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EnglishWhat Are Onboard Weighing Solutions and How Do They Work on Commercial Trucks?
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Onboard weighing solutions are scale systems mounted directly on a vehicle that measure axle or total load weight in real time, so the driver or loader knows the payload before the truck leaves the yard. They differ from fixed platform scales because weighing happens wherever the vehicle is, not at a weigh station. They suit fleets that need to load to the legal limit on the first attempt — general trucking, waste, aggregate, and timber operations — and the choice of system depends mainly on suspension type and the accuracy the application demands.
How onboard scales differ from fixed platform scales
A fixed platform scale weighs a vehicle at one location: the truck must drive onto it, stop, and wait for a reading. An onboard system carries its own sensing hardware, so weight is available continuously — during loading, at the pit, or on the road.
| Fixed platform scale | Onboard weighing solution | |
|---|---|---|
| Where weighing happens | One fixed site | Anywhere the vehicle is |
| When you get the reading | After driving to the scale | During and after loading |
| Effect on loading workflow | Load, drive, weigh, readjust if over | Load to target weight directly |
| Coverage | One vehicle at a time at one point | Each equipped vehicle independently |
The practical consequence: with a platform scale, an overweight load is usually discovered after it has been built, which means time in the scale line and possible re-adjustment. Onboard scales move that check into the loading process itself.
How load cells and strain gauges measure weight
The measurement chain in an onboard system runs from a physical deformation to a number on a display:
- Strain gauges are bonded to a structural element that flexes under load. As the element bends, the gauge's electrical resistance changes proportionally.
- Load cells package those gauges into a sensor that converts the mechanical load into an electrical signal.
- Instrumentation converts the signal into a weight reading and presents it to the operator.
Vulcan states that every part of its systems — including the strain gauge, load cell, EDOC coating, and instrumentation — is designed, manufactured, and supported in-house by VPG, which it describes as a force measurement specialist. That single-source structure matters when diagnosing a fault: sensor, coating, and display all come from one supply chain rather than several vendors.
A useful way to picture it: the load cell is doing the same job as the load cell in a bathroom scale, except it is built into the vehicle's suspension or frame and calibrated for tens of thousands of pounds rather than a few hundred.
What onboard weighing actually delivers
The benefits below are the ones Vulcan attributes to its onboard systems, and they follow directly from measuring weight at the point of loading.
- Avoid overweight fines. Loading to the maximum legal limit without exceeding it removes the most common source of overload penalties.
- Maximize payload. Because the operator can see the weight as it accumulates, the truck can be filled to the legal limit rather than left short out of caution.
- Cut loading and readjustment time. No scale-line wait and no reworking a load that came out heavy.
- Lower maintenance costs and longer vehicle life. Vulcan notes that properly loaded vehicles put less wear on brakes, tires, and suspensions.
- Reduce liability exposure. Keeping weights within legal limits supports vehicle stability and safety, which matters in the event of an accident.
These are operational arguments rather than measured guarantees — the size of the gain depends on how often a fleet currently runs overweight or underloaded.
Where these systems are used
Vulcan lists the following as proven application areas for its onboard scales:
- General trucking and delivery
- Waste and refuse
- Aggregate
- Timber
- Aerospace
- Marine, medical equipment, heavy machinery, and process control
The company reports its solutions are used in more than 30 countries, with offices in North America, Europe, and Asia, and that its overload protection systems are relied on by an estimated 50,000+ riders worldwide. It has manufactured scales since 1984 and describes over 40 years of work in integrated weighing.
What to check before choosing a system
Selection comes down to a small number of concrete questions:
- Suspension type. Vulcan offers solutions for air, spring, and mixed suspensions, and states that fleets can mix and match tractors and trailers without adjustment. If your fleet runs more than one suspension type, confirm the system covers all of them.
- Accuracy requirement. The system needs to be accurate enough that a reading at the legal limit is trustworthy, not approximate. Ask what accuracy the vendor specifies for your configuration.
- Application environment. A refuse truck, a timber hauler, and an aggregate rig expose sensors to different shock, debris, and moisture conditions. Coating and sensor protection are part of the specification, not an afterthought.
- Single-source support. If the strain gauge, load cell, and instrumentation come from one manufacturer, service and calibration responsibility sit in one place.
- Coverage across the fleet. Decide whether you are equipping every vehicle or only the ones that most often run near the legal limit.
For a fleet evaluating onboard weighing for the first time, the fastest test is to pick the routes or material types where overweight fines and scale-line delays actually occur, and compare the cost of equipping those vehicles against the fines and time currently being lost.