Contents EXECUTIVE SUMMARY ........................................................................................................................ 2 1.
INTRODUCTION ......................................................................................................................... 4
1.1
HISTORY ....................................................................................................................................... 4
1.2
DEFINITION .................................................................................................................................. 6
1.3
TYPES ............................................................................................................................................ 7
1.3.1 SURFACE MOUNTED WEIGHBRIDGES .................................................................................. 8 1.3.2 PIT MOUNTED WEIGHBRIDGES............................................................................................... 8 1.3.3 PORTABLE WEIGHBRIDGES ..................................................................................................... 9 1.3.4 STEEL WEIGHBRIDGES ............................................................................................................ 10 1.3.5 PORTABLE AXLE PADS............................................................................................................ 10 1.3.6 CONCRETE WEIGHBRIDGE ................................................................................................... 12 1.4
ON-BOARD SCALES ............................................................................................................... 14
1.5 ADVANTAGES .......................................................................................................................... 15 1.6 APPLICATIONS .......................................................................................................................... 16 1.7 CASE STUDY : ............................................................................................................................ 17
EXECUTIVE SUMMARY Throughout the years, weighbridge technology has evolved from simple mechanical systems to complex advanced structures. Weighbridges exist in a many different sizes and have multiple functions and applications. From a commercial perspective, weighbridges validate between cost and load weight, since they are an accurate way to weigh the load of large vehicles and sizeable content.
What is a Weighbridge A weighbridge is a large scale that weighs bulky items. The scale is typically mounted on a concrete surface and has an electronic monitor that displays the load of the contents weighed. Weighbridges can be used to weigh all types of materials ranging from high tonnage vehicles to agricultural parcels of food.
History of Weighbridges It is important to understand the evolution of weighbridges. In the past, weighbridges were made of wood that utilized a lever system. They were connected to a steel-like balance for weighing and the systems did not advance until the mid-20th century when actual steel was introduced in the systems. It wasn’t until the late 1970s that weighbridges became electronic machines and the use begin to soar in the industry. The old wooden, leverbased systems transformed into digital technologies utilizing load cells.
Weighbridge Types There are many different types of weighbridges. There are mounted weighbridges and even portable weigh scales that can be used to weigh industrial equipment. The two main differences are above ground or in ground weighbridges. Different type of weighbridges will dictate a different application although many applications can be used on the same type of weighbridge. Cost,
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ground conditions, space and the overall purpose will impact the type of weighbridge one chooses.
Above Ground Weighbridges These types of weighbridges are popular because they are the least expensive weighbridge type while not requiring much site preparation. Above ground weighbridges require a lot of surface space and area as the ramps must have a lot of space. The ramps can be single or multi levelled.
Semi Pit Weighbridges Semi Pit weighbridges are ground level and do not require ramps. These are a cost-effective option although extensive site preparation like digging and pipe draining must take place before installation. Semi pit weighbridges can be used for weighing waste management vehicles to ensure recyclable waste is managed and distributed.
In Ground Weighbridges In ground weighbridges are exactly that, large trucking scales that are embedded in the ground. They require the most amount of site preparation because they must be placed underground. Excavation and surveying will be necessary. In ground weighbridges are common for shared weighing and high traffic areas. Often, weigh scales located on highways where truckers stop feature in ground weighbridges for this purpose. In ground weighbridges are also used to weigh livestock.
Portable Weighbridges Designed to be easily transported to multiple sites, portable weighbridges are useful for their mobility and are best used for the construction, transportation, and logging industries.
