The Challenge

In 2018, trucks contributed to 17% of road accidents in Malaysia, with overloading being a key risk factor. Overloaded trucks not only threaten road safety but also damage infrastructure and disrupt logistics efficiency.

Current weight measurement solutions rely mostly on static weighing platforms or complex strain gauge installations — both unsuitable for real-time monitoring. There was a clear need for an accurate, reliable, and practical on-board truck weighing system.

 

Our Research Focus

VITAL Lab, in collaboration with Amtel, set out to reimagine truck weight sensing by applying load cell technology directly on-board, enabling continuous monitoring while the truck is in operation.

We focused on:

  • Exploring load cell types — shear beam, S-type, and compression cells
  • Designing optimized mounting mechanisms to ensure accurate readings
  • Using Finite Element Analysis (FEA) to model and validate the setups
  • Developing prototypes for laboratory validation of linearity, repeatability, and reliability

 

Our Approach

1. Modeling & Simulation

  • Built mathematical and FEA models for various load cell setups.
  • Applied gradient-based optimization algorithms to refine the design.

2. Prototype Development

  • Fabricated optimized mounting mechanisms based on simulation results.
  • Integrated load cells into truck chassis models for real-world compatibility.

 3. Laboratory Validation

  • Tested each configuration to evaluate accuracy, linearity, and repeatability.
  • Compared experimental data with FEA predictions to validate models.

4. Performance Evaluation

  • Identified the best-performing setup balancing cost-effectiveness and measurement integrity.

 

 The Impact

  • Real-time weight monitoring for improved road safety and regulatory compliance
  • Reduced risk of overloading — protecting drivers, fleets, and infrastructure
  • Operational efficiency — empowering logistics companies to optimize cargo loads
  • Smart-city ready — aligned with Malaysia’s 10-10 MySTIE and Ekonomi Madani transportation goals

From lab innovation to logistics transformation — this project sets a new standard for on-board weight sensing, delivering safer roads, stronger compliance, and smarter fleet operations.