺少的幾個主要部分。下面就這三方面簡要論述稱重傳感器工作原理。
稱重傳感器原理圖
一、傳感器電阻應變片
電阻應變片是把一根電阻絲機械的分布在一塊有機材料制成的基底上，即成為一片應變片。他的一個重要參數是靈敏系數K。我們來介紹一下它的意義。
設有一個金屬電阻絲，其長度為L，橫截面是半徑為r的圓形，其面積記作S，其電阻率記作ρ，這種材料的泊松系數是μ。當這根電阻絲未受外力作用時，它的電阻值為R：
R = ρL/S(Ω) (2—1)
當他的兩端受F力作用時，將會伸長，也就是說產生變形。設其伸長ΔL，其橫截面積則縮小，即它的截面圓半徑減少Δr。此外，還可用實驗證明，此金屬電阻絲在變形后，電阻率也會有所改變，記作Δρ。
對式(2--1)求全微分，即求出電阻絲伸長后，他的電阻值改變了多少。我們有：
ΔR = ΔρL/S + ΔLρ/S –ΔSρL/S2 (2—2)
用式(2--1)去除式(2--2)得到
ΔR/R = Δρ/ρ + ΔL/L – ΔS/S (2—3)
另外，我們知道導線的橫截面積S = πr2，則 Δs = 2πr*Δr，所以
ΔS/S = 2Δr/r (2—4)
從材料力學我們知道
Δr/r = -μΔL/L (2—5)
其中，負號表示伸長時，半徑方向是縮小的。μ是表示材料橫向效應泊松系數。把式(2—4)(2—5)代入(2--3)，有 ΔR/R = Δρ/ρ + ΔL/L + 2μΔL/L =(1 + 2μ(Δρ/ρ)/(ΔL/L))*ΔL/L = K *ΔL/L (2--6)
其中
K = 1 + 2μ +(Δρ/ρ)/(ΔL/L) (2--7)
式(2--6))說明了電阻應變片的電阻變化率(電阻相對變化)和電阻絲伸長率(長度相對變化)之間的關系。
需要說明的是：靈敏度系數K值的大小是由制作金屬電阻絲材料的性質決定的一個常數，它和應變片的形狀、尺寸大小無關，不同的材料的K值一般在1.7—3.6之間;其次K值是一個無因次量，即它沒有量綱。
在材料力學中ΔL/L稱作為應變，記作ε，用它來表示彈性往往顯得太大，很不方便
常常把它的百萬分之一作為單位，記作με。這樣，式(2--6)常寫作： ΔR/R = Kε (2—8)
二、稱重傳感器彈性體的原理
彈性體是一個有特殊形狀的結構件。它的功能有兩個，首先是它承受稱重傳感器所受的外力，對外力產生反作用力，達到相對靜平衡;其次，它要產生一個高品質的應變場(區)，使粘貼在此區的電阻應變片比較理想的完成應變棗電信號的轉換任務。
以托利多公司的SB系列稱重傳感器的彈性體為例，來介紹一下其中的應力分布。
設有一帶有肓孔的長方體懸臂梁。
肓孔底部中心是承受純剪應力，但其上、下部分將會出現拉伸和壓縮應力。主應力方向一為拉神，一為壓縮，若把應變片貼在這里，則應變片上半部將受拉伸而阻值增加，而應變片的下半部將受壓縮，阻值減少。下面列出肓孔底部中心點的應變表達式，而不再推導。
ε = (3Q(1+μ)/2Eb)*(B(H2-h2)+bh2)/ (B(H3-h3)+bh3) (2--9)
其中：Q--截面上的剪力;E--揚氏模量：μ—泊松系數;B、b、H、h—為梁的幾何尺寸。
需要說明的是，上面分析的應力狀態均是“局部”情況，而應變片實際感受的是“平均”狀態。
三、檢測電路原理