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1. INTRODUCTION 1.1 HISTORY Transportation of goods has always played an important role for growth of civilization. The important mode of transportation has been roadways, railway, and the seaway. The country having developed road network is considered a developed nation and has distinct edge over the neighbouring countries as far as progress and development is considered. The Government of India has taken priority sector interest for development of roads at every nook and corner of the country through the various schemes launched by the Government. Weighing of goods on the career has played a vital activity for its ease and prompt service. For this purpose a weighload has been used. In the 19th century when seaways was the most popular mode of transport a Weigh lock was used. A weigh lock is a specialized canal lock designed to determine the weight of barges in order to assess toll payments based upon the weight and value of the cargo carried. This requires that the unladen weight of the barge be known. A barge to be weighed was brought into a supporting cradle connected by levers to a weighing mechanism. The water was then drained and the scale
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balance adjusted to determine the barge gross weight. Subtracting the tare weight (the weight of the barge when empty) would give the cargo weight. Originally weighlocks measured the weight of the barge, initially by measuring the displacement of water from the lock by collecting the liquid in a separate measuring chamber after the barge had entered.[1] This method also requires that the unloaded weight of the barge be known. Before the weighload was invented, Arguments over the weight of motor trucks on restricted highways, where state laws set the maximum load, were cut short by members of the "Weight Detail", who weigh the suspected truck on the spot. They use four miniature platform scales, one for each wheel. The readings of the four scales were added together and the sum gave the total weight of vehicle and load. Weights up to thirty tons were recorded by the four scales, each being capable of showing 15,000 pounds. The weighing equipment occupied small space and could be transported easily. It gave accurate evidence and eliminated guess work and mistakes Weighbridges were at first made of wood that utilized a lever system. They were connected to a steel-like balance for weighing and the systems did not advance until the mid-20th century when actual steel was introduced in the systems. It wasn’t until the late 1970s that weighbridges became electronic machines and the use begin to soar in the industry. The old wooden, lever-based systems transformed into digital technologies utilizing load cells. Load cells feature transducers that display a digital output. Once the gauge on the load is compressed, an electronic signal is transmitted to translate the weight load of the vehicle. Software has also been introduced to weighbridge systems that have made them even smarter by featuring enhanced information, increased data storage and logging capabilities. Earlier weighing of the goods was a cumbersome process. With the advent of technology, this activity is simple so that a weighbridge could be installed all over the country to cater to the needs of the people and traders.
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A police officer taking weight of a motor truck. Los Angeles, 1929
1.2 DEFINITION A weighbridge or a truckscale is a set of scale which is used to weigh bulk items. It is a set of scale which is mounted by the weighbridge’s manufacturer on a concrete surface. It has an electronic or digital monitor which displays the weight of the vehicle weighed. Weighbridges are mainly used for weighing large vehicles like trucks or rail containers where movement of goods is done through vehicles. Reliable and accurate weighing helps the industry by giving
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them theexact figures to maintain their goods inward and goods outward.
Manufacturers produce various types of weighbridges for the many requirements. These are electronic pit type or pit less, digital pit type or pit less, rail weighbridge, portable weighbridge, RCC weighbridge, mechanical weighbridges. The main function of weighbridge is to weigh the entire truckloads of goods in industries where material can be weighed only at the time of movement from one place to another. A vehicle is weighed twice, once loaded with goods and once emptied to calculate the weight of materials.
Weighbridge supplier recommends the use of weighbridges in industries like mining, quarries, electrical equipment, iron and steel, household goods, metal, liquid industry, powder industry, where bulk movement occurs. The government officials also make use of the weighbridge to weigh a vehicle to determine whether the vehicle is overloaded as per the laws and regulations. In such cases of overloading, officials can fine the concerned parties for flouting the law and restore road safety laws.
