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Scale, Weighing, & Measuring Systems

What is a System?

At Bay State Scale & Systems, Inc. a “system” is any product that goes out our doors that includes more than just the scale itself. Usually there is peripheral equipment involved such as printers, scanners, or keyboards. Sometimes the system involves a weighing or counting indicator with special programming to perform a specific function. In every case the idea is to provide functionality that gives the customer a more complete solution than a simple scale alone.


How does the system get specified?

Usually we meet with the customer to discuss his/her particular situation. Then we detail a solution in proposal form and “fine tune” it prior to the customer signing off. We strongly suggest that the people who will be using the new system be involved prior to implementation. There are several reasons for this. Often these users give valuable feedback as to why the system will not work as presently specified, or give feedback as to how better to accomplish management’s requirements. Sometimes they don’t buy into the changes either because they see it as more work or they are afraid of job security. It is best that management understand these obstacles prior to implementation and deal with them as early as possible. I remember one system we assembled in which more effort was required of a specific worker to attain the necessary results, but several other workers’ lives were made much easier. We came up with a way that the other more fortunate workers would help the unlucky one, so that there would be a net gain for everyone involved. Without management taking this initiative, the one overworked person would have doomed the new system.


How does a new system get implemented?

Once the system gets specified we purchase the components, interface the components, write any custom application, and test it in our facility with are own employees. This way we try to find, before installation, any weaknesses or deficiencies. We purposely try to think of ways a user might misuse the system to make sure that they are dealt with appropriately. If the system is complex, we might set up a prototype so that the customer can get the feel of it and critique it prior to final installation. We want to know that once it is installed, it will work as intended.


What credentials does Bay State Scale have so that their customers know that they can do a competent job?

We have staff that has been to various training sessions held be the manufacturers we represent. We have personnel who have passed advance training at GSE on programming their 60 series indicators macro language. These indicators can support databases, inputs, outputs, analog outputs, device net, profibus, operator prompting, timers, set points, vibratory feeders, proximity sensors, variable print formats, can interpret serial inputs, have various built-in parameters such as peek gross or net, rate of fall, rate of flow, average piece weight, and variables that can programmed for almost anything you can imagine. The GSE macro language supports nested if, then, else loops so we can do some really sophisticated things. We also are fluent in Setra’s SDL (Setra Dialog Language). “Another Counting Example” application, Although not as powerful as GSE’s 60 series macro language, Setra’s SDL does excel at writing simple applications on the fly to prompt an operator through a sequence of steps. Look below at some of the applications we have solved. You might get some ideas for your own weighing needs.


Here are some areas where systems can help you. Contact us about your application needs. or call 1-800-696-8282 then press 1.

  1. Print some information on a printer. Most indicators today can print gross, tare (container weight), net, time, and date. Many can print one or more ID fields. More sophisticated units can print bar codes, and give us the capability to add control codes that a printer might need to print different font sizes or to feed a certain amount of paper through. Most GSE indicators can be fit with a keyboard adapter so that a normal computer keyboard can be used to enter ID fields. The Setra Super II has a keyboard port for this purpose. Both Setras and GSEs have the ability to prompt the operator for ID information. The GSEs are particularly good at displaying lots of information or providing detailed prompts. Some GSE units have 40 column X 16 row displays for this purpose. Examples below show screen shots of these displays. Printers can be of several different types.
  2. Batching. This can be an off-the-shelf indicator. The operator presses a button and the unit might “TARE,” energize a relay, and shutoff just under the set point. Then the system waits until the operator presses “TARE” again. Why does it shut off under the set point? This is because there is typically material in transition. For example, when you turn off the water in your sink, the valve in the faucet closes, but there is water in the faucet as well as water falling from the faucet into the sink. If we did not account for this additional water, then our controller would shut off too late and too much material would be batched. This extra material is called “preact”. Many of our controllers make automatic adjustments for preact from cycle to cycle. We would do a custom program in applications where the system cannot start until an input is “made” such as when an eye that shows that the container is in place, or where a mixer has to come on at a prescribed time and/or weight. One system had the requirement of cycling a mixer at prescribed time intervals for a give period of time, day and night. This is easy to do with the more advanced GSE indicators. Databases can be used to save weigh data, to retrieve set point data, and to store recipes.
  3. Data Acquisition. This involves saving data to a database. Many of our weight indicators support multiple databases. If you are currently hand writing weights with perhaps time and date, and identification, a database can help by storing the transactions without hard to read handwriting or transcription errors. The macro program forces the operator to enter the correct information, might verify it against acceptable alternatives, and then saves it. We can do reports straight from the indicator or send the data in an ASCII delimited text file format to your computer. We can even fill spreadsheets directly. See the “truck scale program” for more information.
  4. Counting. Systems here often involve average piece weight retrieval. Sometimes we pull information from a database built into the scale. Other times we use labels that have the average piece weight, as well as ID information, perhaps tare weight and time and date.

