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AI-Unmanned Weighbridge Automation System
Helious Tech Solutions provides an advanced AI-powered Unmanned Weighbridge Automation System for steel, cement, mining and other industrial plants across India. Our solution combines Computer Vision, FASTag RFID, ANPR, automatic vehicle positioning and zero-weight validation to deliver secure, operator-free weighment in approximately 45 seconds. With real-time monitoring and seamless ERP integration, it reduces manual errors, prevents unauthorized transactions and improves plant logistics efficiency.
~ 45 secper weighment15k +Daily transactions99.95%Uptime SLA~83tCO2 avoided per wb/year
Trusted by 24+ fast-scaling organizations worldwide
What it does
Every capability ships in the box — nothing here is a paid add-on.
01 of 08FASTag and ANPR, Cross-Checked Against ERP
The RFID reader picks up the FASTag on the truck while the ANPR camera independently reads the plate; both must resolve to the same vehicle, so a tag moved between trucks fails instantly. The verified registration then pulls the open order from your ERP — material, expected tonnage, transporter, gate-pass validity. No matching order, no lane release.
02 of 08A Truck at the Barrier, Not a Tag in Someone's Hand
Computer vision confirms an actual vehicle is standing at the barrier before the RFID read is accepted, correct vehicle class, correct position, physically present. A FASTag held in a hand, carried on a two-wheeler, or read from a vehicle that isn't the one at the lane fails this check and the barrier stays down. It closes the gap every tag-based gate leaves open: the tag proves an identity, this proves the truck is behind it.
03 of 08Zero Weight Validation Before Vehicle Entry
Before the barrier releases, the controller reads the indicator directly and confirms the platform has returned to zero and is holding within [±X kg] for [X] seconds. Outside tolerance, the lane locks and a deviation alert goes to the shift supervisor with a timestamped deck image. Catches carried-over spillage, load-cell drift, and the stored-offset trick.
04 of 08No One on the Weighbridge, Ever
Deck cameras confirm the platform is clear of people before the barrier opens — a safety interlock, and the other half of zero-weight assurance, since a person standing on the bridge is undeclared load on both tare and gross. It also removes the manual override window: physical presence at the deck is what every classic manipulation needs.
05 of 08Driver Face Recognition with DigiLocker-Based Verification
The camera matches the face at the lane against the driver assigned to that consignment, while the licence is validated through DigiLocker for authenticity and expiry. A mismatch, expired licence, or unregistered driver routes an exception to security instead of opening the barrier. Stops driver substitution and unlicensed-driver liability at the gate.
06 of 08Vehicle Positioning With Computer Vision, No Sensors
No loop coils, no photocells, no roadside posts to shear off, positioning is done entirely by camera. The AI confirms every axle sits fully inside the platform boundary with no overhang before weight capture begins, so an off-centre reading never becomes a record. Your load cells stay the scale; the fragile sensor layer around them goes.
07 of 08Top-View Camera for Material Identification
An overhead camera captures the load at weighment and classifies the material against what the ERP order says should be on that truck, and verifies the load is sheeted before clearance. A declared-versus-actual mismatch or an uncovered load raises an exception rather than printing a slip. The timestamped image settles shortage claims later.
08 of 08Seamless ERP Integration for Data Accuracy
Weight, vehicle number, driver ID, material class, order reference, overhead image and timestamps post straight into your ERP the moment the transaction closes, over [IDoc / BAPI / RFC / REST — confirm]. The slip is generated from that committed record, so paper and system cannot diverge. If the link drops, transactions queue locally and replay — a network outage delays the post, it doesn't lose the weighment.
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Questions You Might Have
Find answers to common questions about AI-Unmanned Weighbridge Automation System.
An Unmanned Weighbridge System is an automated vehicle weighing solution that eliminates the need for a weighbridge operator during routine weighment. It uses technologies like AI, Computer Vision, FASTag RFID, ANPR cameras, and automated boom barriers to identify vehicles, verify positioning, and record accurate weights. Helious Tech Solutions' AI-powered system also provides zero-weight validation, real-time monitoring, and ERP integration, helping industrial plants improve efficiency, prevent unauthorized weighments, and reduce manual errors.
An Unmanned Weighbridge Automation System automatically manages vehicle identification, positioning, weighing, and exit authorization. When a truck approaches, FASTag RFID and ANPR cameras verify its identity. AI-powered cameras guide proper vehicle positioning, while zero-weight validation and stable-weight monitoring support accurate weighment. Once the weight is captured, the transaction is recorded digitally and synchronized with the ERP system. Automated boom barriers and audio-visual instructions control vehicle movement, enabling secure, operator-free operations.
Yes, existing weighbridges can be retrofitted into fully unmanned systems using AI cameras, FASTag RFID, ANPR, automated boom barriers, and intelligent software. Helious Tech Solutions enables weighbridge automation while retaining compatible existing infrastructure, reducing manual intervention and avoiding unnecessary equipment replacement.
The cost of an Unmanned Weighbridge Automation System in India depends on the existing weighbridge infrastructure, number of weighing lanes, required AI cameras, RFID readers, boom barriers, software features, and ERP integration requirements. Retrofitting an existing weighbridge may cost less than installing an entirely new system. Helious Tech Solutions provides customized automation solutions based on plant requirements, helping businesses reduce manpower costs, improve weighment efficiency, and evaluate the return on investment.
FASTag RFID and ANPR technology work together to strengthen vehicle authentication and reduce weighbridge fraud. FASTag RFID identifies the registered vehicle tag, while ANPR cameras independently capture and verify the number plate. The system compares both identities with the authorized vehicle record before permitting weighment. Combined with AI-based vehicle profiling, zero-weight validation, camera monitoring, and digital transaction logs, Helious' automation system helps detect mismatches, prevent unauthorized transactions, and improve weighment traceability.
Yes, Unmanned Weighbridge Automation Software can integrate with SAP ERP and other compatible enterprise systems. Helious Tech Solutions supports ERP integration to streamline weighment data exchange, vehicle transaction records, material movement tracking, and digital reporting. Depending on the implementation, verified weighing information can be transferred to the relevant ERP workflows, reducing manual data entry and reconciliation errors. Integration requirements depend on the customer's SAP environment, available interfaces, and business processes.
An Automatic Weighbridge System automates certain weighing activities, such as capturing vehicle weights, recording transactions, or generating weighment slips, but may still require an operator for identification or approval. A Fully Unmanned Weighbridge System automates the complete routine process, including vehicle authentication, positioning, weight validation, transaction recording, and exit control. Helious Tech Solutions combines AI, FASTag RFID, ANPR, and automated barriers to enable secure weighing with minimal manual intervention.
AI Weighbridge Automation Systems are especially beneficial for industries handling high volumes of raw materials and vehicle movements, including steel, cement, mining, power generation, logistics, and ports. These industries require accurate weighing, secure material movement, and faster truck turnaround times. Helious Tech Solutions helps industrial facilities automate vehicle identification, improve weighing accuracy, reduce congestion, and maintain real-time transaction visibility. ERP integration also supports better inventory reconciliation and operational control across plants.
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