1.3 TYPES
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1.3.1 Surface Mounted Weighbridges • Compact, low height deck structures (355mm 405 mm) • Conumes lesser space due to shorter ramp requirement • Big saving an chlt costs of ramps a pedestals • Option of deck-affixed Flex guard retractable safety guide rails • Fully protected load cells in enclosed boxes
1.3.2 Pit Mounted Weighbridges • Low height of structure facilitates minimal pit depth Bottom-senied structure protects from corrosion in pit • Uniform structural strength with e beams Option of floor mounted Flexguard retractible safety guiderails
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1.3.3 Portable Weighbridges • For application where site gets shifting eg. construction industry • Foundation based on precast transportable RCC blocks • No compromise in reliability with same deck design Reduced foundation cost with same accuracy
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1.3.4 Steel Weighbridges A fully Modular Long life steel weighbridge from 6 to 36 Meters Length made from High grade Steel, assembly and installation is simple. Ramps and foundations are formed and then the bridge is installed using the state of the art Load cell technology from Bilianciai, the load cells can be analogue or Digital CPD for long life simple service capability. Steel weighbridges have the possibility to be moved at a later date, however foundations and ramps will need to be formed.
1.3.5 Portable Axle Pads
The portable vehicle weigh pads come in both a wired or wireless version. They are Paired with the 3590ETKR Touch screen Indicator and used in either Dynamic or Static weighing.Both Wired and wireless Pads are IP68 and are made from a special alloy to allow use in even the most demanding environments with Ex versions also available.
Weigh pad capacities vary from 600kg to 25 tonne with special capacities available on request
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Sizes Range from 400mm x 300mm to 900mm x 700mm
WIRELESS VERSION • Reduced high, only 50mm. • Structure made in a special alloy, extremely sturdy and strong. • IP68 stainless steel load cells. • IP68 protection degree. • Built-in weight indicator into the platform and protected thanks to an IP68 hermetic box. • Built-in radio module for weight transmission to a remote indicator or external device. • Integrated wheels to facilitate the transport. • Internal rechargeable battery with a long life. • Nonslip rubber applied under the platform, for good grip on all types of surfaces. • Patented technology: patent number 1.342.302. Available also in: • CE-M approved version. VERSION WITH CABLE • Reduced high, only 50mm. • Extremely sturdy structure, made in a special alloy of high resistance. • IP68 protection degree of the load cells and the connectors, for using in presence of water, mud, or dust. • Cable storage, standard fitted in all the models. • 10 m extension cable for the connection to the indicator. • Integrated wheels to facilitate the transport. • Nonslip rubber applied under the platform, for good grip on all types of surfaces. • Patented technology: patent number 1.342.302.
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Available also in: • CE-M approved version. • R134 approved for the dynamic weighing.
Product Advantages
Easily Transported High resistance to Chemicals & Soils High resistance to Oxidation Installation Versatility Concrete is cast directly into the weighing platform without the need for extra framework. Construction of SBP/CO weighbridge
Salient features: Steel Cum Concrete Weighbridge Fully Welded Fabricated Modules Flexible Module Design Low Profile Easy to Move Raft foundation helps in Low cost of ownership. Strong construction, reliable & long life Easy loading/unloading Quick Installation Box Channel (Hollow) & Fully Welded I-Beam Type Heavy Duty RCC Top Platform Length : 6 Meter ~ 24 Meter Platform Width : 3 Meter ~ 4 Meter Accuracy Class : OIML approved Class – II Weighing Capacity : 200 t Both Side Vehicle Guide Rails
1.3.6 Concrete Weighbridge Concrete Weighbridge is fully Modular Weighbridge from 6 to 36 Meters range with steel supports and cement decks, ramps and foundations are installed first. The bridge frame is assembled on site raised on Dummy load cells and cement can be poured, once cured the bridge is Fitted with load cells. Using the state
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of the art Digital Load cell technology from Bilanciai of Italy The bridge is connected to one of the many Indicators available and Calibrated.
