Checkweigher   Second Generation (R&D Version)

After the first prototype proved stable in real production, I started developing a second-generation checkweigher — focusing on accuracy, electrical reliability, and standardized R&D documentation.

In this version, I redesigned the entire electrical panel and control logic, improved the load cell signal processing, and introduced faster reject timing with servo synchronization
I also restructured the PLC and HMI software to be modular, easier to scale, and aligned with IEC standards for future replication

 My Focus Areas

• Electrical redesign: new panel layout, improved grounding and EMI shielding

• Signal optimization: upgraded analog filtering and calibration stability

• PLC/HMI reprogramming: modular code, automatic zeroing, and real-time statistics

• Reject unit synchronization: servo-based timing linked with encoder feedback

• System diagnostics: built-in error logging and alarm structure for operators

• Documentation: complete wiring diagrams, labeling, and standardized FAT/SAT forms

 Technical Highlights

• Load cell: HBM high-resolution

• PLC/HMI: Fatek series

• Servo drive: Delta integrated with high-speed counter

• Communication: RS485 Modbus between PLC, HMI, and optional printer module

 Results Compared to V1

• ±0.2g repeatability improvement at production speed

• 20% faster reject cycle

• Simplified maintenance through better cable routing and modular connectors

• Standardized PLC template for future projects

 My Role

I acted as the automation and electrical lead, overseeing every part of the upgrade — from control cabinet wiring and PLC programming to coordinating mechanical and software design during the R&D phase
The final result is a more robust, reliable, and production-oriented checkweigher ready for replication and customization