Smart Load Sensor Provides Autonomous Operation

Sensor Technology has developed a smart load sensor that provides all the information needed to optimise efficiency and increase profitability in materials-handling and warehouse operations. Scheduled to be launched at the Sensing Technologies exhibition at the Birmingham NEC on 28-29 September, the Loadsense device allows weighing processes to be fully integrated with handling operations. All live data is captured in real time and can be transferred to a database, stored, totalised and analysed.

For instance, the user may need to know how much material he or she has transported or he or she could be handling two or more materials simultaneously that need to be accounted individually. Alternatively, if working for multiple customers at the same time, the user can bill each appropriately. The Loadsense load sensor can be integrated with a crane hook, a fork lift or another handling device. It features an onboard single-chip computer for recording, analysing and archiving readings and a wireless communications capability that can transfer data in real time to a host computer.

Internal batteries make the Loadsense's operation completely autonomous. As such, it can be deployed with minimal disruption to operations and will automatically begin transmitting data. No special training is required to install or operate the unit. The Loadsense is built around an intelligent load sensor, a handheld display and a receiver. The load sensor is based on strain-gauge technology and is calibrated as standard in the one- to five-tonne range, with other ranges available on request. The transmitter, operating on an unrestricted 2.4GHz waveband, enables accurate load data to be sent to the display - a full-colour, TFT touch-screen computer running Windows XP and Labview.

The display provides a real-time measure of the load, while the computer records and processes real-time values. Tony Ingham of Sensor Technology said: 'Our main markets are materials-handling and warehouse operations, where the intelligence will convert raw data into instant stock counts. 'We have already had enquiries about raising nuclear fuels rods, monitoring window cleaners' cradles on high-rise buildings and winching and weighing building materials,' he added. Theatre stage hands could lift and lower scenery from the wings, rather than from a remote-control room.

Using Loadsense with a tractor-mounted winch, the user could assess roadside trees' susceptibility to wind speed. For applications involving liquid discharge, a system could be configured to monitor and control flow. The Loadsense could be wirelessly integrated into a Scada or manufacturing enterprise system (MES) control system, producing instant operating reports and emailable customer bills. It also improves operating safety because users are free to remove themselves from dangerous locations.

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