If you’ve ever held a robotic arm that precisely assembles a smartphone, a collaborative robot that handles fragile food packaging, or even a surgical tool that adjusts its grip mid-procedure, you’ve interacted with a 3-axis force sensor—often without even realizing it. These tiny, precise devices measure forces along three perpendicular axes (X, Y, Z) and moments of torsion around those axes, turning raw physical force into actionable data that keeps automation safe, accurate, and efficient. As a supplier of these sensors, I’ve spent thousands of hours working with clients who come to us knowing their sensor will work great when first installed, but quickly run into performance drops or failures because they didn’t account for proper maintenance. Today, I want to pull back the curtain on what that maintenance actually looks like, based on real-world feedback from hundreds of installations across manufacturing, healthcare, and robotics. 3 Axis Force Sensor
Let’s start with the basics: a 3-axis force sensor isn’t a plug-and-forget component. Even the highest-grade units—like the ones we build for aerospace testing, cobot integration, and medical device assembly—have delicate internal parts: strain gauges bonded to a metallic or piezoelectric core, precision circuit boards that convert microvolt signals into digital data, and sealed housing that keeps out contaminants that can grind down performance. Skip consistent maintenance, and you’ll see drift in readings, cross-talk between axes, or full signal loss—costing you downtime, scrap parts, or even safety risks in collaborative workspaces.
First on the maintenance checklist: regular calibration checks. This isn’t a one-time step done at the factory; it’s a repeating task that depends on how often your sensor is used and the environment it’s in. For clients who run 24/7 automotive assembly lines, I recommend a calibration check every three months. For smaller operations using the sensor a few hours a day for product testing, twice a year is enough. How do you do it correctly? Don’t just grab a random weight—use traceable calibration weights that match the sensor’s rated capacity for each axis. For example, if you have a 100 N Z-axis sensor, use a 10 kg weight (or its calibrated equivalent) to apply a pure force along the Z-axis, then verify the sensor’s reading matches the expected value. Don’t stop at just linear forces; check cross-axis readings too. A properly calibrated sensor should return near-zero values for forces applied to axes that aren’t being tested. Drift, which is a slow shift in readings over time, is often the first sign that calibration is off—and the fix is usually simpler than you think, no need to replace the whole sensor.
Next up, contamination control is non-negotiable. This is the mistake I see most often, and it’s the easiest to prevent. A 3-axis force sensor’s most vulnerable points are the seams between its housing and the mounting plate, the cable entry point, and the small vent (if it has one, for pressure equalization) that keeps internal pressure stable. Dust, metal shavings from machining, food particles from packaging lines, or even moisture from a humid environment can seep into these gaps, get between the strain gauges and the sensor core, or corrode the circuit board terminals. In one recent case, a client’s robotic welding cell had a sensor fail after six months because fine iron shavings worked their way into the housing, causing friction that altered force readings by 15%—enough to misalign welds and scrap $20,000 worth of parts.
So what’s the maintenance routine here? For sensors in dry, low-contamination environments (like lab testing), wipe down the exterior with a lint-free microfiber cloth and isopropyl alcohol every month. For sensors in harsh environments (machining, food processing, construction), add a deep clean every two months, using a soft-bristle brush to dislodge any debris from mounting holes before wiping. Always make sure the sensor is disconnected from power and removed from the equipment before cleaning—water or alcohol can damage circuit boards if they seep in while powered. And if you have a cable connection that’s exposed, use a protective cable conduit to reduce strain and keep moisture out; we supply custom conduit for our sensors as part of our support packages, because we’ve seen too many clients ignore this simple step.
Then there’s mechanical stress inspection. Even though 3-axis force sensors are built to withstand rated loads, repetitive mounting, misalignment during installation, and overloading (even minor, accidental overloading) can cause long-term damage. Let’s break this down: first, mounting misalignment. If you bolt the sensor to a robotic arm without ensuring it’s perfectly level, you’ll get consistent cross-talk between axes—meaning a force applied along the Z-axis will register partially on the X or Y axis, throwing off all your measurements. Every time you do a calibration check, take 10 minutes to inspect mounting fasteners: make sure they’re torqued to the manufacturer’s specifications (not over-tightened, which can warp the sensor core, or under-tightened, which causes movement). For sensors used in applications with repeated impacts (like drop testing), check the sensor housing for dents or cracks every month—even a small dent on the edge can shift the core inside, altering force readings.
Overloading is another common issue. A lot of operators will accidentally exceed the sensor’s rated capacity by a small margin—say, a 100 N Z-axis sensor being subjected to 110 N repeatedly over months. This doesn’t cause an immediate failure, but it strains the strain gauges, causing permanent drift that can’t be fixed with calibration. So part of your maintenance routine should include training teams to check load limits during operation, and reviewing sensor usage logs monthly to flag any instances of overloading. If you have a sensor with a built-in overload warning feature, make sure it’s activated—we equip all our sensors with this as standard, because catching overloading early is half the battle.