檢測電路的功能是把電阻應變片的電阻變化轉變為電壓輸出。因為惠斯登電橋具有很多優點，如可以抑制溫度變化的影響，可以抑制側向力干擾，可以比較方便的解決稱重傳感器的補償問題等，所以惠斯登電橋在稱重傳感器中得到了廣泛的應用。
因為全橋式等臂電橋的靈敏度最高，各臂參數一致，各種干擾的影響容易相互抵銷，所以稱重傳感器均采用全橋式等臂電橋。
其實稱重傳感器原理上就是壓力傳感器，形狀不一樣而已，通常有很多種方法傳感的，但我見到，用得比較多，比如地磅用的那些，一般為電渦流式。
也就是說，他有一個電渦流觸發繞組，然后還有一個傳感器感應電渦流強度。
由于這個傳感器整體是金屬封裝，電渦流在其內部，受到壓后形變，渦流就發生變化，放大后就可以讀到數據了。
然后，封裝這個東西的材料，通常選用剛性材料， 總之，就是一般的金屬，比如鋼，但肯定不會用很軟的東西的。至少電渦流方式傳感的壓力傳感器，是不會用軟金屬制造的。
因為即使是鋼，就算受到壓力形變那么幾微米，那么電渦流的變化也足夠感應出到底變化了多少而且如果是軟金屬，稱很重東西的時候，可能很容易出問題。
稱重傳感器的使用知識
隨著技術的進步,由稱重傳感器制作的電子衡器已廣泛地應用到各行各業,實現了對物料的快速、準確的稱量，特別是隨著微處理機的出現，工業生產過程自動化程度化的不斷提高，稱重傳感器已成為過程控制中的一種必需的裝置，從以前不能稱重的大型罐、料斗等重量計測以及吊車秤、汽車秤等計測控制，到混合分配多種原料的配料系統、生產工藝中的自動檢測和粉粒體進料量控制等，都應用了稱重傳感器，目前，稱重傳感器幾乎運用到了所有的稱重領域。
本系統由微機控制稱重傳感器的稱重和比較，并輸出控制信號，執行定值稱量，控制外部給料系統的運轉，實行自動稱量和快速分裝的任務。
系統采用MCS-51單片機和V/F電壓頻率變換器等電子器件，其硬件電路框圖如圖1所示，用8031作為中央處理器，BCD拔碼盤作為定值設定輸入器，物料裝在料斗里，其重量使傳感器彈性體發生變形，輸出與重量成正比的電信號，傳感器輸出信號經稱重變送器放大后，輸入V/F轉換器進行A/D轉換，變送成的頻率信號直接送入8031微處理器中，其數字量由微機進行處理。微機一方面把物重的瞬時數字量送入顯示電路，顯示出瞬時物重，另一方面則進行稱重比較，開啟和關閉加料口和變送器，放料于箱中等一系列的稱重定值控制。
傳統概念上，負荷傳感器是稱重傳感器、測力傳感器的統稱，用單項參數評價它的計量特性。舊國標將應用對象和使用環境條件完全不同的“稱重”和“測力”兩種傳感器合二為一來考慮，對試驗和評價方法未給予區分。舊國標共有21項指標，均在常溫下進行試驗;并用非線性、滯后誤差、重復性誤差、蠕變、零點溫度附加誤差以及額定輸出溫度附加誤差6項指標中的最大誤差，來確定稱重傳感器準確度等級，分別用0.02、0.03、0.05......1.0表示。
稱重傳感器的原理是在被測物體上的重力按一定比例轉換成可計量的輸出信號。考慮到不同使用地點的重力加速度和空氣浮力對轉換的影響，稱重傳感器的性能指標主要有線性誤差、滯后誤差、重復性誤差、蠕變、零點溫度特性和靈敏度溫度特性等。在各種衡器和質量計量系統中，通常用綜合誤差帶來綜合控制傳感器準確度，并將綜合誤差帶與衡器誤差帶(圖1)聯系起來，以便選用對應于某一準確度衡器的稱重傳感器。國際法制計量組織(OIML)規定，傳感器的誤差帶δ占衡器誤差帶Δ的70%，稱重傳感器使用知識的線性誤差、滯后誤差以及在規定溫度范圍內由于溫度對靈敏度的影響所引起的誤差等的總和不能超過誤差帶δ。這就允許傳感器制造廠對構成計量總誤差的各個分量進行調整，從而獲得期望的準確度。
