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Wireless Load Cell and Mass Balance Monitoring
A mains-powered industrial weighing and load-balance monitor. It continuously measures the force on a set of load cells, works out the applied weight, and sends that reading wirelessly to a receiver that displays it and passes it on to a cloud dashboard. Once powered it runs on its own indefinitely and restarts automatically after any power interruption, which makes it well suited to silo and hopper inventory, tank contents and general industrial weighing.
Readings reach the cloud over a licence-free long range radio link and low power wide area networks.
Measurement
Load cells sit under the structure being weighed and are combined so their signals average into one output. Each cell produces a tiny voltage proportional to the force on it; that signal is amplified, filtered and digitised many times over, then averaged to suppress electrical noise for a clean, stable reading. The system also watches for faults: a channel sitting at the top of its range is treated as disconnected and ignored, and a channel down in the offset region is read as no-load, or zero. Several channels are read every cycle and the middle value is taken as the trustworthy reading, so this best-of-three approach rejects a single misbehaving or disconnected cell automatically and one bad cell cannot skew the result.
Calibration
Weight is derived from a reference point established on site: a known load sets a known signal level, and the cells' rated span sets the straight line relationship between signal and weight. Below the no-load point the reading is clamped to zero, so an empty or slightly drifting structure never shows negative or phantom weight. No-load reads about zero, the reference load reads its true value, and everything in between follows the straight line. A simple double power-cycle starts a zeroing routine, and the zero settings are stored permanently so they survive resets and power loss.
Wireless link, receiver and display
Readings are transmitted on a licence-free radio band at a fixed, long range setting chosen for reliability over raw speed, at the maximum legal power for the region. Each reading is sent several times so it reliably reaches the receiver, in a form the receiver reads directly. The receiver checks that each message came from the right sender and is well formed, converts the values to weight per cell plus a total, shows them on its own display, and streams them out for logging with signal-strength and quality indicators. Operator tools can scan for the transmitter, flag configuration mismatches, and inject a test reading to confirm the weight calculation with no hardware attached. From there the data is forwarded to the cloud dashboard.
Running behaviour
| [ Reporting ] | Fast reporting every 30 seconds for the first five minutes after start-up, so an installer gets immediate feedback, then a low-traffic production rhythm every 30 minutes, kept up indefinitely. |
| [ Self-healing ] | An internal watchdog resets the unit if it ever hangs, and the reporting timing is arranged so the safety timer never trips during normal quiet periods. |
| [ Link recovery ] | If the radio link is lost or misconfigured, the unit keeps re-establishing and re-configuring it in the background until communication is restored. |
| [ Calibration trigger ] | A double power-cycle starts a zeroing routine, and the zero settings are stored permanently and survive resets and power loss. |
In short: load on the cells becomes an amplified, cleaned-up signal, then a best-of-three trusted reading, then a calibrated weight, sent reliably over radio in readable form, shown on the receiver and pushed to a dashboard, running unattended and recovering from faults on its own.
Applications
| Inventory by weight | Silo and hopper contents, bulk bags and feed bins where weight is a more reliable measure than surface level. |
|---|---|
| Tank contents | Water and liquid tanks measured by mass on load cells or beams. |
| Industrial weighing | Remote or distributed weighing points reporting back to a single dashboard. |
Deploy a monitoring system
We size, supply, install and support the system for your site. Contact us for more information and to discuss deploying load cell monitoring →
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