Weighing scale junction box

Abstract

A system for remote monitoring and operation of a weighing system. The system includes a junction box having a first set of sensors thereon configured to collect data regarding status, use, and operation of the weighing system; a main unit in electronic communication with the junction box; and at least one remote computing device in network communication with the main unit. The digital junction box is retrofit for analog floor / industrial scales. The junction box adds digital intelligence, diagnostics, and connectivity without replacing the scale platform, load cells, or legacy weight indicator. Outputs CAN bus, WiFi, and / or BLE signals alongside preserved analog signals to the existing indicator. The junction box sits between individual load cells and the indicator, observing pre-summation per-cell signals. This observation point, combined with software-controllable digipots and three communication channels enables capabilities no indicator or external monitoring device can replicate.

Description

WEIGHING SCALE JUNCTION BOXRELATED APPLICATIONS

[0001] This application claims priority benefit of U.S. Provisional Application Serial Number 63 / 790,266 filed April 17, 2025, the contents of which are hereby incorporated by reference.FIELD OF THE INVENTION

[0002] The present invention in general relates to weighing scale systems, and more particularly to junction boxes for weighing scale systems.BACKGROUND OF THE INVENTION

[0003] In many industries it is important to determine the weight of a cargo load. For example, in shipping and trucking industries, the cost of delivering a load for commercial purposes is assessed to the customer according to the weight of the load and the distance it must travel. Similarly, in agricultural industries or scrap and recycling industries, a purchaser buys goods based on the weight of the load delivered. Accordingly, such industries commonly rely on weighing facilities to determine the weight of the loads being transported. Often times, weighing facilities, shippers, scrap yards, or agricultural facilities provide scales in order to weigh cargo loads for cost calculations and other purposes. It is crucially important that such weighing scales be accurate given that associated monetary transactions are often based on the load data determined by such scales.

[0004] Weighing scales typically include a scale platform that is supported by individual load cells. The individual load cells are then tied together for summation at a junction box throughindividual load cell cables. The junction box then communicates the summation of the individual load cells to an indicator through a home run cable.

[0005] With an increased interest in many industries to provide remote service for weighing systems, remote data collections and analysis of weighing systems, and even unattended operation of weighing systems, there is a need for a cost effective way to collect additional information regarding existing weighing systems and a need for a way to communicate that collected information to remote indicators in order to provide remote data analysis, remote service, and / or remote operation of the existing weighing station.SUMMARY OF THE INVENTION

[0006] The present invention provides a system for remote monitoring and operation of a weighing system. The system includes a junction box having a first plurality of sensors thereon configured to collect data regarding status, use, and operation of the weighing system; a main unit in electronic communication with the junction box; and at least one remote computing device in network communication with the main unit. This is a drop-in digital junction box retrofit for analog floor / industrial scales. The junction box adds digital intelligence, diagnostics, and connectivity without replacing the scale platform, load cells, or legacy weight indicator. Outputs CAN bus, WiFi, and / or BLE signals alongside preserved analog signals to the existing indicator. According to embodiments, the junction box sits between individual load cells and the indicator, observing pre-summation per-cell signals. This observation point, combined with software-controllable digipots and three communication channels (CAN + WiFi + BLE), creates a uniquely powerful position that enables capabilities no indicator or external monitoring device can replicate.BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The present invention is further detailed with respect to the following drawings that are intended to show certain aspects of the present invention but should not be construed as a limit on the practice of the present invention.

[0008] FIG. 1 is a schematic drawing of a weighing system provided with a remote monitoring system and smart junction box according to embodiments of the present invention;

[0009] FIG. 2 a schematic drawing of connectivity and information flow in a remote monitoring system according to embodiments of the present invention;

[0010] FIG. 3 is a schematic drawing of a weighing system provided with a remote monitoring system and smart junction box according to embodiments of the present invention;

[0011] FIG. 4 is a schematic drawing of a weighing system provided with a remote monitoring system and smart junction box according to embodiments of the present invention;

[0012] FIG. 5 is a schematic drawing of a weighing system provided with a remote monitoring system and smart junction box according to embodiments of the present invention;

[0013] FIG. 6 is a schematic drawing of a weighing system provided with a remote monitoring system and smart junction box according to embodiments of the present invention; and

[0014] FIG. 7 is a schematic drawing of a weighing system provided with a remote monitoring system and smart junction box according to embodiments of the present invention.DESCRIPTION OF THE INVENTION

[0015] The present invention has utility as a junction box for a weighing scale where the junction box is provided with additional sensors to collect additional information regardingexisting weighing systems beyond load cell summation and weight signal digitization. These junction boxes are additionally configured to communicate the information collected from the junction box sensors to remote indicators in order to provide remote data analysis, remote service, and / or remote operation of the existing weighing station. The junction box thus is capable of acting as a monitoring system for a weighing system, communicating data regarding the use of the weighing system thereby enabling unattended use or remote monitoring of the weighing system and also providing valuable information regarding service and maintenance needs of the weighing system, thereby reducing time during which the weighing system may be down for maintenance.

[0016] According to embodiments, the inventive junction box is a drop-in digital junction box retrofit for analog floor / industrial scales. This adds digital intelligence, diagnostics, and connectivity to existing scales without replacing the scale platform, load cells, or legacy weight indicator. Outputs CAN bus, WiFi, and / or BLE signals alongside preserved analog signals to the existing indicator. According to embodiments, the junction box sits between individual load cells and the indicator, observing pre-summation per-cell signals. This observation point, combined with software-controllable digipots and three communication channels (CAN + WiFi + BLE), creates a uniquely powerful position that enables capabilities no indicator or external monitoring device can replicate.

[0017] The present invention will now be described with reference to the following embodiments. As is apparent by these descriptions, this invention can be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. For example, features illustrated with respect to one embodiment can be incorporated into other embodiments, and features illustratedwith respect to a particular embodiment may be deleted from the embodiment. In addition, numerous variations and additions to the embodiments suggested herein will be apparent to those skilled in the art in light of the instant disclosure, which do not depart from the instant invention. Hence, the following specification is intended to illustrate some particular embodiments of the invention, and not to exhaustively specify all permutations, combinations, and variations thereof.

[0018] It is to be understood that in instances where a range of values are provided that the range is intended to encompass not only the end point values of the range but also intermediate values of the range as explicitly being included within the range and varying by the last significant figure of the range. By way of example, a recited range of from 1 to 4 is intended to include 1-2, 1-3, 2-4, 3-4, and 1-4.

[0019] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used in the description of the invention herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0020] Unless indicated otherwise, explicitly or by context, the following terms are used herein as set forth below.

[0021] As used in the description of the invention and the appended claims, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0022] Also as used herein, “and / or” refers to and encompasses any and all possible combinations of one or more of the associated listed items, as well as the lack of combinations when interpreted in the alternative (“or”).