剪切梁式稱重傳感器原理是彈性體受力的作用后，需要測量的不是其正應力，而是由剪切力引起的切應力。但切應力本身是測量不出來的，它只能產生于與工字梁中心軸 線成45“的互相垂直的主應力，也就是產生于由切應力而引起的拉伸應力及壓縮應力。因此，將4片應變計分別貼在工字梁腹板的兩面，并與中心軸線成45。的 相互垂直的位置上，如圖1所示。這4個應變計組成全橋，當傳感器承受載荷時，應變計R,,R3的電阻值增大，R2,R;的電阻值減小，其結果在電橋的對角 線上產生與載荷成正比的不平衡輸出。利用這一原理，便可測出力或載荷的大小。
2005年期間，某電廠#4爐給煤機稱重傳感器故障率較高，有一個傳感器輸出信號超出使用范圍0-30mV，有一個輸出信號時而超出使用范圍，時而在正常范圍內，最近，又有兩個稱重傳感器輸出信號不隨稱重變化發生明顯變化的現象，工作人員認為問題比較嚴重，做初步分析，可能原因如下：
該時期機組負荷高，煤質差，煤量大，給煤機稱重傳感器長時間處在高負載的運行工況下，同時給煤機內部濕度較大，有時溫度稍高，可能超過60℃(稱重傳感器工作溫度不超過60℃)，不同程度影響使用壽命。
從#4爐密封風機改造后，故障率比改造前明顯增加，懷疑改造后給煤機內部工作環境發生變化，影響稱重傳感器的使用壽命。
經咨詢廠家，建議將給煤機內部的出煤擋板降低，減少出煤量，稱重傳感器負載相對降低，為保證目標給煤量，給煤機的轉速自然會提高，將目前的高負載低轉速改為低負載高轉速運行方式，會延長重量傳感器的使用壽命。
該電廠采取的措施是將壞稱重傳感器切除，維持單只給煤機傳感器運行。
#4機組小修進入第2天，認真進行鍋爐熱風門執行機構檢修和給煤機稱重傳感器更換工作，截止目前，三臺磨煤機熱風門執行機構全部拆除完畢，A1、A2給煤機4臺稱重傳感器更換接線完畢，B1給煤機2臺稱重傳感器已經更換，B2給煤機拆除2臺原稱重傳感器。
三臺熱風門執行機構位于12米平臺下方，位置狹小，灰塵多，光線暗，檢修小組克服困難，首先在集控室將熱風門全部關閉，然后通過爬梯到達檢修場地，清掃積聚的灰塵，打開定位器端蓋，記錄接線端子編號與對應的端子，解除接線用絕緣膠布包好，拆除氣源管路，用白膠布包好敞開的管口，松開固定底座上的四個螺絲并保管好，抬好執行機構并使之脫離底座，用準備好的繩索系牢靠后，慢慢下放到地面，最后用三輪車拉到辦公樓，克服執行機構笨重等困難，一鼓作氣抬到二樓檢修間進行檢修。
給煤機稱重傳感器更換工作進展順利，首先清除煤灰，拆開保護罩，松開銷子和壓緊螺絲帽，去除稱重托輥，接著松開固定傳感器的四個螺絲，特別是靠近皮帶的里側2個螺絲，由于生銹特別難拆，尤其是接近下班時間，看不到螺絲，手電因為已經使用一天不能發亮，只能憑手感覺，本著高度的責任心和高超的技能，盡管煤粉弄黑了衣袖和雙手，松動劑帶著煤粉刺了一身，大家沒有一句怨言，沒有一個退卻，心中只有一個信念：更換給煤機傳感器，讓入爐煤計量準確，以便為供電煤耗等指標的計算提供可靠依據。
