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A module of TAT Guard
AI-Unmanned Weighbridge Automation System
~ 45 seconds from wheels-on to boom-up: zero-weight validation, weight-stability check, driver face match, top-view material verification, digital slip, ERP sync. No operator, no manual override, no manipulation window. The load cells you already own remain the physical scale — TAT Guard's camera-native automation layer sits on top of any weighbridge, any brand.
~ 45 secper weighment15k +Daily transactions99.95%Uptime SLA~83tCO2 avoided per wb/year
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.
Related solutions
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Questions You Might Have
Find answers to common questions about AI-Unmanned Weighbridge Automation System.
Automatic weighbridge systems deliver the highest ROI in Steel & Iron Manufacturing, Thermal Power Plants (for fast coal unloading), Cement Plants (handling limestone and clinker), and Mining Operations managing bulk ore and mineral transport. Any facility with high truck volumes typically 50+ trucks per day sees immediate productivity gains, reduced wait times, and elimination of pilferage with an AI weighbridge solution.
Zero Weight Validation is an automated pre-transaction check that confirms the weighbridge platform reads exactly zero before any vehicle drives on. This critical safety feature prevents ghost-load errors caused by debris, calibration drift, or deliberate manipulation. It is a key component of Helious's weighbridge accuracy assurance system and helps plants maintain regulatory compliance with Weights & Measures requirements.
Yes. Helious's AI Unmanned Weighbridge integrates seamlessly with SAP, Oracle, and other enterprise ERP systems in real time. Every transaction weight, driver ID, material type, timestamp, and vehicle number is automatically pushed to the ERP, eliminating manual data entry and paper-based errors. This ERP integration for weighbridge management improves data accuracy by up to 100% and enables live operational dashboards.
The Top-View Camera captures real-time overhead images of the vehicle's load at the time of weighing. This visual record is used for material type verification, load integrity monitoring, and anti-pilferage surveillance. The AI engine analyses the image to confirm the declared material matches what is loaded, creating an auditable digital trail that protects against material theft and misrepresentation in logistics operations.
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