[0023] Implementations described herein provide a system and method for one or more users (e.g., a scale operator, scale serviceperson, or technical expert) to remotely monitor use, status, and operating characteristics of a weighing scale system. These characteristics include, but are not limited to, any of zero counts, individual load cell counts, counts at various positions on the load cell (e.g. ends and middle), number of weighments, highest weighment of the day, weight measurements, and environmental factors such as temperature, water, level, motion, depth of debris under the load cell, metal or other objects in the vicinity of the load cell, or any combination thereof. The operating characteristics are gathered using a weighing monitoring system that incorporates a remote computing interface, such as a web browser used on a remote computing device, such as a smart phone, computer, or tablet; a main unit including at least one printed circuit board (PCB), a local computing device containing a microprocessor, and a programable microcontroller; and a weighing scale junction box including one or more sensors. Additionally, a user can manually input information into the computing device, such as known environmental factors, maintenance and repair information, known operating errors, and the like. The information gathered by the junction box can then be transmitted from the local computing device of the main unit to one or more remote computing device monitored by a remote user. The remote users can then receive information about the weighing system’s condition using the remote monitoring system. In some implementations, a monitoring system transmits information directly to the one or more remote computing devices and / or the monitoring system transmits information first to a remote server, which then transmits information to the remote computing devices.

[0024] For purposes of illustration only, the following example is a non-limiting exemplary environment in which implementations of remote monitoring systems described herein can be used.

[0025] In this exemplary environment, for example as shown in FIG. 1, use, status, and operating characteristics of a weighing system 12 may be monitored by several different users, local and remote. For example, the users are on-site load cell operators, on-site load cells servicepersons, and / or remote operators or servicepersons. As shown in FIG. 1, a typical scale or weighing system 12 includes a loading area 14 and a bottom side 14’. The loading area 14 includes multiples load cells 10. The weighing system 12 additionally includes a junction box 16 that receives weighing information from the load cells 10 via load cell cables 13. The junction box 16 is configured to sum the weighing information from the load cells 10 and then communicate the summation to an indicator 18 via a main cable 17. The indicator 18 of the weighing system 12 displays a weight measured by the load cell 10 and summed by the junction box 16. According to embodiments, the junction box 16 is provided with a plurality of sensors for collecting use, status, and operating characteristics of the weighing system 12. As such, the inventive junction box is part of a continuous condition and characteristic monitoring system 50 that monitors the weighing system 12. It will be understood that new scales can be manufactured to include a continuous condition and characteristic monitoring system 50, while existing scales can be easily and at a low cost retrofitted to include a continuous condition and characteristic monitoring system 50, including an inventive junction box 16.

[0026] As shown in FIG. 1, embodiments of a continuous monitoring system 50 include a main unit 52, the junction box 16 provided with a plurality of sensors thereon, at least one remote computing device (shown in FIG. 2), and optionally at least one sub-unit 54. According toembodiments, the main unit 52, which is described in detail below, is part of the junction box 16. The main unit 52 includes at least one printed circuit board (PCB), a local computing device containing a programable microcontroller. As shown in FIG. 1, the main unit 52 of the monitoring system 50 is installed adjacent to the weighing system 12 near the indicator 18. The main unit 52 is electrically tied to the indicator 18 of the scale 12, the main unit 52 receiving power therefrom. According to embodiments, the main unit 52 is in serial communication with the scale indicator 18, for example using an RS 232, 485 communication standard. The main unit 52 is configured to log data received from the junction box 16 and the sub-unit 54, when present, perform computations, and transmit the data and computations to other components of the system 50 via an internet connection, such as a 2G, 3G, or LTE connection.

[0027] According to embodiments, the main unit 52 and the junction box 16 are powered passively by harvesting from excitation lines. This includes a method of siphoning operating power from the load cell excitation voltage without degrading signal-to-noise ratio on the measurement channels. Voltage regulation and filtering are designed specifically to not introduce noise back into the excitation / sense lines. There is an option for 5V / 10V excitation optionality, with the junction box operating correctly and harvests power from either standard excitation voltage with auto-detection or manual configuration. Power budget management: running digital subsystem (ADCs, MCU, CAN transceiver, WiFi / BLE radio) within the harvested power envelope.

[0028] According to embodiments, the main unit 52 and the junction box 16 are configured to accept external supplemental power in addition to passive harvesting. Arbitration logic between passive and supplemental sources provides a seamless switchover, brownout handling, graceful degradation. This allows for full analog pass-through even if the digital subsystem loses power entirely (fail-safe to “dumb junction box” mode).

[0029] Notably, embodiments of the present invention provide for full analog signal pass-through to legacy weight indicator. That is, the indicator sees electrically identical characteristics to a plain junction box. Impedance matching / buffering is present so digital measurement taps do not load or alter the analog signal path. As such, there is zero-downtime to retrofit given that analog weighing is never interrupted during junction box installation or digital subsystem operation.

[0030] According to embodiments, the continuous monitoring system 50 uses digital potentiometers (digipots) for per-cell corner correction and sensitivity adjustment and electronic trimming. These digipots replace manual trimpots with software-controllable, repeatable, precision adjustment. Digipot settings are stored in non-volatile memory, restorable after power loss. Remote adjustment of digipot values can be done via CAN, WiFi, or BLE command, meaning no physical access to junction box is required after installation, thereby further enabling remote use and control. Digipot resolution and range selection can be matched to load cell signal levels for fine-grained trimming without quantization artifacts. Additionally, dynamic real-time trim compensation is achieved by continuously adjusting digipot values in operation to compensate for temperature drift, cell aging, or slow mechanical changes. The analog signal to the indicator is actively improved in real-time without the indicator knowing. Aging compensation is also present by slowly adjusting trim over months as cells drift, extending the interval between required recalibrations. This allows the scale to stay more accurate longer, autonomously. Linearization at the source additionally is provided by applying multi-point linearity correction via digipots before the analog signal reaches the indicator, improving the indicator’s accuracy without the indicator having that capability itself. This upgrades indicator performance from the junction box. Cell failure simulation mode is also provided, by intentionally misadjusting a digipot to simulate adegraded or failed cell, for technician training or downstream alarm system testing. This provides a built-in test capability.

[0031] According to embodiments, the junction box 16 is a true retrofit design. That is, the PCB and enclosure is designed to fit standard junction box mounting patterns and cable gland layouts. The internal arrangement accommodates both analog pass-through wiring and digital PCB within an existing junction box footprint.

[0032] According to embodiments, the junction box 16 includes one or more sensors for detecting use, status, and operating characteristics. According to embodiments, the junction box 16 is installed on the second side 14’ of or below the loading area 14 to avoid interference with weighing traffic and to ensure consistent measurements are taken. Such an underneath location on the second side 14’ of the scale 12 avoids sun, shade, and precipitation. Alternatively, the junction box 16 is installed in line with the loading area 14 to provide a line of sight of the loading area 14 and to better assess weather conditions at the loading area 14. The main unit 52 is connected to a the junction box 16 via communication bus such as a digital and / or analog signal(s). It is appreciated that the signal can be extended over longer distances using conventional techniques. Communication buses operative herein illustratively include scalable coherent interface (SCI), small computer system interface (SCSI), disk / tape peripheral attachment bus, controller area network (CAN bus), and serial attached SCSI (SAS).

