Weighbridge Software and Man-less Automation

Key features

• RFID vehicle assignment and weight capture
• Stable weight, platform clear, and challan weight checks
• LAN, ERP, SAP, SMS, and email options
• Multiple weighbridge connectivity

Automation hardware

Weighbridge automation integrates hardware and software to fully or partly automate the weighing cycle, cutting manual errors and queue delays. A typical setup combines the following components around the weighbridge platform.

• Digital load cells and weighbridge indicator / terminal
• Boom barriers and entry/exit traffic lights
• RFID readers and smart cards for vehicle identity
• ANPR (automatic number plate recognition) cameras
• CCTV surveillance and a set of infrared position sensors

Direction sensing

Direction sensing detects whether a vehicle is entering or leaving the platform, so the software records the correct weighing sequence and keeps in-weight and out-weight separate.

• Enforces the correct entry → weighbridge → exit sequence
• Prevents reverse weighing and tampering
• Keeps accurate in/out weight logs

Vehicle Positioning System (VPS)

A vehicle positioning system confirms the truck is fully and correctly placed on the platform before a weight is captured, so overhang and partial entry cannot corrupt the reading.

• Detects vehicle overhang or partial entry
• Blocks weighing until the vehicle is fully on the platform
• Triggers alerts when a vehicle is wrongly placed

Weighment software

Vepro weighment software suits both industrial and public weighbridges. A standalone build stores all data on a PC connected to the indicator, while networked builds add multi-weighbridge and enterprise connectivity.

• Mining software with online and offline modes
• Multiple-weighbridge connectivity over LAN
• Automatic SMS and e-mail on weighment
• SAP / ERP integration and text/exe file export
• Fully customized software on request

Where weighbridge fraud happens, and what blocks it

Weight loss on a site is rarely one large theft; it is a small margin taken repeatedly. Each of the controls below closes one of the openings, which is why they are specified together rather than individually.

• Partial entry — a vehicle parked with an axle off the deck. Blocked by the vehicle positioning system, which refuses capture until the vehicle is fully on the platform.
• Unstable capture — a weight taken while the load is still settling or the vehicle is rolling. Blocked by the stable-weight check.
• Reverse or repeat weighing — running the cycle out of sequence to reuse a tare. Blocked by direction sensing and the entry/exit barrier sequence.
• Substituted identity — one vehicle weighed under another's record. Blocked by RFID identification, with ANPR number-plate reading as a second check.
• Disputed weighments after the fact — settled by the CCTV image captured against each record.
• Challan mismatch — the recorded weight is compared against the challan weight, and a violation raises an alert.
• Quiet edits after the fact — a saved weighment changed later. Traced by per-user logins and the software's edit/tamper log.

Records, reporting and multiple weighbridges

Each weighment is stored with the details that make it defensible later, and networked sites can be managed together rather than reconciled by hand at month end.

• Weighment records held in software, with 99,999 records also retained in the indicator itself
• Gross, tare and net weight against vehicle identity and time
• ANPR read and CCTV image attached to the record
• Multiple weighbridges connected over LAN and reported together
• Mining software operating in both online and offline modes, for sites with unreliable connectivity
• Export to ERP and SAP, plus text file export, automatic SMS and e-mail
• Per-user logins, so every weighment is recorded against the user who took it
• Edit and tamper log, so any change to a saved weighment leaves a trace — the control mining and cement tenders usually ask for

Where it's used

• Mining weighbridges
• Sugar mill gate automation
• Toll and logistics yards
• Plants needing controlled vehicle weighing

Operator-based weighing versus man-less automation

Automation is not about removing staff for its own sake — it removes the points in the cycle where a weight can be influenced, delayed or recorded against the wrong vehicle.

Both modes are supported. Many sites run operator-based weighing on the main gate and man-less weighing at a second or remote weighbridge. Automation can also be retrofitted to a weighbridge you already own.

The automated weighing cycle, step by step

This is the sequence a truck goes through on a man-less Vepro terminal. Every step is a control point: if one fails, the cycle stops rather than recording a doubtful weight.

1. Vehicle approaches

   The truck arrives at the entry barrier, which stays closed until the vehicle is identified.

2. RFID identification

   The reader picks up the vehicle's RFID card and matches it to the assigned vehicle record.

3. Entry barrier and signal

   The boom barrier lifts and the traffic light turns green for that vehicle only.

4. Position check

   Infrared sensors confirm the vehicle is fully on the platform, with no overhang or partial entry.

5. Stable weight capture

   The weight is recorded only once the indicator reports it as stable and the platform is otherwise clear.

6. Image and plate capture

   ANPR reads the number plate and CCTV captures the vehicle image against the weighment.

7. Record and push

   The weighment is written to the database with time, identity, gross/tare/net, then pushed to ERP or SAP and sent by SMS or e-mail.

8. Exit

   The exit barrier releases the vehicle and the terminal resets for the next one.

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Frequently asked questions

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