1.

0 WEIGHBRIDGE
1.1 INTRODUCTION

Weighbridge is the large scale set on the ground, which is

usually used to weigh the product that carried by lorry or
any transport. Weighbridge is a necessary auxiliary
equipment in every Palm oil mill. The Weighbridge system
consist of weighbridge platform, load cell, weighing
indicator, computer that is installed with weighbridge
system, and printing system.

Figure 1.1(a) : HOM Weighbridge

a) Weighbridge platform - To determine the weight of goods bought and sold in quantities
expressed in weight.
b) Load cell - A load cell measures mechanical force, mainly the weight of
objects.
c) Weighing indicator - The weight of the object or load is determined by the amount of air
required by the scale. The scale works when it uses pressurized air
in order to balance the weight of the object that has to be
measured. After a little wait, the pressure gauge then converts the
reading of the weight of the object into an electrical reading. A
digital screen then displays the weight on it.
d) Weighbridge system - Weighbridge software is used for managing scales and weighing
data on desktop computer. The scales are connected to the
software, which enables the weighing data produced by the scales
to be transferred and utilized for various purposes.
- The weighbridge software measures and manages weight-based material
flows received, sent and transferred internally by the company. With the
help of weighing software, you and all the stakeholders can form an
overall picture of the various material flows easily in one place.
e) Printing system - Provide printed weighbridge ticket with information
(See Appendix A) as prove for each weighbridge transaction.

Figure 1.1(a) : Havys Oil Mill Weighbridge

1.2 WEIGHBRIDGE DESIGN

Weighbridge is mainly composed of

three parts, load-bearing force
transmission mechanism (scale body),
high-precision load cell, and weighing
display instrument. With these three
parts, the weighbridge can finish the
basic weighing function.

Figure 1.2(a) : The layout of weighbridge

Havys oil mill is surface mounted weighbridge (pit-less). A surface-mounted weighbridge (pit-less).,
simply sits on top of the ground. It requires ramps for vehicles to drive on and off. The weighbridge is
constructed using I-beam for supporting and plain plate as platform on top the i-beam.

Figure1.2(b) & 1.2(c) : the

cross-section of
weighbridge
Below are the type of Weighbridge used in Havys Oil Mill (HOM) :-

WEIGHBRIDGE 1
MANUFACTURE’S MARK : CARDINAL 04
NAME OF APPLICANT : CARDINAL WEIGHING (M) SDN BHD
MODEL NUMBER : DAUNTLESS ASD-S-PIT-LESS (ANALOG)
DESCRIPTION : WEIGHBRIDGE MODULE STEEL DESK
CLASS : III
PLATFORM SIZE : 19M x 3M
NUMBER OF LOAD CELLS : 6 UNIT
SERIAL NUMBER : ASD-S-PL-A1680-S4706
MAXIMUM CAPACITY : 80 000 KG
MINIMUM CAPACITY : 1 000 KG
SOFTWARE : WEIGHBRIDGE SYSTEM HAVYS OIL MILL

WEIGHBRIDGE 2
MANUFACTURE’S MARK : CARDINAL 04
NAME OF APPLICANT : CARDINAL WEIGHING (M) SDN BHD
MODEL NUMBER : DAUNTLESS ASD-S-PIT-LESS (ANALOG)
DESCRIPTION : WEIGHBRIDGE MODULE STEEL DESK
CLASS : III
PLATFORM SIZE : 19M X 3M
NUMBER OF LOAD CELLS : 6 UNIT
SERIAL NUMBER : ASD-S-PL-A171680-S4404
MAXIMUM CAPACITY : 80 000 KG
MINIMUM CAPACITY : 1 000 KG
SOFTWARE : WEIGHBRIDGE SYSTEM HAVYS OIL MILL

Figure 1.2(d) : Weighbridge 1 figure 1.2(e) : weighbridge 2

1.3 LOAD CELL & DESIGN

1.3.1 ORIGIN OF THE LOAD CELL

Before strain gauge based force sensors became the method of choice for industrial weighing
applications, mechanical lever scales were widely used. Mechanical scales can weigh everything from
pills to railroad cars and can do so accurately and reliably if they are properly calibrated and
maintained. The method of operation can involve either the use of a weight balancing mechanism or
the detection of the force developed by mechanical levers. The earliest, pre-strain gauges load
sensors included hydraulic and pneumatic designs.

In 1843, English physicist Sir Charles Wheatstone devised a bridge circuit that could measure
electrical resistances. The Wheatstone bridge circuit is ideal for measuring the resistance changes
that occur in strain gauges. Although the first bonded resistance wire strain gauge was developed in
the 1940s, it was not until modern electronics caught up that the new technology became technically
and economically feasible. Since that time, however, strain gauges have proliferated both as
mechanical scale components and in stand-alone load cells.

Today, except for certain laboratories where precision mechanical balances are still used, strain gauge
load cells dominate the weighing industry. Pneumatic load cells are sometimes used where intrinsic
safety and hygiene are desired, and hydraulic load cells are considered in remote locations, as they
do not require a power supply. Strain gauge load cells offer accuracies from within 0.03% to 0.25%
full scale and are suitable for almost all industrial applications.