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1.4 On-board scales These are devices for determining the approximate loaded weight of a truck. For many types of trucks, knowing the loaded weight is important for operating safely and maximising payload whilst avoiding fines for overloading. On-board scales use either load cell technology or pressure readings from air suspension to calculate the weight on the vehicle axles. Operating the truck at its optimal payload ensures that the owner minimises his running costs whilst maximising his profit. The convenience of being able to weigh at the loading site is a key factor in the popularity of on-board scales. This ability eliminates the costs associated with using an in-ground scale, such as lost hours of service, scale fees, and driver wages. Types There are four types of on-board scales in use: Load-cell scales Load-cell scales are based on electronic load cell transducers and can be mechanical or strain-gauge. There is a wide variety of scale types that can be built with load cell technology. Typically load cells are used in payload scales for vehicles with spring suspension. Air-suspension PSI gauges Air-suspension PSI gauges are used on commercial trucks and semi-trailers where accurate weights are not as critical. Air-suspension load scales Load scales for air-ride applications that show on-the-ground weight in pounds (LBS) or kilograms (KG) instead of standard PSI. These non-electric gauges are dial-face with versions that can calibrate for accuracy. Electronic scales with PSI sensors Electronic scales with PSI sensors measure temperature and pressure changes in a vehicle's air suspension. It relays this data to a receiver hardwired into the cab, or wirelessly to a handheld unit, which interprets the data and displays an approximate axle weight or gross vehicle weight.
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1.5 Advantages These are four universal benefits of using weighbridges:
Firstly, they enhance productivity. Utilizing a weighbridge is an efficient way of checking the weight. The process is quick, which stops drivers from waiting around unnecessarily.
They instantly notify you if a vehicle is overloaded. Weighbridges prevent overloaded cars from driving onto the roads; you are immediately protected from potential infringements. Weighbridges help to enforce compliance with the rules.
With a good weighbridge, you get access to extensive reporting as data is recorded automatically and stored securely. This could be useful if needed to be referred to at a later date.
Lastly, they’re cost-effective. Implementing a weighbridge has minimal
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1.6 Applications 1.
Selling or charging by weight over the bridge (Trade Approved)
2.
Check weighing both axle weights and gross vehicle weights. This helps to stop axle overloading and possible heavy fines.
3.
Weight based tolling A Weigh in Motion (WIM) system weight-based tolling helps to generate additional revenue for road construction and ensures road usage fees are fair. Based on the "polluter pays principle", road users are charged a toll according to their vehicle's actual weight and associated road surface wear. Because of weight based tolling, road owners and operators can sanction weight limit violations immediately and deny overloaded vehicles access to bridges or roads. Using integrated cameras, they can identify vehicles directly, which allows for levying the toll automatically, without hindering the flow of traffic. Our fully automated measurement systems transmit data in real time, based on which fines for overweight and fees for using toll roads are calculated depending on the vehicle weight.
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1.7 Case Study : SPECIFICATION FOR 100TON CAPACITY 16M X3M CAPACITY PITLESS TYPE ELECTRONIC ROAD WEIGHBRIDGE (TWO NOS WITH ONE COMMON CONTROL ROOM) Procurement of Two number of 100 Ton capacity, Fully Automatic, pit Less Type Road Weigh Bridge and its installation at Manoharpur, Odisha. SCOPE: Design, engineering, manufacturing, testing, inspection, supply, erection, commissioning and stamping (by Legal Metrology dept) of 100 MT Pit-less Type Electronic Road Weighbridge complete with weigh controller, Load Cells, Platform, large size LED display, P.C., Printer, UPS, Test weights, Construction of one no control room complete in all respect and fitted with AC, Manufacturer’s Test certificates and stamping by Legal metrology dept. The entire job is to be undertaken on Turnkey basis covering mechanical, civil & electrical works including supply of all required