Checkweigher   Future Development & Continuous Improvement

After completing the second-generation version, I’ve started planning the next phase of development — focusing on industrial reliability, modular design, and smart data integration
The next evolution of this system isn’t just about hardware improvement — it’s about turning the checkweigher into a connected, intelligent, and maintainable product that can be replicated and serviced easily in the field

Planned Improvements

1. Electrical & Control System

• Designing a new modular panel architecture for faster assembly and maintenance

• Transitioning to a compact industrial PLC platform with built-in communication ports

• Adding diagnostic LEDs and labeled I/O test points for quick troubleshooting

• Improving sensor wiring and shielding for long-distance and high-noise environments

2. Mechanical & Integration Enhancements

• Redesigning the reject unit for higher throughput and easier access

• Upgrading the belt and load cell mounting for better vibration isolation

• Refining the mechanical calibration process to reduce setup time

3. Software & Automation

• Implementing a data logging system that exports weight reports and error logs automatically

• Integrating real-time communication with MES / ERP systems (via Modbus TCP or OPC UA)

• Expanding the HMI with multi-level user access, maintenance reminders, and batch traceability

• Developing a standardized PLC template for faster cloning in future projects

4. Smart Features (R&D Path)

• Exploring AI-based weight prediction for products with variable density

• Using load cell drift analysis for predictive maintenance

• Adding remote support access for troubleshooting and firmware updates

My Role & Vision

As the automation and electrical designer, my focus is on creating a scalable, documented, and future-proof architecture — one that allows other engineers to pick up where I left off without losing design intent
Each revision of the checkweigher teaches something new: from signal stability to user interface clarity, and from production line challenges to the importance of good documentation

The goal is to turn this project from a single R&D machine into a repeatable product platform that can be deployed across different industries — fully standardized, documented, and supported

Next Objectives

• Develop a production-ready prototype for industrial rollout

• Finalize safety and CE compliance documentation

• Integrate network data exchange with AKNOVA’s vision and labeling systems

• Establish a remote diagnostic interface for maintenance teams

harmaceutical packaging lines
It ensures that every product leaving the production line meets strict weight and quality standards while maintaining seamless data communication with higher-level control systems

Developed and implemented under my direction, this project reflects a combination of mechanical accuracy, smart electrical design, and hands-on field experience gained through extensive commissioning and testing phases

Concept & Purpose

The system continuously monitors product weight in motion using high-accuracy HBM load cells and advanced filtering algorithms
Any deviation from the acceptable range automatically triggers a servo-driven reject mechanism, removing non-conforming items without interrupting production flow

Its design aligns with pharmaceutical Good Manufacturing Practice (GMP) and complies with international serialization and inspection requirements

Mechanical Design & Structure

The mechanical structure was designed with a focus on

• Vibration isolation for load cell stability

• Easy belt adjustment and maintenance access

• Compact footprint for integration into existing production lines

• Hygienic design suitable for cleanroom environments

Over multiple iterations, the system’s frame and reject assembly were refined for greater precision and smoother operation, ensuring reliability even at high throughput speeds

Electrical & Control System

I personally designed and implemented the complete electrical and control system using EPLAN, integrating a combination of industrial components from leading brands

• FATEK PLCs for high-speed control and I/O management

• LS servo drives for dynamic reject actuation

• Schneider and Omron for power distribution and protection

• Pepperl+Fuchs sensors for product detection and synchronization

The control logic includes

• High-speed counter (HSC) integration for accurate product tracking

• Real-time weight filtering and data averaging

• Automatic reject confirmation feedback

• Alarm diagnostics and maintenance prompts via HMI

Software & Data Integration

The HMI interface allows operators to monitor live weight data, adjust thresholds, and record batch statistics
The system logs every rejected item and can export reports for quality assurance and production management

It is fully compatible with vision inspection modules and Track & Trace servers, enabling unified data flow across the packaging line — from labeling to serialization and aggregation

Evolution & Field Performance

The checkweigher has evolved through multiple design versions, each incorporating improvements inspired by field experience and customer feedback
During installation and testing phases, I personally spent over three months on-site at pharmaceutical facilities such as Kharazmi Pharma, troubleshooting both mechanical and electrical issues and optimizing the machine’s performance under real operating conditions

This hands-on approach allowed the system to reach a level of maturity and robustness suitable for continuous production environments

My Role & Vision

As the lead electrical designer and R&D manager, I directed both mechanical redesigns and the complete control system development
Beyond engineering, I focused on improving serviceability, user experience, and long-term reliability — ensuring the system could serve as a reference platform for future inspection technologies under Aknova Engineering

The Checkweigher project represents more than a machine — it’s the result of years of practical engineering, teamwork, and iterative innovation aimed at redefining precision and reliability in pharmaceutical automation.