[0033] According to embodiments, the junction box 16 includes a plurality of sensors including, but not limited to, an accelerometer, a magnetometer, an air temperature sensor, and a depth sensor, which is, for example, an ultrasound depth sensor. According to embodiments, an accelerometer provided with the junction box 16 is configured to detect things like shock and abrupt movement on the scale loading area 14. The accelerometer in conjunction with the main unit 52 is additionallyable to characterize motions that take place on the loading area 14, for example if an item is dropped on the loading area 14 or is placed on or backed off the loading area. According to embodiments, the junction box includes a gyroscope in order to sense rotational information (spinning), beyond the basic 3-axis translations (movement). This is a useful sensor for determining if the junction box itself has been handled or tampered with, for example allowing the monitoring system 50 to record when the junction box 16 has been opened for maintenance or tampering, given that opening a cover on the junction box 16 includes a rotational aspect. This also is able to provide information as to whether the scale of the weighing system has fallen or has become unlevel. According to embodiments, the junction box 16 is provided with a temperature and / or humidity sensor in order to provide precise weather conditions at the exact weighing system 12. According to embodiments, the temperature / humidity sensor is able to provide actual deck temperature to anticipate thermal expansion and contraction to predict binding before the scale locks up, thereby allowing for preventative maintenance or shutting down of the scale in order to avoid damage to the weighing system 12. According to embodiments, the junction box 16 is provided with a depth sensor, which according to embodiments is an ultrasonic depth sensor. This sensor is able to measure level of water / mud I debris underneath the scale and / or at chosen critical points like over a sump or drainage area of the weighing system 12. According to embodiments, the junction box 16 is provided with light or optical sensors, which is another way to sense if someone is opening up weighing system parts. Recording such information can assist in warranty preservation, required service intervals, etc. According to embodiments, the junction box 16 is provided with diagnostic lights thereon that are visible outside of the junction box 16 without opening the junction box, thereby allowing for diagnosis of potential issues without needing to open the junction box. According to embodiments, the junction box 16 is additionally providedwith additional GPTO (general purpose inputs / outputs) for additional sensors that can be added based on specific needs of a weighing system 12. For example, floats with mechanical contact switches could be added to the junction box for monitoring of a sump pump in order to cross-check depth of water in the drainage system, or an external temperature sensor can be added to the junction box 16 to place exactly where a measurement point is required, like water temperature of the sump crock. According to embodiments, the junction box 16 is provided with a sound sensor that is able to detect and even record sounds or chirps near the weighing system or recorded messages. According to embodiments, the sound sensor of the junction box 16 enables voice activated commands or replies for communicating with the monitoring system 50. According to embodiments, the junction box 16 is provided with ethemet ports for additional technology to be added as needed based on the specific needs of the weighing system 12. For example, cameras could be plugged into the ethernet ports of the junction box 16 and aimed at desired locations for visual monitoring of the weighing system 12. According to embodiments, the junction box 16 is provided with wireless ability, to send digitized signals to main unit without the need for additional wires to connect to the main unit 52. According to embodiments, the junction box 16 is provided with GPS / GNSS - to help locate a weighing system 12, for example a weighing system that is portable and has been moved or stolen.

[0034] According to embodiments, the junction box 16 provides hidependent Weight Verification and Shadow Metering. That is, the junction box 16 reconstructs a complete weight reading independently of the indicator from per-cell digital data. This enables fraud detection in that the junction box-computed weight can be compared to the indicator-displayed weight and any discrepancy flags tampering or indicator malfunction. Thus, an independent audit capability is provided from a passive component, without a second indicator being required. Embodiments alsoprovide a legal metrology application where the junction box 16 is used as a certified verification device independent of the indicator.

[0035] The inventive system and junction box 16 are configured to provide weighing transaction reconstruction. By logging complete transaction-level data at per-cell resolution, including approach, settle, stable weight, departure. CG trajectory throughout. In contrast, the indicator only records final stable weight. Advantageously, the junction box 16 captures the full dynamic event. This enables a richer audit record from a passive component than the active indicator produces.

[0036] As shown in FIG. 1, some embodiments of the monitoring system 50 include a sub-unit 54 that includes one or more additional sensors for detecting use, status, and operating characteristics of the weighing system 12. The sub-unit 54 includes a plurality of sensors including, but not limited to, an accelerometer, a magnetometer, an air temperature sensor, and a depth sensor, which is, for example, an ultrasound depth sensor, a water level sensor and a water temperature sensor. According to embodiments, the sub-unit 54 is installed near a side of the loading area 14 but separate from the junction box 16. According to embodiments, the sub-unit 54 is connected to the junction box 16 and / or the main unit 52 via similar bus (digital and / or analog).

[0037] The condition data sensed by the plurality of sensors of the junction box 16, and when present the sub-unit 54, is communicated to and logged by the main unit 52. The main unit 52 analyzes and runs computations based on the data collected by and communicated from the junction box 16, and when present the sub-unit 54. The main unit 52 then communicates the collected data, the analyzed data, and / or the computations based on the data to at least one remote computing device 60 via a 2G, 3G, of LTE connection. According to embodiments, the main unit 52 communicates to the at least one remote computing device 60 via a cloud or server 70. The atleast one remote computing device 60 may be any of a smart phone, a computer, a tablet, or a combination thereof. The at least one remote computing device 60 provides a user dashboard that presents the collected data, the analyzed data, and / or the computations based on the data to a user. Additionally, a user may receive alters to a remote computing device 60 via email and / or SMS.

[0038] The inventive monitoring system 50 provides a more holistic and more detailed picture of the overall operating conditions of a weighing system 12 as compared to existing systems that tend to provide much more limited data, namely a summation of the individual load cells. In contrast, the inventive monitoring system 50 and its junction box with a plurality of data collecting sensors collect and analyze a greater amount of data relevant to the overall operations of the weighing system 12, thereby enabling remote operation of the weighing system 12, that is operation of the weighing system 12 without an attendant at the site of the weighing system 12. The monitoring system 50 and the junction box with sensors additionally allows for remote troubleshooting and service of the weighing system 12, without requiring a service person go to the site of the weighing system 12. For example, the inventive monitoring system 50 is able to alert users to a scale error, for example an imbalance of load cell(s), and also provide data that indicates a root cause of the error, such as whether there is material built-up under the scale, whether there was a large shock or blow experienced soon before the imbalance or error, whether there is a misalignment or seized or damaged component, or whether the error is likely caused by long term damage such as corrosion due to components being submerged. Accordingly, the present invention provides a larger, more detailed view of all relevant factors that contribute to an error state or condition of a scale or weighing system, and thus enables a better, faster response to avoid scheduling a loss to a weigh facility.

[0039] Advantageously, the junction box expands the root cause failure analysis capability into the scale component itself, integrated at the signal source, without requiring a custom indicator or reinventing the entire scale. Root cause analysis is performed within the junction box using percell raw data, rather than relying on the indicator’s post-summation view. This is able to use celllevel granularity that the indicator never sees (indicator only gets the summed analog signal). This is able to provide a causal chain construction: specific shock event subsequent cell drift onset — measurement degradation. Tying specific logged impact events (with timestamp, magnitude, per-cell detail) to the onset of cell performance changes. Thus the system can build a causal history: e.g., “Cell 3 began drifting 0.02% / week starting 3 days after a 4.2mV shock event on [date].” Embodiments use a multi-signal fusion for root cause, correlating voltage diagnostics, shock logs, CG patterns, zero-drift trends, and (future) IMU / accel data to isolate failure root cause. The system is able to distinguish between: cell failure, cable / connection degradation, mechanical platform issue, environmental damage, overload damage, and normal wear. According to embodiments, integration with environment sensors provides combined analysis without requiring those sensors to be connected to a custom indicator. Importantly, this provides a system with root cause monitoring without reinventing the scale. This achieves indicator-grade (or better) diagnostic and root cause capability from a passive, retrofit junction box component — no proprietary indicator, no replacement of existing infrastructure. The junction box as an intelligence layer added to any analog scale, preserving the customer’s existing indicator and workflow.

