Cloud-based truck weighbridge automation

Highlights

✓ AvtomatikaAz MMC is an Azerbaijani industrial automation company specialising in truck weighbridges, weighing systems, access control, and cloud-based automation.

✓ Their AzTruck platform digitalises truck weighing by connecting weight indicators, cameras, traffic barriers, position sensors, and operator equipment to a central cloud-based system.

✓ Teltonika TRB246 IoT gateway provide wired and dual-SIM cellular connectivity, RS232 & RS485 interfaces, secure VPN communication, automatic failover, and digital I/O for access-control automation.

✓ Meanwhile, Teltonika TSW200 industrial Ethernet switch extends the TRB246's network to four IP cameras and the operator's PC, with room for additional auxiliary IP devices on site.

Risk of delays and disputed records

Truck weighbridges keep heavy industries and logistics supply chains running smoothly. Facilities rely on these systems to quickly verify, track, and authorise every incoming and outgoing vehicle.

Traditional setups, however, often struggle with fragmented infrastructure. When cameras, operator's PCs, weight indicators, and barriers run on separate networks, installation becomes complicated, troubleshooting turns difficult, and every extra component adds another potential point of failure.

To solve these integration challenges, industrial automation specialist AvtomatikaAz MMC developed AzTruck, a cloud-based weighbridge platform that centralises and automates the entire weighing process. By consolidating hardware into a single interface, the platform lets operators manage the entire weighing and gate management workflow directly from a browser.

Centralising operations in the cloud simplifies management, but it also raises the stakes on connectivity. A single network interruption can stop weight data from reaching the platform, halt an operator mid-session, and leave trucks queuing at the gate.

Supporting different weight indicators adds another layer of complexity as some of our partner's sites run an ESIT PWI-D weight indicator over RS232, while others use an e-tarti LPi weight controller connected over Ethernet or RS485. A single gateway needs to support every configuration, so the system avoids a custom connectivity design for each new installation.

Vehicle identification presents a separate challenge. Manual entry of licence plates, vehicle details, and cargo information is slow and open to human error, and without visual evidence, disputed weighing records become difficult to investigate.

What every weighbridge installation needs is a unified hardware approach that provides end-to-end operational visibility and fail-safe performance in a single compact footprint.

Topology

Unified weighbridge automation with Teltonika devices

The Teltonika TRB246 industrial IoT gateway acts as the backbone of every installation, tying the weighbridge equipment to the cloud and keeping the whole site running as one connected system.

It holds three internet paths in priority order: wired Ethernet, the primary SIM, and the backup SIM. A dropped connection triggers automatic failover, so a truck never has to wait at the barrier while the network catches up. Every byte crossing that connection travels through a secure OpenVPN tunnel to our partner's cloud infrastructure. Indicators, cameras, and control devices stay off the public internet entirely, yet still reach the platform in real time.

With connectivity secured, the gateway turns to the scale itself. The weight indicator connects over a serial RS232 & RS485 link, so one TRB246 can serve either the ESIT PWI-D or the e-tarti LPi without redesigning the setup for each site. It then converts that serial reading into a TCP/IP stream and sends it straight to the AzTruck platform through the same OpenVPN connection.

Teltonika TSW200 industrial Ethernet switch joins the setup here, wiring together four IP cameras and the operator's PC to turn the gateway into a complete evidence-gathering hub. Front and rear cameras capture the license plate, make, model, and colour, while an overhead camera confirms the cargo. A cabin camera keeps a record of the indicator display and the operator's actions, so every session has a visual trail attached.

Those feeds let the weighbridge system identify a vehicle automatically instead of relying on manual entry, closing the door on disputed records before they start. From there, a sequence of digital I/O signals guides the truck through the rest of its visit: relay modules wired to the gateway raise the entrance barrier, letting the vehicle move onto the platform, where front and rear position sensors confirm it's sitting exactly where it needs to before a weight gets logged. 

Once the weight is captured, the same relays raise the exit barrier and switch the traffic light, releasing the vehicle.

One gateway now does the work of a cabinet full of separate components: routing, cellular failover, VPN security, serial-to-IP conversion, camera and PC connectivity, and full access-control automation. This consolidation is what lets our partner roll out the same design to any customer site, regardless of which indicator is installed or how the site connects to the internet, giving every installation the same fast, traceable, hands-off weighing process from entrance to exit.

Are you looking for a similarly resilient setup for your own site? Get in touch with our team, and let's find the right solution for your needs.