In applications not requiring great accuracy, such as in bulk material handling and truck weighing
mechanical platform scales are still widely used. However, even in these applications, the forces
transmitted by mechanical levers often are detected by load cells because of their inherent
compatibility with digital, computer-based instrumentation.
load cell is a transducer which converts force into a measurable electrical output. Although there are
many varieties of force sensors, strain gauge load cells are the most commonly used type.

Except for certain laboratories where precision mechanical balances are still used, strain gauge load
cells dominate the weighing industry. Pneumatic load cells are sometimes used where intrinsic safety
and hygiene are desired, and hydraulic load cells are considered in remote locations, as they do not
require a power supply. Strain gauge load cells offer accuracies from within 0.03% to 0.25% full scale
and are suitable for almost all industrial applications.
1.3.2 WHAT IS A LOAD CELL
A load cell is a transducer which converts force into a measurable electrical output. Although there
are many varieties of force sensors, strain gauge load cells are the most commonly used type.
Except for certain laboratories where precision mechanical balances are still used, strain gauge load
cells dominate the weighing industry. Pneumatic
load cells are sometimes used where intrinsic safety
and hygiene are desired, and hydraulic load cells
are considered in remote locations, as they do not
require a power supply. Strain gauge load cells offer
accuracies from within 0.03% to 0.25% full scale
and are suitable for almost all industrial
applications.

Figure 1.3.2(a) : Load Cell Diagram

1.3.3 HOW DOES A LOAD CELL WORK

A load cell works by converting mechanical force into digital values that the user can read and record.
The inner working of a load cell differs based on the load cell that you choose. There are hydraulic
load cells, pneumatic load cells, and strain gauge
load cells. Strain gauge load sensors are the most
commonly used among the three. Strain gauge load
cells contain strain gauges within them that send up
voltage irregularities when under load. The degree
of voltage change is covered to digital reading as
weight.

Figure 1.3.3(a) : Load cell

1.3.4 WHEN TO USE A LOAD CELL?

A load cell measures mechanical force, mainly the weight of objects. Today, almost all electronic
weighing scales use load cells for the measurement of weight. They are widely used because of the
accuracy with which they can measure the weight. Load cells find their application in a variety of
fields that demand accuracy and precision. There are different classes to load cells, class A, class B,
class C & Class D, and with each class, there is a change in both accuracy and capacity.
1.3.5 LOAD CELL TYPES
Load cell designs can be distinguished according to the type of output signal generated (pneumatic,
hydraulic, electric) or according to the way they detect weight (bending, shear, compression, tension,
etc).

➢ HYDRAULIC LOAD CELLS

Hydraulic cells are force-balance devices, measuring weight as a change in pressure of the internal
filling fluid. In a rolling diaphragm type hydraulic force sensors , a load or force acting on a loading
head is transferred to a piston that in turn compresses a filling fluid confined within an elastomeric
diaphragm chamber.

As force increases, the pressure of the hydraulic fluid rises. This pressure can be locally indicated or
transmitted for remote indication or control. Output is linear and relatively unaffected by the amount
of the filling fluid or by its temperature.

If the load cells have been properly installed and

calibrated, accuracy can be within 0.25% full scale
or better, acceptable for most process weighing
applications. Because this sensor has no electric
components, it is ideal for use in hazardous areas.

Typical hydraulic load cell applications include tank,

bin, and hopper weighing. For maximum accuracy,
the weight of the tank should be obtained by
locating one force sensor at each point of support
and summing their outputs.
Figure 1.3.5(a) : Hydraulic Load Cell
 ➢ PNEUMATIC LOAD CELLS
Pneumatic load cells also operate on the force-balance principle. These devices use multiple
dampener chambers to provide higher accuracy than can a hydraulic device. In some designs, the
first dampener chamber is used as a tare weight chamber.

Pneumatic load cells are often used to measure

relatively small weights in industries where
cleanliness and safety are of prime concern.High
Capacity Tension Link Load Cell Miniature load cell

The advantages of this type of load cell include

their being inherently explosion proof and
insensitive to temperature variations. Additionally,
they contain no fluids that might contaminate the
process if the diaphragm ruptures. Disadvantages
include relatively slow speed of response and the
need for clean, dry, regulated air or nitrogen.

Figure 1.3.5(b) : Pneumatic Load Cell

➢ STRAIN-GAUGE LOAD CELL

Strain gauge load cells are a type of load cell where a strain gauge assembly is positioned inside the
load cell housing to convert the load acting on them into electrical signals. The weight on the load
cell is measured by the voltage fluctuation caused in the strain gauge when it undergoes
deformation.

The gauges themselves are bonded onto a beam or structural member that deforms when weight is
applied. Modern load cells have 4 strain gauges installed within them to increase the measurement
accuracy. Two of the gauges are usually in tension, and two in compression, and are wired with
compensation adjustments.