[0040] The information regarding the status, use, and operating conditions of the weighing system 12 that is collected by the sensors of the junction box and analyzed by the main unit 52 is able to provide enhanced features to the weighing system 12 not previously possible. For example, the junction box 16 and main unit 52 are able to provide information regarding vehicle velocity onthe loading area 14. Additionally, the junction box 16 and the main unit 52 are able to provide in formation regarding change in movement over time on the scale, for example using the accelerometers to monitor for changes in structural behavior, even broken parts in the weighing system. The inventive junction box 16 and main unit 52 provide the ability to learn through previously collected data or training data and determine if a weighing system was installed correctly in the first place. The information collected from the junction box 16 and analyzed by the main unit 52 additionally provides for auditing how many times the weighing system has been used, either through motion or weight signal itself (like usage auditing, or even loss prevention in case a paid-for scale terminals is closed after-hours). According to embodiments, the junction box 16 is additionally provided with magnetometers to assist in providing information to the monitoring system 50 regarding the type of vehicles that use the weighing system. According to embodiments, the monitoring system includes an Al algorithm that continuously learns from the data collected from the junction box 16, and when present the sub-unit 54, to generate deduced outputs based on the collected information, for example who is using the weighing system, what various motion patterns mean, and how hard the weighing system is being used. The inventive monitoring system additionally, is able to act as a use meter for the weighing system, telling a user how much wear / tear has happened on the weighing system, thereby allowing users to plan for upcoming service on the weighing system.

[0041] According to embodiments, the junction box 16 is able to provide process intelligence from weight data, that is extracting operational and process insights purely from weight signal analysis, without integration into process control systems. This includes throughput and cycle analytics such as counting weighing cycles, measuring dwell time on scale, and calculating loading / unloading rates. Operational efficiency metrics are extracted purely from weight datawithout any process system integration. Shift-level, daily, weekly productivity reporting are provided from the scale alone. Embodiments include loading behavior profiling, with center of gravity trajectory during loading revealing how operators approach the scale, where they place loads, whether they center correctly. Operator training feedback can be generated from the scale and weight data itself, thus eliminating the need for cameras or additional sensors. Thus, specific operator behaviors that cause scale damage or measurement error can be easily identified. Furthermore, process anomalies can be detected from weight patterns. For example, the system is able to detect that today’s batch weights have shifted distribution compared to the historical norm. Thus, an important quality / process control signal is obtained from a passive scale component, with no integration into the process control system. This provides an early warning of upstream process drift (e.g., filling line miscalibration) detected at the scale.

[0042] According to embodiments, the junction box 16 and main unit 52 are able to provide cell fingerprinting and authentication. That is, each cell develops a unique signature over time based on, for example, linearity curve, creep profile, temperature coefficient, noise floor, hysteresis pattern. The junction box then builds per-cell identity profiles to detect unauthorized cell swaps (even same model / brand), verify installed cell matches calibrated cell, and flag counterfeit cells. This additionally enables calibration integrity verification by providing information to confirm that a given cell is the same cell that was present at the last legal calibration.

[0043] The cell-fingerprinting enables a hot-swap cell replacement with back calibration. That is, stored per-cell coefficients and historical sensitivity data enable recalculation when a cell is replaced. A new cell’s characteristics are then computed relative to the known remaining cells. This enables functional calibration before a legal / compliance metrology visit and ensures that the scale is operational immediately after cell swap. This provides an audit trail of original comparedto recalculated parameters. Additionally, the cell fingerprint comparison confirms the swap actually occurred and identifies the new cell’s characteristics versus the original.

[0044] The inventive system 50 also provides a one touch comer balancing algorithm. The method includes cycling a weight once on all comers. Then, the junction box 16 auto-computes per-cell sensitivity trim coefficients. Digipot values are adjusted automatically based on computed coefficients. This does not require physical (mechanical) balance of the platform. This is a singlepass process: one weight, four corners, done — versus iterative manual trimming. Prior to calibration, the system 50 is able to provide pre-calibration assistance using raw cell counts (before any electronic trim) to assess physical platform balance. This provides an installer guidance on mechanical leveling based on digital readout of per-comer counts. This is distinct from the electronic sensitivity trim — this is the mechanical assessment step that informs whether physical adjustment is needed before 1 -touch.

[0045] Additionally, remote calibration parameter management is provided. Push calibration parameters (digipot settings, trim coefficients, configuration) are provided over CAN, WiFi, or BLE. A verification and rollback mechanism confirms new parameters produce expected readings before committing. This provides a calibration audit trail stored locally injunction box non-volatile memory (tamper-evident, timestamped) and a multi-point linearity correction per cell if sufficient data is captured during calibration process.

[0046] According to embodiments, the continuous monitoring system 50 with the junction box 16 includes Triple-Channel Communication with CAN, WiFi, and BLE. Advantageously, this includes simultaneous CAN bus output (to edge gateway I loT infrastructure), WiFi (infrastructure wireless), and BLE (walk-up mobile access). The same command set is available on all three transports — calibration, diagnostics, configuration accessible via any channel. This enables athree-tier failover architecture — CAN (primary / wired) WiFi (secondary / wireless infrastructure) — BLE (tertiary / walk-up). Specific failover hierarchy and data synchronization across three heterogeneous transports. Additionally, there is a data synchronization protocol ensuring no data loss during transport switching.

[0047] With the BLE walk-up commissioning and calibration, a user is able to perform full 1-touch calibration, digipot adjustment, configuration, and diagnostics from a mobile device via BLE. No gateway infrastructure is required for installation and commissioning, instead, an installer walks up to the system with a phone. Some embodiments include authentication and pairing protocol for secure access.

[0048] With the WiFi direct connectivity, that is embedded web server , the WiFi enables a configuration / diagnostic web UI hosted on the junction box 16 itself. A user is thus, able to walk up with any device with a browser to interact with the system, no app install required. This communication channel is distinct from BLE which typically needs a dedicated app. Embodiments include direct MQTT / cloud connectivity — WiFi which means the junction box can talk to the cloud directly without a gateway at all. The gateway becomes optional even for 24 / 7 monitoring, not just commissioning. Embodiments include WiFi presence / proximity detection and enables knowing when a known device is nearby without explicit pairing. According to embodiments, this can be enabled to trigger status display, auto-wake from low-power mode, or technician proximity logging.

[0049] The CAN protocol communication channel is a purpose-built CAN message framing that is optimized for scale data: per-corner weights, diagnostics, status, alerts. Embodiments includes multi-j unction box addressing on shared CAN bus, which enables multiple scales to be on one network segment. According to embodiments, information from the junction box can bestored and forward buffering in junction box when no transport is connected and then timestamped data is delivered on reconnection.

[0050] According to embodiments, full calibration and commissioning functionality are available without any gateway (BLE or WiFi). A gateway provides enterprise-grade 24 / 7 / 365 continuous monitoring, data aggregation, and cloud connectivity. The junction box operates autonomously in any mode — gateway is additive, not required.