material for civil construction & electrical works. TECHNICAL SPECIFICATIONS: Load Cell Capacity Minimum 33 Tons Or Higher, Compression Type Load Cells, Minimum 6 (Six) Nos , Excitation Digital:10-12 Ac/Dc , Analog-5v Dc, Rated Output 2.5 mv/V Or Higher, Zero Balance 1% Of Rated Output Combined Error 0.02% Of Rated Output Repeatability 0.010% Of Rated Output, Overload Rating(Ultimate) >225% Rated Output Resistance To Dirt &Moisture Hermetically Sealed Conforms To IP 68,69, Stainless Steel Non-Linearity < 0.01 Hysteresis < 0.0165 , Accuracy +/- 0.05% or better and confirming to legal metrology requirements. WEIGH BRIDGE CONTROLLER: Microprocessor based system , Display Type Blue backlit LED, graphics up to 64x240 pixels, display up to 8 digits, minimum character size 17mm x 10mm, Tare , Net, Kg., print, Unit of Measure Type: pit less, fully Electronic Road Weigh Bridge b. Capacity: 60 MT. SYSTEM SPECIFICATIONS: Least count: 10 Kg. Platform Size: 16 m x 4m Platform Construction: Fully welded module type M.S. structure to meet Indian Standard IS: 800, 2062 comprising of RS joists, transoms, and plates ,12mm thick antiskid to be provided. M.S. checkered plate on top.,. Painting of structure: EPOXY to meet IS:2074, Suitably designed to bear 200% of the maximum capacity. Load Cell: Hermetically Sealed Unit, Capacity - 33 Tons Minimum each, Ambient temp. – 55 Degree C, IP 68 Max. Safe load - 150% of capacity
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Ultimate Load - 300% of capacity Destructive Load - 500% of capacity Junction Box & Cable: Stainless steel with IP68protected and required length of steel breaded, 6 Core, Load Cell Cable from power panel and load cells to Junction Box & Junction Box to Indicator. COMPUTER: Industrial grade PC, - Core-I5 or better make Dell (Two nos) PRINTER: 2 Nos. Laser Printer Model - Laser Jet Pro (MFP M126nw) Make – HP UPS: 2 number of 1000 VA, with 2.00 Hr. battery backup, Make – Exide/APC. SOFTWARE FOR WEIGHBRIDGE MANAGEMENT: Complete weighbridge management user friendly Software for processing data date wise, truck wise, challan wise, shift wise, customer wise etc. for generation of daily / Weekly & monthly report. Preparing Transport Permit, Invoice etc. as per our requirement. All the required information for developing the Software shall be provided by us. Provision for connecting with other weighbridges /server computer by LAN & sharing the common data base. The software should be compatible for integrating with Terminal Automation System software and migration of data. CIVIL JOB: Civil job shall include total civil foundation with M-25 RCC as per the drawing for the platform, approach Ramps and other equipment’s. Construction of one no common Weigh House of minimum size 12 x 12m (carpet area) fitted with front transparent glass windows with grill in two sides, air conditioner of minimum 1.5Ton capacity (5 star rated), LED light fittings, operators’ desks, and chairs of make Godrej, two no’s ceiling fans etc. Suitable drainage system is also included in the scope. ELECTRICAL JOB: All electrical connection from weigh bridge to our automation control room or as advised by EIC and laying of the cables for complete integration of the Weighbridge. Providing all required socket, switch, cable, junction box of good quality to be used for weigh bridge. EARTHLING: Providing earthing as per IS-3043. TEST WEIGHTS: Suitable test weights are to be supplied along with the road weighbridge confirming to the legal meteorology laws. COMPLETE ERECTION, COMMISSIONING, AND STAMPING OF THE WEIGHBRIDGE: Execution of civil work, erection, and Commissioning, liaising with the inspector of Legal metrology department (Weight and Measure Dept.), Govt. of Odisha for verification and Stamping of Weigh Bridge and also paying the required fee to Legal Metrology department.
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DRAWINGS AND MANUAL: The supplier must provide three sets each of the following manuals and drawings along with soft copies in CDs. Operation Manual: Three sets of operation manual must be provided by the supplier. GUARANTEE: Supplier shall provide full guarantee against any manufacturing defects / poor work Manship / inferior design or quality etc. for a period of 12 months from date of commissioning. supplier will arrange to repair / replace any defective part free of cost or replace complete item as required. supplier shall guarantee that in case of any problem the manufacturer will extend the service and spares back up within 24hrs from the time of receipt of breakdown intimation.
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