Figure 1.3.5(c) : Strain Gauge Load Cell

When there is no load on the load cell, the resistances of each strain gauge will be the same.
However, when under load, the resistance of the strain gauge varies, causing a change in output
voltage. The change in output voltage is measured and converted into readable values using a digital
meter
 ➢ PIEZORESISTIVE LOAD CELL
Similar in operation to strain gauges, piezoresistive force sensors
generate a high level output signal, making them ideal for simple
weighing systems because they can be connected directly to a
readout meter. The availability of low cost linear amplifiers has
diminished this advantage, however. An added drawback of
piezoresistive devices is their nonlinear output. High Capacity
Tension Link Load
Cell Miniature load cell.

Figure 1.3.5(c) : Piezoresistive Load cell

➢ INDUCTIVE AND RELUCTANCE LOAD CELLS

Both of these devices respond to the weight-proportional displacement of a ferromagnetic core. One
changes the inductance of a solenoid coil due to the movement of its iron core; the other changes
the reluctance of a very small air gap.

Figure 1.3.5(d) : Piezoresistive Load cell

1.4 WEIGHBRIDGE MAINTENANCE

i. Check visual appearance of the load cell, load cell cable, junction box, cable gland connection
and indicator.
ii. Check clearance around the weighbridge.
iii. Tag number to be provided in all load cells and the same identification should be in junction
box for easy identification.
iv. Check Input impedance and output impedance, it should be as per the data sheet ofload
cells.
v. Check tightening of the load cells installation kits, load cells connection and indicator
connection. If not make it the same.
vi. Check mV output at no load, it should be 0.0mV or +/- 0.1mV is acceptable
vii. Balancing to be done by providing packing (SS Sheet, Aluminum Sheet), the same to be
confirmed by measuring individual load cells output.
viii. Measure individual load cell output. Individual load cell output should be equal or +/-0.2mV
of Average output of the load cells is acceptable.
ix. Measure average mV output of load cells and Record it.
x. Check configuration of the indicator, like capacity, readability, and calibration weight value.
The same to be modified if required.
xi. Do software calibration or data sheet calibration if calibration disturbed.
xii. Ensure zero in the indicator, Move unknown or pre-weighted lorry (Approximately 1/4 of
capacity of the weighbridge) on the weighbridge, Record the indicator reading in 5 location.
weighbridge to ensure zero, normally the indicator should come back to zero. Repeat 10
times and record the values.
xiii. Indicator comes back to zero if repeatability of the weighbridge achieved.
xiv. Repeatability not achieved then again follow step vii, viii & xii .
xv. Minimum require weights for the calibration is 10% of the weighbridge capacity
xvi. Linearity of the system to be verified by adding standard weights or pre-weighted material
up-to full scale capacity of the weighbridge in the interval of 10% of full scale.
xvii. Weighbridge calibration to be checked up-to maximum capacity by build up method.
1.5 SAFETY OPERATING PROCEDURE
DEFINITION
FFB: Fresh Fruit Bunch
HOM: Havys Oil Mill

a) FFB coming from suppliers will be delivered to HOM for processing.

b) Lorry driver will stop at supplier's Office to collect FFB Despatch Chit from the supplier Clerk
c) Lorry driver will then proceed to HOM's weighbridge to weigh the FFB. Prior to weighing, the
FFB Despatch Chit will be passed to the weighbridge clerk. FFB Grading Chit will be issued to
the lorry driver which consists of date, time of entry, weight of lorry, lorry plate number.
d) Lorry driver will proceed to the loading ramp to unload the FFB. The grader will then grade
the FFB based on the criteria stated on the FB Grading Chit. Upon completion of the FFB
Grading Chit, the grader must verify by placing a signature at the bottom of the Chit.
e) Empty lorry will be returned to the weighbridge for the purpose of re-weighing. Prior to re-
weighing, FFB Grading Chit will be signed by the driver before passing back to weighbridge
clerk to update the POM System as well as issuance of receipt.
f) Document returned to the lorry driver :
i. 3rd Receipt issued by the POM System
g) Document kept by HOM:
i. Copy of the FFB Despatch Chit (Original Copy)
ii. FFB Grading Chit (Original copy)
iii. FFB weighbridge ticket: 3rd Copy
h) Document kept by supplier:
i. V. FFB. Despatch Chit (Yellow & Pink Copies)
ii. FFB Grading Chit (3rd Copy)
iii. FFB weighbridge ticket : 1st copy and 2nd copy for transporter

1.6 SECURITY ASPECT

The weighbridge and surrounding area must provide a safe working environment for drivers and
other feedlot employees. Adequate directional and safety signage and clearance from other vehicle
movements around the weighbridge should be provided. Using a “Boom Gate” to allow the lorries to
enter to weighbridge for weighing to avoid collision between lorries. If sampling of feed commodities
from an elevated deck is required, the design of the sampling deck (including handrails) must comply
with relevant work, health and safety regulations and should be long enough to access all parts of
the load.
1.7 APPENDIX

Appendix A : Form-D is the ‘Perakuan Penentuan Timbang dan Sukat, Akta Timbang dan Sukat 1972’

Appendix B : Load Cell used in Havys Oil Mill Weighbridge

Appendix C : Delivery order

Appendix D : Weighbridge ticket

Appendix E : Corner test and results