Modular Wireless Scale System for Large Load Weighing
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Solution Overview
Problem
Existing scale systems for weighing large loads are cumbersome and inefficient, requiring movement of the scale and being prone to mechanical failures due to wired connections, which affects reliability and space utilization in manufacturing and warehousing environments.
Innovation Solution
A modular wireless scale system comprising a master scale and multiple slave scales with load cells, microcontrollers, wireless transceivers, and accelerometers, allowing for wireless communication and remote data processing, enabling accurate weight measurement of loads up to several tons without the need for physical movement of the scale.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a large scale is used to weigh large loads, then the weighing capacity is sufficient, but the scale takes up valuable space and is cumbersome to move
Solution Approach 1:
The patent divides a large-scale weighing system into multiple smaller microscale units (e.g., four individual microscales). Each microscale is compact and occupies minimal space, yet when combined through wireless communication and data processing, they collectively measure large loads equivalent to traditional large scales, thus resolving the contradiction between weighing capacity and space occupation.
2Ease of operation
If cables are used to connect load cells to the controller, then the system is mechanically connected, but the cables may become entangled and the system becomes cumbersome
Solution Approach 1:
The patent replaces the mechanical cable connection system with a wireless communication system. Each microscale unit communicates weighing data and operational status wirelessly to a central controller, eliminating physical cables entirely. This substitution removes cable entanglement issues and enhances portability while maintaining system functionality.
3Reliability
If wired connections are used to connect scale components, then the system is mechanically connected, but the potential for mechanical failure decreases reliability
Solution Approach 1:
The patent eliminates mechanical cable connections between load cells and the controller by implementing wireless communication technology. Each microscale unit transmits data and receives commands wirelessly, removing the mechanical connection points that are susceptible to failure. This increases system reliability by reducing mechanical failure points while maintaining complete system functionality.
4Ease of operation
If a portable scale system is created with multiple components, then the scale can be moved to the load, but the components must still be moved in a case which is cumbersome
Solution Approach 1:
The patent segments the scale system into independent wireless microscale units that can be easily transported individually or in small groups. Each unit is self-contained with its own load cell, processor, and wireless communication capability, eliminating the need for a large protective case and extensive cable management systems, thus improving portability while reducing complexity.
Solution Approach 2:
By replacing the mechanical case-and-cable system with wireless communication technology, the patent eliminates the cumbersome protective case required for wired systems. The wireless microscale units can be transported more easily without requiring rigid protective enclosures, significantly enhancing portability while reducing system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system provides a portable, reliable, and efficient means of weighing large loads, reducing mechanical failures and space requirements, while enabling accurate weight measurement and inventory tracking through wireless communication and remote data processing.
Implementation Method 1
The master scale includes a heavy load cell and a light load cell
Implementation Method 2
a wireless transceiver, enabling accurate weight measurement and inventory tracking through wireless communication
Implementation Method 3
an accelerometer
Data Source
AI summary
A modular wireless scale system comprising microscales comprises a master scale that may be configured to be used with one or more slave scales. The master scale includes a heavy load cell and a light load cell disposed on opposite sides of a cuboid master housing. The master scale housing encloses a master computer-based microcontroller, a wireless transceiver, an accelerometer, and a power source, and may optionally include a display. The master scale may be used as a stand-alone scale for weights up to the maximum weight supported by the heavy load cell and the scale housing. Each of the slave scales includes a heavy load cell supported by a cuboid housing that encloses a slave computer-based microcontroller, a wireless transceiver, and a power source.