UK-based Sensor Technology has developed a smart load sensor that integrates weighing with handling operations. The device, called LoadSense, captures data in real time from cranes, forklifts and other handling systems, and can transmit it wirelessly for storage and analysis.

The system combines an intelligent load sensor, a handheld display and a receiver. An on-board, single-chip computer records, analyses and archives readings.

A transmitter sends the load data to the display – a colour touchscreen computer running Windows XP and NI’s LabView software. The display shows real-time readings of the load, while the computer can record and process real-time values.

The battery-powered system (above) can be deployed with minimal disruption, and will start to transmit data automatically. No special training is required to install or operate it.

The sensor is based on proven strain gauge technology, and is calibrated for measurements in the range 1–5 tonnes, with other ranges available on request.

Sensor Technology says the system can optimise the efficiency and profitability of a wide range of industrial operations. For instance, it can work out how much material is being transported, or keep track of two or more materials being used simultaneously which need to be accounted for separately.

“Our main markets are materials-handling and warehouse operations, where the intelligence will convert raw data into instant stock counts,” explains Sensor Technology’s Tony Ingham. “We have already had enquiries about raising nuclear fuels rods, monitoring window cleaners’ cradles on high-rise buildings, and winching and weighing building materials.
 
“Theatre stagehands could lift and lower scenery from the wings rather than from a remote control room,” he adds. “And for applications involving liquid discharge, a system could be configured to monitor and control flow.”
 
LoadSense can be integrated wirelessly into Scada or MES systems, producing instant operating reports and email-able customer bills. It also improves safety because operators can be moved away from dangerous locations.