Digital load monitoring

Digital load monitoring is a complex system that has been developed to ensure the safety and efficiency of machines and systems.

How it works:

1. Sensors: Monitoring begins with sensors that detect the physical quantity, in this case the load or force.

2. Signal processing: The analogue signals recorded by the sensors are forwarded to an electronic unit, which amplifies these signals and converts them into digital data. This is often done by an analogue-to-digital converter (ADC).

3. Microcontroller: A microcontroller or microprocessor processes the digital signals. It executes algorithms that analyse the load data and compare it with preset threshold values.

4. Threshold value comparison: The monitored load values are continuously compared with defined threshold values. These threshold values can be permanently programmed or configurable via an interface.

5. Reaction to overload: If the measured load exceeds one of the limit values, a predefined action is triggered. This can be the triggering of an alarm, the switching off of the machine or the activation of a safety mechanism.

6. Communication interfaces: Modern load monitoring systems often have communication interfaces such as RS232, USB, or Bluetooth to transfer the monitoring data to a central control system or to enable external configuration.

7. Display and operation: Many systems offer a local display unit that shows the operator the current load values and system status. Control elements can be used to make settings and configure the system.

8. Data storage: Some systems store the load data for later analysis. This can be useful for identifying load peaks or unusual operating conditions.

9. Self-diagnostics: Advanced systems perform self-diagnostics to check the functionality of the sensors and electronics. In the event of an error, a warning is issued.

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