[0051] Advantageously, the inventive monitoring system with its junction box 16 with sensors provides the feature of remote disconnection of the weighing system 12. That is, the junction box 16 along with the main unit 52, enable the ability to disconnect the weighing system 12, check for shorts and then reconnect, all remotely. This is particularly useful for situations when the weighing system 12 is not being used, after hours, etc. This enables a useful starting point for trouble shooting issues of the weighing system by allowing the various cables to be checked for shorts.

[0052] According to embodiments, the junction box 16 conducts per-cell independent sampling using Individual high-rate ADC channels per load cell (50 Hz+) operating simultaneously with the preserved analog summation path. This dual-path architecture provides a digital intelligence channel independent from the analog measurement channel to the indicator. Embodiments of the inventive system 50 also maintain per-comer (per-cell) digital weight data, versus the traditional summed-analog-only approach. This provides real-time per-cell data and enables all downstream diagnostics, calibration, and predictive features.

[0053] According to some inventive embodiments, signal processing applied to the per-cell digital data is modified consistent with a given industrial weighing platform specification. Factors considered in the modification illustratively include mechanical ringing of the scale deck, vibration profiles induced by surrounding industrial equipment, low-frequency oscillation of the platformon load cells thereof, transient loading dynamics typical of vehicle, axle, forklift loading events, or combinations thereof. In still other inventive embodiments, the junction box 16 applies a first filter stage matched to expected mechanical ringing frequencies of the platform and a second filter stage matched to expected loading transient profiles, with oversampling strategies selected to preserve per-cell resolution of shock and center-of-gravity events while rejecting environmental vibration noise. In some embodiments, noise floor of each per-cell channel is itself monitored and reported as a diagnostic signal, distinct from the transducer output, such that changes in the noise floor over time are used to infer wiring, connection, or environmental changes independent of the transducer itself.

[0054] According to embodiments, the junction box 16 and operation of the weighing unit 16 is turned on or enabled by an input to the junction box 16 from a connected pay station and / or gate access controls. According to embodiments, the gate access allowing a vehicle to pass onto the loading area 14 of the weighing system and activating of the junction box 16 is activated by an RFID. Thus, only authorized users with gate access, a required RFID, or those who have paid a required fee are able to access and / or utilize the weighing system 12.

[0055] Embodiments of the inventive remote monitoring system 50 also provide predictive monitoring such that preventive repair and maintenance measures may be undertaken before a scale ever experiences an error. That is, rather than using a static, inflexible style of testing based on guessing that must be customized for each scale, the present invention uses a statistical approach that obtains a unique understanding of each weighing system 12 and its specific environmental surroundings. To do so, the present invention employs 3 Sigma control limits for monitored condition variables and paired T-tests for quality control statistics. An algorithm of the remote monitoring system 50 uses these statistics to automatically take into account and set thresholds forthe myriad factors that affect the performance of each load cell. Thus, the present invention avoids the need to catalog every single variation of scale performance and the need to set overly broad, general limits that may miss true alerts for some scales and generate false alarms for others. Instead, the remote monitoring system 50 of the present invention determines and sets thresholds intelligently without interventions by a user and alerts a user to conditions that may lead to or result in a weighting error before such an error becomes a reality.

[0056] The predictive monitoring provides predictive analytics and failure prediction. Embodiments include cell degradation trending where per-cell zero-return consistency, creep behavior, sensitivity drift, and hysteresis are tracked over time. Trending against baseline established at commissioning to quantify degradation rate. From this the system is able to generate remaining-useful-life estimates per cell. Embodiments also include anomaly detection and adaptive thresholds. On-junction box anomaly detection learns normal operating patterns for each specific installation. This includes adaptive alert thresholds that self-tune from observed usage, replacing fixed factory defaults. This works without cloud connectivity (edge intelligence) — cloud enhances but is not required. Embodiments include proactive alerts before failure affects measurement (cell degrading, connection deteriorating, overload accumulation approaching limit). Severity classification and recommended actions are also provided. Additionally, maintenance scheduling guidance is provided based on predicted degradation trajectory. Embodiments also include load distribution anomaly monitoring with long-term tracking of CG patterns during normal use to detect platform mechanical issues (foundation settling, frame bending, pivot wear, summing card degradation). The system is then able to Flag when usage CG distribution shifts over weeks / months. Embodiments also include environmental inference from cell behavior by estimating ambient conditions (temperature cycles, humidity effects) from cell behavior patternswithout dedicated environmental sensors. Temperature compensation uses inferred or measured thermal data per cell.

[0057] Additionally, embodiments of the inventive remote monitoring system 50 provide a user with trend reports available on the remote computing device(s) 60. Such trends are developed by way of the system 50 collecting and analyzing the load cell data. The algorithm automatically identifies trends in the collected and analyzed data regarding the operation and conditions of the weighing system 12. Such trends enable a user to identify and prioritize areas of the load cell that are ready for improvement in order to reduce variation and create more robust load cells and avoid weighing errors and shutdowns caused by such weighing errors. These trend reports are more than the timestamped error logs of fault reporting, sum or errors, and temperature reports available in existing local monitoring systems. The trend reports of the inventive remote monitoring system 50 continuously read and show data points, but also presents a holistic picture of the health and operation of a load cell. That is, the dashboard on a remote computing device 60 is able to provide a user with time plots of all condition applicable variables, revealing patterns such as clusters or spikes in operation conditions that may correlate or otherwise help explain situations that lead to weighing errors. The present invention also compiles weekly technical summaries that are visible in the dashboard on the remote computing device(s) 60 to statistically discriminate and highlight trends, beyond simple reporting.

[0058] According to embodiments, the inventive junction box 16 with sensors and monitoring system 50 may be installed on a new or existing scale 12. A manufacturer of serviceperson installs the inventive junction box 16 to the weighing system 12 and connects it via cables to the load cells. The junction box 16 is then electronically connected to a main unit 52 near the scale 12 and / or electrically connected to the indicator 18 of the weighing system 12. Installation continues byattaching at least one sub-unit 54 to the side or underside 16 of the loading area 14 and connecting the sub-unit 54 to the main unit 52 via wires that provide an analog or digital signal between the units. Next the remote monitoring system 50 is calibrated. That is, an operation baseline is established by collecting operation data. Operation data that is collected to establish a baseline of operation includes, but is not limited to, any of zero counts, individual load cell counts, counts at various positions on the load cell (e.g. ends and middle), number of weighments, highest weighment of the day, weight measurements, and environmental factors such as temperature, water, level, motion, depth of debris under the load cell, metal or other objects in the vicinity of the load cell, or any combination thereof. Upon collecting this calibration data, the computing device of the main unit 52 analyzes the data to compute and catalog statistics to enable preventive altering. Namely, the algorithm analyzes control chart statistics for each set of data points illustratively including 3 sigma, a mean, and standard deviation and analyzes quality control statistics wherein regular recalculation of control chart statistics are compared using paired T-test values and significant level of 0.05.

[0059] As time goes on and the load cells 10 are used in the normal course of business, the remote monitoring system 50 continues to monitor and collect data regarding the operation and condition of the weighing system 12 to identify operation and condition trends and potential error causing conditions before they occur.

[0060] According to embodiments, the main unit 52 is in communication with a gateway device, either wired communication or wireless communication. The gateway transmits information gathered by the remote monitoring system 50 wirelessly to the secure server or cloud over a cellular network, Wi-Fi network, and the like.

