COMPRESSION LOAD CELLS IN AEROSPACE MAINTAINENCE
Lloyds Beal Lifting Equipment & Crane Specialists
24/07/2025
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The Challenge
Precise & Reliable Load Measurement
Lloyds Beal, a key supplier of ground support equipment to the aviation sector, approached us with a highly specialised requirement. They were developing a bespoke stress jacking system used during critical phases of aircraft maintenance. These systems needed to precisely apply heavy loads, ranging from 30 to over 110 tonnes, to specific points on the aircraft, enabling engineers to safely disassemble and reassemble vital structural components.
At the heart of their solution was a 55-tonne hydraulic ram. To ensure absolute control and safety, Lloyds Beal required real-time load feedback from each jack point. This meant integrating a digital load cell beneath every ram that could not only handle the significant forces involved, but also deliver accurate, repeatable readings under demanding conditions. The challenge was ensuring that the load cells could be tailored to the unique geometries of the jack assemblies and meet strict aerospace maintenance requirements.
Our Solution
CNC Compression Load Cells
Understanding the application’s criticality and the performance demands, we recommended our CNC Compression Load Cell. Known for its rugged build and low-profile design, the CNC is engineered for high-force applications where space is limited and reliability is paramount. Its stainless steel spring element, which is enclosed within a strong thick-walled case and sealed to IP65, made it well-suited to the environment and duty cycle expected in ground support operations.
We supplied 5 off 75t CNC Compression Load Cells for integration beneath each hydraulic ram. In addition, 5 PSDS digital indicators were provided to offer Lloyds Beal real-time visual feedback for each individual jack. Overall, the supplied units would ensure engineers could monitor and control applied loads with precision throughout the maintenance process.
Machining The Load Cells
Robust, Identical Components With Zero Imperfections
The machining process for the 3 components that comprise each load cell build saw raw
stainless steel billets
transformed into something exceptional
using our top of the range
Mazak Mill-Turn CNC machine. Dimensional tolerances were tightly controlled to ensure proper interfacing between the load cells and the hydraulic rams, especially considering the custom nature of Lloyds Beal’s jacking solution. As each load cell would be mounted in a unique location with slightly different design constraints,
attention to detail was vital. The result: 15 individually verified, visually stunning components ready for the next stage.
The Strain Gauging Process
Creating A Work Of Art Under The Microscope
Once machined, each load cell moved to our dedicated
strain gauging laboratory. Here, high quality
foil strain gauges were bonded to the spring elements, in positions that would ensure optimum sensitivity and accuracy - it's a process that requires meticulous preparation, steady hands, and a
controlled environment to avoid any contamination or misalignment. The strain gauges were then wired and tested for
continuity and signal integrity, before being
encapsulated for protection during operation.
Accurate Calibration
Full Traceability & Assurance
The final step was
calibration: all 5 load cells were calibrated to the highest standards in our
UKAS-accredited ISO 17025 laboratory.
This involved using our 5000kN hydraulic, servo-controlled test frame to accurately apply a series of 5 point 3 run load cycles, as well as custom-coded HBM catman software to capture the necessary readings. Comprehensive
calibration certificates were issued with each device, giving Lloyds Beal
full traceability and confidence in the performance of the system.
The Final Product
On-Time & Up To Scratch
The completed load cells and digital indicators were delivered on time with zero issues. According to Lloyds Beal, integration into their jacking system was seamless. The real-time feedback provided by our load cells allowed engineers to apply force with confidence and precision, which is critical when working around safety-critical aircraft components.
The system performed exactly as intended, with no anomalies reported during use. Our CNC Compression Load Cells proved once again why they’re trusted in high-stake applications, delivering performance, reliability, and adaptability when it matters most.
Joel Cousins
Director at Lloyds Beal
"Brilliant service and high quality product! Would use again and again!"