Here are some notable examples. All of these are based on a digital indicator alone. There is no process controller, computer, or other device managing the process:


Set point example:
Screenshot of GSE 562 display. Set point number is followed by set point value and then preact. Operator presses “F1” and the set point number to start a batch.

GSE 562 		This customer wanted a batching controller with 8 set points. He wanted to view the set point values for each set point, along with the preact values. Preact is the amount of material that goes into the batch after the signal is given to stop the fill. In other words, if we want 1000 lb. of material and have a 10 lb. preact, the signal to stop batching occurs at 990 lb. and 10 lb. is expected to continue to flow once the signal to stop occurs. We used a GSE 562 with two four-output modules to give the 8 outputs. When the operator presses the “START” button, the unit prompts, “Enter material number 1 to 8, then press “ENTER”. Then the unit automatically tares to zero, energizes the appropriate relay, then shuts off at the set point value less the preact.
Here is a screenshot of the entry window when entering set point data. Look above and you see the data for ingredient 5 as entered below.

GSE 562 		Here you can see what an entry window looks like for the above application. We can totally customize this for any application. Once “ENTER” is pressed, the database is updated and the new values are displayed. We could temporarily turn off the scale weight update window to add more entry space, if needed. We can also incorporate timers, look at inputs, save recipes, do material usage reports, or many things that a computer and/or process controller can do.

Rate of flow example:
Here is the screen that the operator sees after he starts the process. We are using the built-in rate of flow parameter (shown at 1.5 g./min.), timer (shown at .67 min or 41.14 sec.), and built-in RMP parameter (shown at 2). The system is automatically saving data points every 3 seconds. He can “STOP” or “PAUSE” data collection as needed.
This customer wanted to measure and record flow rate in order to verify the operation of some valves they produced. They needed to get quick and accurate data and be able to record that data to the scale database. They did not want a computer in the area in which the scale would be used. They also needed to adjust how often data was saved to the database and also the RMP setting. RMP is the Rate Measurement Period. This is a moving average so the longer the RMP, the more accurate the rate, but the longer it takes for the recorded rate to catch up to the actual rate. Since all this data is saved in the scale database and can easily be sent to a computer spreadsheet, the customer can recompute the rate based on a different RMP from his computer after the data is collected. We can accurately collect data every 0.2 sec.—much faster than it can be sent to a computer via normal serial communications. We installed a 1 Meg. database for the data collection. When “STOP” is pressed, the operator is prompted as to what key to press to set up the system parameters, or to send the data to a computer. It is very easy to use. The above display is showing that 5820.5 g. has been batched, the present rate is 1.5 g./min., the test has been ongoing for .67 minutes or 41.140 seconds, the RMP is 2 seconds, and data is being collected every 3 seconds. We could include a relay that, as well as collecting data as the unit presently does, also could energize a relay to start the flow of material. Of course we could also automatically terminate the test based on time, the amount of material, or a combination of both. We used a GSE 60 series weight controller for this application. They can be calibrated for resolutions of up to 1 part in 100,000.


Truck Scale Management — Databases, Reports over time, Data look-ups:
Here is what an operator sees when the scale is turned on. Notice that we have filled the screen with choices as the application grew. If it grew any bigger we would use sub screens. For example, we might use F7 for “Reports”. Once “F7” is pressed, the operator can pick from the reports he wants. No mouse, no hard drives, no environmental issues. It is much easier to use than a computer for the typical operator. No navigational skills are needed. You cannot get lost in the program and it is easy to return to the main menu whenever necessary.
You might not know what a truck scale is, but this example might spark an idea for an application you have. This customer wanted us to duplicate a computer based system that he bought from a competitor—it is one of the big players—you would know the name. The problem for the customer was that this system was a few years old and he needed some changes made to it. The manufacturer had moved on to a new system and no longer supported changes on the customer’s system. Also, since the old system was a catchall system, it had lots of screens that were not appropriate for this customer and required the operator to navigate through them, increasing time and inefficiency. The system we proposed did everything the customer needed; nothing more, nothing less. For a system this big, we write a detailed specification that the customer signs off on. Then we do a prototype, bring it in so that management and the users can try it and give feedback. We expect to make minor changes and do not charge more for them. Sometimes we find that something important is needed resulting in changes to the specifications. On the day of installation everyone knows what to expect. The key to a truck scale management system such as this is that trucks that come in full will leave empty and ones that come in empty will leave full. The difference is the net weight either received or shipped. We match an incoming weight with an outgoing one to produce a transaction. All the user has to do is press the function button on the computer keyboard for what he is trying to do. Then the system prompts him from there on the display you see above. Very little training is needed. This system utilitzes several databases. There are databases for trucks that are in, but not yet left, permanent trucks, valid product, valid jobs, and valid truck types. The operator can pick the valid choices from screens full of choices. Each transaction is printed on an 80-column printer, but also remembered in the GSE indicator. That’s how we can do “F7” and “F8” that give product or job reports over time. The operator enters beginning and ending dates and the report is generated for that period. Each report uses the same data, but job reports show the products as allocated to each job and product reports show the job as allocated to each product. The reports show a high degree of detail. “F10” sends the whole transaction file to a computer for further analysis or archiving. “F12” allows the operator to void a transaction. In this case we would mark it as “VOID” and not include it in the report totals, but list it as a voided transaction. This way we can account for any voided transactions. ”F1” is pressed to process a truck. The system knows if it is incoming or outgoing by whether it finds it in the system (an incoming truck is not yet in the system, but an outgoing one will have a matching incoming ID)