[0061] The remote server or cloud is configured to store the monitoring information received from the remote monitoring system. The system compares the sensed values of the weighing system (generated by the continuous remote monitoring system and transmitted to the server via the gateway) to predetermined thresholds and initiating an action if a threshold is exceeded. For example, the server can compare a current sensed condition value with a predetermined alert generating threshold that has been determined by the algorithm and initiate a notification, such as a text message over a cellular network, to a remote computing device if a monitored condition value exceeds the threshold. The server can also provide historical and current operating condition values to the remote computing device on demand.

[0062] As discussed above, the remote monitoring system is configured to alert a user to operation characteristics of a weighing system. The remote monitoring system generates and receives notifications from the server when an automatically generated threshold is crossed with respect to any of the monitored operation conditions, notifying the user of the condition of the load cell or of a predictive condition of the weighing system. The remote monitoring system can also be used to view historical information about the monitored operating characteristics of the load cell and automatically modify notification rules, such as the threshold levels that trigger alerts.

[0063] According to embodiments, the inventive remote monitoring system operates on a network, which illustratively can include any communication medium, such as wired and wireless networks including cellular networks, local area networks, wide area networks, Wi-Fi networks, the internet, and the like. The network can also include one or more servers to process the data received from plurality of sensors and transmit notifications and data to one or more remote computing devices either automatically or in response to a request from a remote computing device. Each remote computing device can be associated with an individualthat is interested in monitoring the operating conditions of one or more weighing system using an inventive remote monitoring system. Each remote computing device can be associated with a user, such as technical expert, service person, weighing facility operator, and the like. As discussed above, the remote computing device includes a computing device that receives notifications from a network and requests additional information, such as historical data generated by one or more remote load cell monitoring systems.

[0064] According to embodiments, the inventive remote monitoring system also includes a workstation. The workstation may be a computing device, such as a personal computer, that has access to the remote monitoring system for configuring settings of system during calibration and / or viewing information associated with one or more remote monitoring systems, such as reports generated by remote monitoring system based on a weighing system’s operating characteristic data.

[0065] Using the remote monitoring system, one or more remote computing devices can monitor one or more remote load cell monitoring systems. That is, a weighing system can be monitored from multiple remote computing devices at the same time, allowing multiple interested users to view and monitor the operating conditions of a weighing system cell at a given time. Various permissions and invitations can be used to limit which remote computing devices can access a given remote monitoring system of a particular load cell.

[0066] In some example implementations, the remote computing device 60 may comprise one or more of the following: a mobile station, a wireless terminal, a tablet, a smart phone, or the like. For example, the remote computing device may be implemented as a wireless handheld device, a wireless plug-in accessory, or the like. Moreover, the remote computing device may be implemented as multi-mode device configured to operate using a plurality of radio accesstechnologies, such as Long Term Evolution (LTE), wireless local area network (WLAN) technology, such as 802.11 Wi-Fi and the like, Bluetooth, Bluetooth low energy (BT-LE), near field communications (NFC), and any other radio access technologies. Moreover, the remote computing device may be configured to establish connections to access points in a network, such as cellular base stations, Wi-Fi access points, and the like, using at least one of the plurality of the radio access technologies. Although some of the examples herein refer to the remote computing device as a mobile, wireless device, the remote computing device may also be implemented as a stationary device, such as a personal computer and the like.

[0067] In some example implementations, a secure server may register and / or configure one or more of the main unit 52, sub-unit 54, junction box 16, and remote computing device 60 before the remote monitoring of a weighing system is initiated, although registration and / or configuration may occur at other times as well. Moreover, the configuration process may be performed to configure the system including the identities of the one or more remote computing devices used to monitor the weighing system, configure one or more rules used to trigger notification messages to the remote computing devices, configure one or more rules designating primary and secondary remote computing devices, configure one or more rules establishing schedules for the primary and secondary monitoring operations, configure one or more rales defining an escalation sequence representative of when to elevate an event to an alert, and the like.

[0068] To illustrate by way of an example, the main unit 52 may receive sensor data from the junction box 16, and when present the sub-unit 54, and process the sensor data. If the main unit 52 determines that the sensed data is outside a threshold limit or when compared with previously sensed data indicates a concerning trend regarding the operation of the weighing system, the main unit 52 will transmit the sensor data to a secure server or cloud, according to someembodiments via a gateway and network. Additional analysis and processing of the sensor data may determine that the measured data is outside one or more rules defining events and then follow its self-imposed rules defining the identities of the remote computing devices that are deemed to need to receive a notification message indicating the operating condition of the weighing system. For example, the rule may define that when a high level of debris is detected under a load cell, a certain remote computing device, such as a weighing facility operator should receive a notification message, so that the weighing facility operator can quickly go remove the accumulated debris from under the load cell. The notification message may include an indication of the type and cause of the event, the time of the event, and other information, such a plot of current and past debris levels, load cell identifying information, and / or any other host related information.

[0069] The one or more rules defining the events may be defined during the configuration process by a user and / or predefined as default rules (which may be reconfigured by a user or may be automatically adapted by the remote monitoring system over time to accommodate the unique characteristics and environmental conditions of a particular weighing system. In some example implementations, the one or more rules may define a threshold value representative of a severity of the event that should be reported to the one or more remote computing devices, the times of day when a notification message should be sent to each of the remote computing devices, the identities (e.g., phone number, Internet Protocol address, email address, and the like) of the one or more remote computing devices, and the like.

[0070] Furthermore, the one or more rules may include escalation rules, so that events can be handled differently based on severity of event, type of event, and / or lack of responsiveness by a designated remote computing device. For example, a rule may define that a sensed value below or a above a set threshold value should not be the subject of a notification messageto remote computing device (although an alert may be indicated locally on the main unit); another rule may define that a sensed value between a range of values should be the subject of a notification message to remote computing devices; while another rule may define sending, when a critically out of line value is detected, notification messages and alerts to remote computing devices may be pushed with an indication of high importance. In some example implementations, the rules used to trigger alerts regarding some operating characteristics may be different from the rules used to send notification messages for other operating characteristics, although one or more of the rules may be the same as well.

[0071] In some example implementations, the secure server may send a notification message to a push notification service, which then pushes a notification to the remote computing device. Examples of push notification services include the Apple Push Notification Service (APNS) and Google Cloud Messaging, although any other messaging mechanism including email, short messaging service, tweets, and the like may be used

[0072] as well. In the case of APNS, the remote computing device (or a notification message center therein) may establish an Internet Protocol (IP) connection with the APNS. This connection may be encrypted, persistent, and / or accredited, so that the notification service can send notification messages to the notification message center even when the remote computing device is not actively being used. For example, the notification message center may alert the user of the remote computing device that a notification message had arrived for the remote computing device.

[0073] In an implementation utilizing a push notification service, the notification service may receive a notification message from the secure server. The notification message may include a destination address, such as a phone number of the remote computing device, an IP address, andthe like, and a payload, such as the contents of the notification message. Returning to the previous example regarding debris level, the notification message may include the phone number of remote computing device and a short text message, such as a high debris level value, time of measurement of the value, and / or an identity of the load cell. The notification message may be limited to 256 bytes, although other sized messages may be used as well. In any case, the notification service pushes the notification message to remote computing device via a connection, such as an Internet Protocol (IP) connection, between the notification service and a notification message center at the remote computing device. When the notification message center at the remote computing device receives the notification message, the notification message center may display the notification message, generate a sound, a vibration, and another other indication to a user of the remote computing device. Additionally, in some example implementations, the notification message center or a user of the remote computing device may activate the dashboard if the dashboard at the remote computing device is not actively being used. The notification service may be used in implementations in which the remote computing device, such as a smart phone and the like, that places the remote monitor or the applications therein in an idle or an inactive mode to conserve power or reduce signaling to / from the network.

