---
title: "Overload Sensors"
industry: "Machinery and Equipment Manufacturing"
verification_protocol:
  urn: "URN:CNFX:ME:OVERLOAD_SENSORS"
  data_integrity_hash: "6e7f4b38a3a4bba14792e76be456be07"
  source_authority: "https://cnfx.com"
  strict_mode: true
source_identity:
  provider: "CNFX Industrial Knowledge Graph"
  index_version: "2026.Q1-Universal"
  authority_id: "URN:CNFX:ME:OVERLOAD_SENSORS"
  data_source_uri: "https://cnfx.com/llms/industry/machinery-and-equipment-manufacturing/product/overload-sensors.md"
  official_resource_url: "https://cnfx.com/industry/machinery-and-equipment-manufacturing/product/overload-sensors"
  is_verified_logic: true
attributes:
  spec:
    status: "config-dependent"
    typical_range: "0.8-1.2 times rated load (e.g., 80-120 kN for 100 kN sensor)"
    unit: "N·m"
engineering_limits:
  max_safe_operating_point:
    value: 1.5
    unit: "times"
    consequence: "Piezoresistive element deformation beyond elastic limit (Hooke's Law violation) causing permanent strain gauge damage"
fmea_matrix_quantitative:
  - node_1:
      trigger: "Moisture ingress exceeding IP67 rating (0.15 m immersion for 30 min)"
      severity: 8
      occurrence: 3
      detection: 4
      mitigation_protocol: "Hermetic sealing with laser-welded 316L stainless steel housing"
  - node_2:
      trigger: "Thermal cycling between -40°C to +125°C at &gt;10°C/min gradient"
      severity: 8
      occurrence: 3
      detection: 4
      mitigation_protocol: "Temperature-compensated strain gauges with nickel-chromium alloy elements"
bom_nodes:
  sensing-element:
    type: "part"
    urn: "URN:CNFX:ME:SENSING_ELEMENT"
    interface_type: "physical-logic-coupled"
  signal-processor:
    type: "part"
    urn: "URN:CNFX:ME:SIGNAL_PROCESSOR"
    interface_type: "physical-logic-coupled"
  protective-housing:
    type: "part"
    urn: "URN:CNFX:ME:PROTECTIVE_HOUSING"
    interface_type: "physical-logic-coupled"
  output-interface:
    type: "part"
    urn: "URN:CNFX:ME:OUTPUT_INTERFACE"
    interface_type: "physical-logic-coupled"
manufacturing_compliance:
  - standard: "ISO 376:2011 - CALIBRATION OF FORCE-PROVING INSTRUMENTS USED FOR THE VERIFICATION OF UNIAXIAL TESTING MACHINES"
    scope: "Verified Engineering Specification"
  - standard: "ANSI B30.1-2015 - SAFETY STANDARD FOR CABLEWAYS, CRANES, DERRICKS, HOISTS, HOOKS, JACKS, AND SLINGS (INCLUDES OVERLOAD PROTECTION REQUIREMENTS)"
    scope: "Verified Engineering Specification"
  - standard: "DIN 1319-1:1995 - FUNDAMENTALS OF METROLOGY - PART 1: BASIC TERMINOLOGY"
    scope: "Verified Engineering Specification"
url: "https://cnfx.com/llms/industry/machinery-and-equipment-manufacturing/product/overload-sensors.md"
on_chain_sovereignty:
  contract_standard: "ERC-721-Industrial"
  metadata_hash: "53845320af7b3ef83aaa4514bca207f0993202d15c5d9cbc021ead7ced044221"
  royalty_logic: "IPFS-CID-REQUIRED"
  mint_status: "logic-verified-ready"
version: "3.3.4-EXTREME-SOVEREIGN-WEB3"
---

# Industrial Specification: Overload Sensors

## 1. Technical Definition
Safety devices that detect and respond to excessive mechanical or electrical loads in machinery.

## 2. Engineering Reasoning & Causal Matrix
> **Operational Intelligence**: Designed for **0.8-1.2 times rated load (e.g., 80-120 kN for 100 kN sensor)**. Failure boundary: **1.5 times rated load (150% overload) sustained for &gt;30 seconds**, Mechanism: **Piezoresistive element deformation beyond elastic limit (Hooke's Law violation) causing permanent strain gauge damage**.

