Truck overloading is still a major issue in the transportation sector, as it raises the risk of accidents, shortens vehicle lifespans, increases road damage, and generally results in inefficient operations. Conventional manual weighing techniques take a lot of time, are not continuous, and are frequently impractical when in transit. The design, development, and deployment of an on-board, real-time load sensing and overload prevention system utilizing load cells, HX711 amplifiers, microcontrollers, and alert mechanisms are presented in this paper. The system improves vehicle efficiency and road safety while providing continuous load monitoring and instant alerts upon overload detection. The methodology, literature review, system design, implementation, outcomes, and potential areas for future development are all covered in the paper.

This research presents the systematic design, development, and implementation of a Load Sensing and Overload Prevention System (LSOPS) for commercial trucks. Overloading of heavy vehicles remains a critical concern in the transportation sector, contributing to increased accident rates, premature mechanical degradation, diminished fuel efficiency, and accelerated damage to public infrastructure. Despite regulatory efforts and manual inspection procedures, the absence of real-time monitoring systems has allowed overloading practices to persist. This study addresses these challenges by proposing an embedded solution that continuously monitors vehicle load conditions during operation. The LSOPS employs load cells in conjunction with HX711 amplifier modules and a microcontroller unit (Arduino UNO) to measure and process load data in real time. The system is calibrated to detect when the applied load surpasses legally permissible or mechanically safe limits. Upon detecting an overload condition, the system provides immediate feedback to the driver via visual indicators (LCD display and LEDs) and audible alarms (buzzer). This real-time alert mechanism facilitates prompt corrective action, thereby reducing the likelihood of accidents and mechanical failures.

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