[0074] The main unit 52 is configured to receive sensed data from the plurality of sensors on the junction box 16, and when present the sub-unit 54. According to embodiments the main unit 52 includes a sensor electronics module. The sensor electronics module may include sensor electronics that are configured to process sensor information, such as sensor data, and generate transformed sensor data and displayable sensor information. For example, the sensor electronics module may transform sensor data into one or more of the following: filtered sensor data, raw sensor data, calibrated sensor data, rate of change information, trend information, rate ofacceleration information, sensor diagnostic information, location information (which may be provided by a location module providing location information, such as global positioning / navigation system information), alarm / alert information, calibration information, smoothing and / or filtering algorithms of sensor data, and / or the like.

[0075] According to embodiments, the system provides local diagnostics and detection, including voltage monitoring, shock detection, velocity and motion detection, connection and cable integrity monitoring, overload event logging, mechanical health inference, and analog signal tampering detection. Voltage monitoring and signal range monitoring includes per-cell voltage monitoring against expected ranges for the specific cell type and installation configuration. Detection of out-of-range excitation, sense, or signal voltages indicate wiring faults, cell damage, or environmental issues. Shock and impact detection include detection of impact events via rate-of-change (dV / dt) of load cell voltages at high sample rates (50 Hz+). Differentiation of impact events from normal loading profiles are detected by ramp-rate thresholds. The system is able to log shock events with magnitude, duration, and per-cell detail. Sensors can be fused to correlate with IMU / accelerometer data to disambiguate shock source (forklift impact vs. dropped load vs. seismic). Velocity and motion detection monitoring includes center of gravity migration monitoring with instantaneous center-of-gravity (CG) computation from per-comer voltage balance at high sample rates. The CG movement trajectory is used to infer load velocity, direction, and behavior on the platform. Advantageously, this enables the inventive system to detect dynamic loading conditions that may affect measurement accuracy. Connection and cable integrity monitoring includes monitoring for noise floor and impedance signature changes per channel as indicators of cable degradation, moisture ingress, or connector corrosion. Distinct from cell failure — this detects the wiring and connections, not the transducer itself. Overload event loggingincludes per-cell overload detection with magnitude and duration (not just a binary flag). Embodiments include a damage accumulation model where the system tracks cumulative overload exposure per cell over time. Mechanical heath inference is accomplished by signal alone. This includes detecting platform mechanical issues (cracked welds, corroded pivots, warped frame, debris under a corner) purely from asymmetric signal patterns evolving over time. No external sensors are needed — inferring mechanical condition from electrical signals at a resolution the indicator never sees. This distinguishes mechanical degradation from cell degradation based on cross-comer correlation patterns. Analog signal tampering detection includes the junction box 16 knowing what the cells are producing and what is being passed to the indicator. If someone splices into the analog line downstream to manipulate the reading, the junction box detects the discrepancy. Thus, embodiments, provide a man-in-the-middle detection on a scale signal path, which is a novel security capability for trade / commerce applications. This is applicable to fraud prevention in high-value weighing (precious metals, pharmaceuticals, commodities trading).

[0076] According to embodiments, the main unit 52 includes a processor module and may provide the hardware, firmware, and / or software that enable wireless communication between the components of the system 50. A variety of wireless radio technologies that can be implemented including Bluetooth, Bluetooth Low-Energy, the ANT protocol, NFC (near field communications), ZigBee, IEEE 802.11, IEEE 802.16, cellular radio access technologies, radio frequency (RF), infrared (IR), paging network communication, magnetic induction, satellite data communication, spread spectrum communication, frequency hopping communication, near field communications, and / or the like.

[0077] According to embodiments the processor of the main unit 52 comprises a digital filter, such as for example an infinite impulse response (IIR) or a finite impulse response (FIR) filter.This digital filter may smooth a raw data stream received from sensors of the junction box 16, and when present the sub-unit 54. Generally, digital filters are programmed to filter data sampled at a predetermined time interval (also referred to as a sample rate). In some example implementations, such as when the system is configured to measure the operating characteristics of the weighing system at discrete time intervals, these time intervals determine the sampling rate of the digital filter. In some example implementations, the system 50 is configured to measure continuously the operating characteristics of the weighing system, for example, using a current-to-frequency converter. In these current-to-frequency converter implementations, the processor may be programmed to request, at predetermined time intervals (acquisition time), digital values from the integrator of the current-to-frequency converter. These digital values obtained by the processor may be averaged over the acquisition time due to the continuity of the current measurement. As such, the acquisition time may be determined by the sampling rate of the digital filter.

[0078] The processor may further include a data generator configured to generate data packages for transmission to remote computing devices. Furthermore, the processor may generate data packets for transmission to these outside sources via a telemetry module. In some example implementations, the data packages may, as noted, be customizable and / or may include any available data, such as a time stamp, displayable sensor information, transformed sensor data, an identifier code for the sensor and / or sensor electronics module, raw data, filtered data, calibrated data, rate of change information, trend information, error detection or correction, and / or the like.

[0079] The processor may also include a program memory and other memory. The program memory may be implemented as a semi-static memory for storing data, such as an identifier for a coupled sensor to configure the system to perform one or more of the operations / functionsdescribed herein. For example, the program code may configure processor to process data streams or counts, filter, calibrate, perform fail-safe checking, and the like.

[0080] The memory may also be used to store information. For example, the processor including memory may be used as the system's cache memory, where temporary storage is provided for recent sensor data received from the sensors of the sub-units. In some example implementations, the memory may comprise memory storage components, such as read-only memory (ROM), random-access memory (RAM), dynamic-RAM, static-RAM, non-static RAM, easily erasable programmable read only memory (EEPROM), rewritable ROMs, flash memory, and the like.

[0081] According to embodiments, the remote computing device 60 includes a user interface, which may include a variety of interfaces, such as one or more buttons, a liquid crystal display (LCD), a vibrator, an audio transducer (e.g., speaker), a backlight, and / or the like. The components that comprise the user interface may provide controls to interact with the main unit 52 of the system 50 or with the controls of the weighing system. One or more buttons may allow, for example, toggle, menu selection, option selection, status selection, yes / no response to on-screen questions, a “turn off’ function (e.g., for an alert), a “snooze” function (e.g., for an alert), a reset, and / or the like. The LCD may provide the user with, for example, visual data output. The audio transducer (e.g., speaker) may provide audible signals in response to triggering of certain alerts. In some example implementations, audible signals may be differentiated by tone, volume, duty cycle, pattern, duration, and / or the like. In some example implementations, the audible signal may be configured to be silenced (e.g., snoozed or turned off) by pressing one or more buttons or selection on a display device (e.g., key fob, cell phone, and / or the like).

