Why it is important to use the right materials for car scales: a real example from Lithuania

Truck scales are equipment that operates in some of the most challenging conditions – outdoors, in humidity, dirt, temperature fluctuations, vibrations and constant load. Therefore, every detail , even as simple as the sensor junction box, directly determines the durability and measurement accuracy of the entire system.

Unfortunately, there are still cases on the market where installers save on materials and use household, indoor boxes instead of hermetic components. In this article, we present a real example of why such savings ultimately cost the customer several times more.

Real-world situation: a simple leaky electrical box outdoors

In the photo you can see the assembled analog sensor junction box. It:

• not sealed;

• has cracked, damaged areas;

• does not have the appropriate IP protection class;

• not suitable for outdoor use and humidity;

• wires inserted through leaky plastic;

• Condensation, dirt and oxides accumulate inside.

This is a classic example of how unsuitable materials cause systemic problems that the customer does not notice until the scale stops working.

What problems do improper junction boxes cause?

1. Moisture ingress into signal cables

When the box is not sealed, rain, condensation and dirt get into the connections. Moisture causes:

• oxidation,

• abbreviations,

• sensor signal noise,

• incorrect readings.

This is especially sensitive to analog systems.

2. Sensor fluctuations and erroneous measurements

Damaged connections often lead to problems that customers describe as follows:

• "The readings are jumping."

• "The scales are showing minus."

• "We asked the service, and they said it needed to be calibrated."

Meanwhile, the real cause is moisture in the junction box .

3. Frequent service calls

A cheap box "save" the installer 10-15 euros, but for the customer:

• failures are recurring;

• requires regular inspections;

• The scales are stagnant, and the business is incurring losses.

Service costs ultimately exceed the cost of several professional components.

4. Shorter sensor life

Sensors that operate with constantly wet connections fail faster, which means higher operating costs and unnecessary investments.

What should the right decision look like?

Professional junction boxes for car scales must be:

• IP67 or IP68 sealing classes;

• resistant to UV rays and chemicals;

• with metal or high-quality sealing sleeves;

• adapted to temperature fluctuations;

• with hermetic cable entries;

• with rust-resistant inner plate.

Such boxes protect sensor signals, so the scales work stably and accurately.

Why we invest to quality, while competitors don't always?

KEMEK Engineering has been working with industrial scale systems for over 30 years. Our goal is not only to install the scales, but also to ensure that they operate without interruption for 10-20 years .

That's why we don't use domestic components. Because that's not saving money - it's creating problems.

What should an IP68 protection class junction box look like? (Mettler Toledo example)

Main symptoms:

• Hermetic housing made of stainless steel or UV-resistant polycarbonate.

• Silicone gasket around the entire lid.

• Professional metal cable seals.

• High resistance to moisture, cold and corrosion.