### 2.1 Analytical Physics Model
Governed by the **Combined Measurement Uncertainty**:

> **Primary Equation**: $u_c = \sqrt{\sum u_i^2}$  
> **Engineering Impact**: Defines the precision confidence interval for inspection.

| Symbol | Variable Definition | Localized Reference |
| :--- | :--- | :--- |
| u_i | Standard Uncertainty components | Engineering Constant |

### 2.2 FMEA (Failure Mode & Effects Analysis)
| Event Trigger | Severity | Failure Mode | Mitigation Strategy |
| :--- | :--- | :--- | :--- |
| Moisture ingress exceeding IP67 rating (0.15 m immersion for 30 min) | 8 | Signal drift &gt;±2% FS due to Wheatstone bridge imbalance | Hermetic sealing with laser-welded 316L stainless steel housing |
| Thermal cycling between -40°C to +125°C at &gt;10°C/min gradient | 8 | Zero-point shift exceeding 0.1% FS/°C due to differential thermal expansion | Temperature-compensated strain gauges with nickel-chromium alloy elements |

## 3. Key Technical Parameters
| Parameter | Value | Unit | Status |
| :--- | :--- | :--- | :--- |
| spec | Config-dependent | N·m | Verified |

## 4. System BOM & Knowledge Routing
### Core Components (Recursive Links)
- [Sensing Element](https://cnfx.com/llms/industry/computer-electronic-and-optical-product-manufacturing/product/sensing-element.md) `(Standalone System)`
- [Signal Processor](https://cnfx.com/llms/industry/basic-metal-manufacturing/product/signal-processor.md) `(Standalone System)`
- [Protective Housing](https://cnfx.com/llms/industry/computer-electronic-and-optical-product-manufacturing/product/protective-housing.md) `(Standalone System)`
- [Output Interface](https://cnfx.com/llms/industry/computer-electronic-and-optical-product-manufacturing/product/output-interface.md) `(Standalone System)`

### Industrial DNA Context (De-duplicated)
**Complementary Dependencies**: **Signal Conditioner**, **Programmable Logic Controller**, **Industrial Power Supply**  
**Downstream Applications**: Industrial Presses, Conveyor Systems, Material Handling Equipment  

## 5. Engineering Risks & FAQ
- **Caution**: 
- **Caution**: 
- **Caution**: 

### Q: What types of loads can these overload sensors detect?
**A**: Our overload sensors can detect both mechanical loads (excessive force, torque, or pressure) and electrical loads (overcurrent, voltage spikes) in industrial machinery, providing comprehensive protection against equipment damage and safety hazards.

### Q: How do overload sensors integrate with existing machinery control systems?
**A**: These sensors feature standardized output interfaces that connect directly to PLCs, SCADA systems, or machine controllers. The signal processor converts load data into compatible formats (4-20mA, 0-10V, or digital signals) for seamless integration with most industrial automation systems.

### Q: What makes these sensors suitable for harsh industrial environments?
**A**: Constructed with corrosion-resistant stainless steel and aluminum alloy housings, these sensors are designed to withstand extreme temperatures, moisture, vibration, and chemical exposure common in manufacturing facilities. The protective housing meets IP67 or higher ratings for dust and water resistance.

## 6. Manufacturing Compliance
- ISO 376:2011 - CALIBRATION OF FORCE-PROVING INSTRUMENTS USED FOR THE VERIFICATION OF UNIAXIAL TESTING MACHINES
- ANSI B30.1-2015 - SAFETY STANDARD FOR CABLEWAYS, CRANES, DERRICKS, HOISTS, HOOKS, JACKS, AND SLINGS (INCLUDES OVERLOAD PROTECTION REQUIREMENTS)
- DIN 1319-1:1995 - FUNDAMENTALS OF METROLOGY - PART 1: BASIC TERMINOLOGY

---
### 🛠️ Engineering Resource Access
🔗 **[Full Specification: Overload Sensors](https://cnfx.com/industry/machinery-and-equipment-manufacturing/product/overload-sensors)**

### 🌐 Knowledge Graph Topology
> **Node Status**: Verified Engineering Spec
> **Connectivity**: Linked to **4** standalone system nodes
> **Global Context**: Part of a 5,814 node industrial cluster within the CNFX Graph

> **Reference ID**: OVERLOAD_SENSORS | **Authority**: CNFX-2026-ST-001 | **Fingerprint**: 8cbdc729