[0082] According to embodiments, the present invention provides fleet and cloud analytics and cross-industry learning. The system provides usage information and operational insight with edge-to-cloud pipeline for per-scale operational data including cycle counts, load distributions, usage patterns, uptime and a dashboard / reporting layer for fleet operators. Aggregating usage patterns, failure modes, and performance data across many scales Provides cross-scale fleet analytics. Population-level statistical models for expected cell life, failure rates, and degradation curves are also provided. Additionally, benchmarking individual scale health against fleet / population norms. Learning industry-specific failure modes and usage patterns (food processing vs. logistics vs. chemical vs. agriculture) enables cross-industry performance tailoring. Auto-tuning alert thresholds and predictive models based on industry profile is thus possibly. Then industry insights can be provided back into junction box firmware / configuration for new installations. According to embodiments, the invention provides a cloud-maintained virtual model of each scale’s mechanical and electrical state, continuously updated from junction box telemetry. This enables a digital twin of each scale and enables remote assessment, what-if scenarios, and historical replay. Additionally, a particularly useful feature of the present invention is cross-scale load tracking and synchronized multi-platform weighing. With cross-scale load tracking, if a load moves from Scale A to Scale B (e.g., forklift transfers), CG and weight signatures can correlate the event across junction boxes on the same CAN bus. This enables material tracking and chain-of-custody verification without barcodes or manual logging. With synchronized multi-platform weighing, multiple junction boxes on a shared CAN bus coordinate timestamped sampling for vehicle scales, combo scales, or multiplatform systems. Synchronized per-cell data across platforms enables vehicle axle weight distribution, multi-section combo scale intelligence, and coordinated diagnostics no single indicator can provide.

[0083] According to embodiments, the junction box hardware is configured with extensible input capability for future sensors (IMU, accelerometer, temperature, humidity) beyond load cells. The software architecture is designed such that it accepts and correlates additional sensor streams without firmware redesign. Fusing accelerometer data with load cell dV / dt, the system is able to confirm and classify shock events. Using IMU for real-time platform tilt compensation on imperfect installations and validating load cell diagnostics with independent physical measurement is also provided.

[0084] As detailed herein, the inventive system features several security and compliance features. For tamper detection, the junction box is able to sense if the enclosure has been opened or if the analog signal path has been interrupted or tapped. The junction box additionally logs tamper events with a timestamp. Analog signal tamper detection is provided by comparing the junction box’s per-cell readings against the summed signal path to detect downstream manipulation. The system additionally includes calibration record integrity with cryptographic signing or hashing of calibration records and configuration changes. The system additionally provides a locally stored, tamper-evident audit trail for weights-and-measures compliance. This feature enables a forensic weight audit — tamper-evident, cryptographically signed, per-cell weight logs stored in the junction box that can be subpoenaed or audited independently of the indicator’s records. This provides an important tool for trade dispute resolution capability. The inventive system additionally provides access control with role-based access for BLE / WiFi commissioning (installer vs. auditor vs. operator vs. read-only). Embodiments also provide authentication requirements for calibration-affecting commands.

[0085] According to embodiments, the inventive junction box provides a horizontal intelligence platform for the weighing industry. This is an indicator-agnostic intelligence platform. Thejunction box works with any brand indicator from any manufacturer. It creates an open intelligence layer for a market that is historically vertically integrated (buy our indicator to get our smart features). Breaking free of vendor lock-in: customers get loT, diagnostics, and predictive capability without replacing their existing indicator investment. Advantageously, enhanced intelligence is delivered from a passive, interstitial component rather than the active measurement device.

[0086] According to embodiments, firmware OTA updates are available via WiFi or BLE. The junction box receives firmware updates in the field. New algorithms, new diagnostics, new features deployed to installed base without truck rolls. Versioned firmware with rollback capability and update verification is also available. Because the junction box is firmware-updatable and indicatoragnostic, different analytics packages are easily deployed for different industries on the same hardware. As such, the present invention provides a configurable intelligence layer whose capabilities grow post-installation via software, not hardware changes.

[0087] Patent documents and publications mentioned in the specification are indicative of the levels of those skilled in the art to which the invention pertains. These documents and publications are incorporated herein by reference to the same extent as if each individual document or publication was specifically and individually incorporated herein by reference.

[0088] The foregoing description is illustrative of particular embodiments of the invention but is not meant to be a limitation upon the practice thereof. The following claims, including all equivalents thereof, are intended to define the scope of the invention.

Claims

CLAIMS1. A system for remote monitoring and operation of a weighing system, the system comprising:a junction box having a first plurality of sensors thereon configured to collect data regarding status, use, and operation of the weighing system;a main unit in electronic communication with the junction box; andat least one remote computing device in network communication with the main unit.

2. The system of claim 1 wherein the main unit is electrically connected to a scale indicator of the weighing system.

3. The system of claim 1 wherein the main unit comprises at least one printed circuit board (PCB), a local computing device, and a programable microcontroller.

4. The system of claim 1 wherein the main unit is contained within the junction box.

5. The system of claim 1 further comprising a sub-unit comprising a second plurality of sensors configured to collect data regarding status, use, and operation of the weighing system, the sub-unit being in wired communication with the main unit.

6. The system of claim 5 wherein the sub-unit is fixed to a side or underside of the weighing system.

7. The system of any one of claims 1 to 6 wherein the first plurality of sensors comprise and accelerometer, a magnetometer, an air temperature sensor, a depth sensor, a water level sensor, a water temperature sensor, or a combination thereof.

8. The system of any one of claims 1 to 6 wherein the at least one remote computing device is a smart phone, a computer, or a tablet.

9. The system of any one of claims 1 to 6 wherein at least one of the first plurality of sensors of the junction box is a gyroscope configured to sense rotational information related to the junction box.

10. The system of any one of claims 1 to 6 wherein at least one of the first plurality of sensors of the junction box is a temperature and humidity sensor configured to provide precise weather conditions at the weighing system.

11. The system of claim 1 wherein at least one of the first plurality of sensors of the junction box is a depth sensor configured to measure a level of liquid underneath the weighing system.

12. The system of claim 11 wherein the depth sensor is an ultrasonic depth sensor.

13. The system of any one of claims 1 to 6 wherein at least one of the first plurality of sensors of the junction box is a light sensor configured to sense when the junction box has been opened.

14. The system of any one of claims 1 to 6 wherein the junction box is provided with a plurality of diagnostic lights thereon.

15. The system of any one of claims 1 to 6 wherein the junction box is provided with at least one input / output port thereon.

16. The system of any one of claims 1 to 6 wherein the junction box is provided with a GPS tracker.

17. The system of any one of claims 1 to 6 wherein at least one of the first plurality of sensors of the junction box is a sound sensor.

18. The system of any one of claims 1 to 6 wherein the junction box is retrofit for an existing analog weighing system.

19. The system of any one of claims 1 to 6 wherein the junction box is configured to build an identify profile of the weighing system based on at least one of linearity curve, creep profile, temperature coefficient, noise floor, hysteresis pattern of the weighing system over time.

20. The system of any one of claims 1 to 6 wherein the remote monitoring includes comparing a weight computed by the junction box to a weight displayed on an indicator of the weighing system and flagging any discrepancy as a sign of tampering or indicator malfunction.

21. The system of any one of claims 1 to 6 wherein the junction box is configured to extract process intelligence insights including throughput, operator behavior, and quality anomaly from weight data alone.

22. The system of any one of claims 1 to 6 wherein the junction box and main unit are powered by excitation lines of the weighing system.

23. The system of claim 1 wherein the main unit features redundant network communication.

24. The system of claim 23 wherein the redundant network communication includes CAN, WiFi, and BLE.

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