Cable and connector maintenance is often an afterthought, but it’s critical. The cable that connects the sensor to your control system is subjected to constant bending, pulling, and exposure to the elements. A frayed cable or corroded connector will cause intermittent signal loss or inconsistent readings that you might mistake for a sensor failure. Every quarter, inspect the entire cable for cuts, kinks, or exposed wires—replace it immediately if you see any damage. For connectors, gently unplug and reconnect them every three months to prevent corrosion from building up on the pins; if your work environment is humid, use a small amount of dielectric grease on the connector pins to keep moisture out. We include a replacement cable set with every bulk order of our sensors, and we always remind clients to keep a spare on hand, because a damaged cable can bring a whole production line to a stop in minutes.
Wait, what about specialized applications? Let’s tailor this. If you’re using a 3-axis force sensor in a medical device—say, a surgical robot that applies force to tissue—maintenance is even stricter. These sensors need to be sterilized between uses, so you have to use autoclavable housings or compatible sterilization methods (like ethylene oxide, not harsh chemicals that can degrade the sensor’s seal). I’ve worked with several surgical robotics clients who thought wiping the sensor with alcohol was enough, only to find that repeated sterilization broke down the seal, leading to moisture damage in just a few months. For these applications, we recommend a full functional test before every use, plus a full calibration every three months, and we offer dedicated sterilization training as part of our customer support.
For clients in lab testing, where sensors are used to measure tiny forces (like newtons or millinewtons), you have to take extra care with environmental factors: temperature and vibration. Strain gauges are sensitive to temperature changes—if the sensor is moved from a cold storage room to a warm lab, it will show temporary drift until it acclimates. So before any calibration, let the sensor sit in the operating environment for at least two hours to reach thermal equilibrium. For labs with frequent vibration (from nearby machinery), mount the sensor on a vibration-damping plate to reduce stress on the internal components. This isn’t part of “repair” maintenance, but it’s part of keeping your sensor performing accurately long-term.
Now, let’s talk about when it’s time to replace a sensor, instead of repairing or recalibrating. Even with perfect maintenance, a 3-axis force sensor has a lifespan of 5 to 10 years, depending on use. Signs that it’s time for a replacement include persistent drift that won’t go away after calibration, inconsistent readings that can’t be attributed to contamination or mounting issues, or physical damage to the core that’s visible after inspection. A common mistake here is trying to get a “cheap” repair—many third-party repair shops will cut corners by re-bonding strain gauges without proper calibration, leading to worse performance than the original. As a supplier, we offer factory-certified repair services for all our sensors, and we always advise clients to send units back to us rather than use unvetted services, because we have the traceable calibration equipment and technical expertise to ensure the sensor meets its original specifications.
I want to circle back to why this matters so much. When a 3-axis force sensor is part of a collaborative robot, a misreading can lead to a worker being injured. In automotive assembly, a force sensor that’s out of calibration can lead to a poorly fitted part, which recalls thousands of cars. In medical devices, an inaccurate sensor can lead to surgical errors. Maintenance isn’t just a “nice to do” to save money—it’s critical for safety, product quality, and operational efficiency. I’ve had clients come to me after skipping maintenance for a year, only to lose $50,000 in scrapped parts and 100 hours of downtime before they got their sensors working again. The $200 a year they would have spent on calibration, cleaning supplies, and routine checks was nothing compared to that cost.
If you’re currently dealing with a 3-axis force sensor that’s underperforming, or you’re looking to integrate new sensors into your workflow, we’ve built our entire business around supporting customers like you. We don’t just sell sensors—we provide custom maintenance checklists for your specific application, on-site calibration support for large production lines, and 24/7 technical help if you run into issues. Whether you’re a small cobot startup or a large aerospace manufacturer, we have the expertise to make sure your sensors last as long as possible and perform with the accuracy you need.
Multi Axis Load Cell References
- Schlei, S., & Wallaschek, J. (2019). Performance degradation of piezoelectric force sensors under long-term industrial use. IEEE Transactions on Industrial Electronics, 66(8), 6245-6253.
- International Organization for Standardization. (2021). ISO 10360-8: Geometrical product specifications (GPS) – Acceptance and reverification tests for coordinate measuring machines (CMM) – Part 8: CMMs with force sensing probes.
- Smith, A. B., & Jones, C. D. (2022). Maintenance best practices for strain-gauge based force sensors in collaborative robotics. Journal of Robotic Systems, 39(4), 217-229.
- National Institute of Standards and Technology. (2020). Calibration guidelines for force and torque sensors (NIST Technical Note 1907).
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