Meeting Reliability Challenges
Raw materials processors need to be highly productive to be profitable. However, even the most state of the art operation can be brought to a halt by a problematic vehicle scale. Without the ability to monitor incoming and outgoing goods at the scale, production, shipments and deliveries can be delayed.
Troubleshooting a traditional scale is complicated. Technicians must access the scale’s junction boxes and other components to manually test various electrical circuits. It is a time consuming process resulting in lost production time and costly repair bills.
Self monitoring systems can help you avoid these situations while providing additional advantages with specially designed features and enhancements. These include developments in on-board microprocessing, load cell networks, hardware design, and environmental protection, which work together to immediately notify the user of any inconsistencies.
Load Cell Microprocessing
In traditional vehicle scales with analog load cells, signal processing takes place in the junction boxes and indicator terminal. This means the system does not notice inconsistencies in performance or even component failure. It is up to the user to notice weighing errors or other symptoms of a problem. These errors can skew weight readings and transactions for days or weeks before an operator realizes there is a problem.
Microprocessor equipped load cells make the scale “smarter.” First, they enhance accuracy by monitoring and compensating for variables that affect weight readings. Next, the performance of each load cell is logged to provide a constant measure of correct operation. This means that in the event of a problem, the system can tell a technician the details of the problem and eliminate guesswork and complicated troubleshooting.
Eliminating Junction Boxes
New POWERCELL PDX load cell systems are able to eliminate the need for troublesome junction boxes by instead using a simplified cell-to-cell network. This reduces the number of connections in the scale by 25 percent. This simplified network design not only enhances reliability, but also makes installation and ongoing service much more convenient throughout the lifetime of the scale. In the event of damage to a load cell or cable, the individual component can be easily replaced.
Encasing critical electronics in hermetically sealed, fully welded load cell enclosures with waterproof connections (IP68/IP69K rated) keeps the scale in working order despite environmental challenges. Scales using this protection have been submerged in major floods and subjected to extreme temperatures without damage.
Most traditional scale failures happen unexpectedly and at inopportune times. However, self-monitoring systems now offer built-in networked breach detection that can immediately alert operators to accidental load cell puncture or tampering. This provides a warning that environmental protections have been compromised, but still allows the scale to function normally. Such a warning allows a repair to be scheduled at a convenient time, as opposed to rushing repairs during a sudden unexpected failure.
Confident Performance and ROI
Self-monitoring vehicle scale systems offer many benefits. Chief among them for many users is the confidence that the system is operating correctly and accurately every day.
Eliminating unplanned service events can result in significant savings and increased productivity. In a high-volume throughput situation, avoiding just one day of downtime can offset the cost of a new vehicle scale system. An upgrade to self-monitoring technology should pay for itself in less than a year. In some cases, it only takes a few months to see performance gains and positive bottom line results.
METTLER TOLEDO has pioneered self-monitoring vehicle scale load cell technology in POWERCELL PDX load cells. These load cells have been specially designed for the unique challenges faced in vehicle weighing applications. POWERCELL PDX systems can be utilized in new scale installations, as well as retrofitted to existing scales.
Additional information is available at http://us.mt.com/us/en/home/products/Transport_and_Logistics_Solutions/Truck_Scales/Load_Cells.html?als=POWERCELL?crel=ePR_PP_En
Mettler-Toledo International Inc.
Im Langacher, Zip Code 8606
E-Mail : ePublicRelations@mt.com
Phone : +41-44-9443385
Website : www.mt.com
METTLER TOLEDO specializes in the area of precision instruments for professional use. METTLER TOLEDO laboratory instruments are used in research, scientific, drug discovery, and quality control labs, amongst many others in the pharmaceutical, chemical, food and cosmetics industries. METTLER TOLEDO comprehensive industrial solutions cover the various steps in a host of manufacturing processes at many of the same customers that laboratory serves. Solutions range from receiving raw materials through various manufacturing processes, in-line process control and end-of-line packaging control, to logistics and shipping. Increasingly, these solutions are fully integrated into the customer’s IT environment, helping automate their workflows. In food retail, our offering for fresh food management ranges from receiving and pre-packaging, to in-store solutions for self-service departments, deli counters, and checkout terminals.
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