Counting Scale Application — With Some Twists
Customer Parts

What are the requirements?

This customer had a lot of requirements for us to meet. He already had several very good counting scales that he had purchased from us—Setras, and he was making labels for two purposes. One was an internal label that identified several things about the part including part #, lot #, heat #, and average piece weight. The average piece weight was important because once it was scanned, the scale was ready to count, instead of hand counting another sample all over again. The ID fields enabled him to scan these into the scale to put them onto a second kind of label, he calls an “external” label because it is sent with the product to customers, without having to key the IDs in again.
His immediate problem was that he was making some very small parts and the Setra scales could not count such small parts accurately without a huge sample. . Even the Setra Super II, the best Setra has to offer, in the smallest capacity, 4.4 lb., just could not count them without a huge sample. Take a look at the picture to the left to see what the parts look like. Labels produced on the Setra have “discriminator” characters imbedded in the bar code. These discriminator characters tell the scale what to do with the information being scanned into the scale. For example when a “heat number” is scanned in we want to fill a “heat number” field, not some other field. When we scan an average piece weight into the scale, the scale needs to know not only that an average piece weight was scanned, but also what unit of measure the label is in. For example, if the label is in grams, but the scale is in pounds, we need to imbed a code so that the scale will change units to grams instead of being in pounds. The way Setra uses these imbedded characters is proprietary to Setra, not any other manufacturer. So, we had to find a solution that would not only count the tiny parts, but also allow the customer to use his labels the way he was presently using them and produce identical labels.


What is the solution?

We came up with a total solution for this customer. It includes all the items below (figure 1). The 0.01 mg. balance was sensitive enough to accurately determine an average piece weight for these parts. The average piece weight computed out to 0.0002346 grams/piece for the piece on the finger above. You can see this number on the screen shot below (figure 2). We needed to get the weight from the analytical balance and into the GSE 675 counting scale so that the GSE 675 could count the piece and make the customer Setra compatible label. Luckily the 675, like all 60 series GSE scales, has an “input interpreter.” This means that we can bring a string of data into the 675 through an RS232 port, parse the string, and handle the data as necessary. Above you see the 0.01172 gram sample weight that is being continuously sent from the analytical balance to the GSE 675, you see the APW, the count, all the ID fields (they have not yet been filled in), that the “analytical balance” has been selected, and instructions for which function key to press to perform a particular action. Note that this screen provides identical information whether the analytical balance is selected or either of the other two scales is selected, so the customer is not inconvenienced by the unique way we communicate with the analytical balance. In fact the “Scale Select”, “Select”, “Zero”, “Tare”, and “Sample” keys all operate in a similar fashion no matter which scale is selected, even the analytical one. We accomplished this by programming “macros” to run when any of these keys are pressed, this way we have full control over what a key does, instead of using GSE’s defaults for these keys.
Figure 1:
The solution from left to right:
  • Analytical balance (.01 mg. sensitivity)
  • GSE 675 6 lb. counting scale with special programming, database module
  • Keyboard module to enter ID information (front)
  • Printer to make labels (rear)
  • Scanner (to scan APW and ID to the GSE 675)
  • Remote 50 lb. platform

How did we make the right things happen when a label is scanned?

Well, again we used the “input interpreter”—this time to decode the fields on the labels as they are scanned by non-contact scanner. Even as the user sees the screen (figure 2), he can scan APW and ID fields and the scale will process the data and update the fields on the screen. If the fields need to be entered via keyboard, he simply presses“F1” and he is prompted for his four fields one at a time. He can scan them if he wants to, but the scale will not allow him to scan an incorrect field just like a Setra won’t! In other words if he scans a “lot #” when the scale is expecting a “part rev.”, the scale will refuse the data.


How did we make the printer print an identical label to the Setra scale?
Fortunately, the GSE 675 supports “custom transmits.” This means we can program the scale to send whatever we need through the RS232 port to the printer. Since we knew what the Setras were sending to the printer, it was easy to make the GSE 675 send the same data. We use these same custom transmits to populate some of the fields you see in figure 2. Instead of sending them to the appropriate RS232 port, we send them to the display instead. The bar code fields that require Setra control codes are concatenated to contain those codes, so this GSE 675 or any Setra scale can read and respond appropriately to any bar code we produce. Figure 2
Figure 2

What else did we do for this customer?

There are two things. The first he did not ask for, but when he saw it work, he really liked it. We used the database feature to store records that include all the ID fields and the average piece weight. This means that when the part # is scanned, all the other fields are populated automatically, as long as the particular part number is known to the system. We put a 256 kb. database module into the scale that can hold a few thousand of these records. The customer was concerned that eventually the database might fill up. Then what would we do? We came up with the solution. We store the last date and time that each database record is used and order them once a day when the scale is not being use (note the 1:00 AM sort time in figure 2, along with the number of seconds until the next sort). Then, if the database should fill up, we will remove the record last used the longest ago and replace it with a new one.
The second thing we did is we made an additional print format that uses a different size label so that the customer can connect an additional printer to make this smaller label. Luckily, the GSE 675 has four communication ports. We are using three of them. Port 1 for bidirectional communications with the analytical balance, port 2 for input from the scanner and output to the main printer, and port 4 for output to the second printer and input from the keyboard adapter so that the computer keyboard will work.
We still have port 3 left maybe to someday send data to a computer. Since the system can handle multiple databases we could still add other databases to the system, if the customer can come up with a reason to do this, maybe, for example, to store all the transactions performed on the scale. We could also add relays so that the customer could turn off a feeder after a box filled to a certain weight or count. Perhaps a network card, if the customer wants each scale to be a node on a network.

Contact us about your application needs. or call 1-800-696-8282 then press 1.


Another Counting Scale Example
Each workstation has a Setra Super II, a printer, a scanner, and a keyboard




Here are 4 ladies working at their workstations. Each bench has 2 workstations.




Here is Jen. She’s a happy camper after trying the “password controlled” prototype.

 This application is from a company that sells jewelry—stones, chains, settings, and the like. Each operator had a station. At each station was a Setra C model scale. The customer loved the Setra scales, but they were obsolete and did not perform some functions that he wanted. He wanted to make a label for each package that he shipped, with the count, APW (average piece weight) and ID on the label. He also liked the idea of scanning the APW into the scale rather than forcing the operators to hand count samples every time they needed to count parts. The Setra Super II fits this need. We can use Setra’s Scripcoder capability to customize labels and a scanner to send ID and APW information stored on a label back to the scale. Also, this customer thought that he may have reason to communicate with the scales from his computer system and the Super II has a second communication port for this purpose. This customer has purchased 17 scales for this application. Two have higher capacity remote platforms as well as the built-in ones, so that he can weigh/count bulk as it is received. The pictures at the far left show what the workstations look like.

One day the owner called and said that he wanted some changes made. Sometimes customers reported mistakes and the owner had no way of knowing which operator made the error, so he could not take corrective action. He asked what we could do to remedy the situation. The Setra Super II is set up so that when the operator presses the “PRINT” key and chooses the proper label format, a label is printed. We had to devise a way to interrupt this so that labels could only be printed after a “password” label was scanned. We determined that if we devised a “macro” that controlled every interaction that the operator had involving the scale, we could not only be sure that the password was scanned, but be sure that each operator utilized the system in an identical manner. Below are the screen shots of the Super II showing how this macro worked.

We were afraid that, although this worked well, that the operators would be hesitant to use a system that regimented them to a precise way of using the equipment. We found that they actually liked it, because they did not have to think about what to do next and it eliminated errors.

Screenshots from “Above Counting Example”
1. This is the first screen that the operator sees. He/she sees it as soon as the unit is turned on. If there is an APW label, she chooses 2, otherwise 1.
2. We see this if the operator chooses “1 for sampling” above. If “2” was chosen, she would be asked to scan the APW. The empty container is automatically “zeroed” by the next step.
3. The operator is prompted to add a sample. The default “10 pieces” can be changed if necessary. The Super II can control minimum sample size if we want to use it.
4. We placed our 10-piece sample on as required above. The operator can change platforms—2 stations have a remote platform to enable weigh/counting bulk items.
5. Here is where we ask for the operator ID. Each operator knows her number, but the number alone will not work here. It is an encoded number. We ask for the number here so that anyone can use the scale for normal counting—the steps that come before this one. The next steps pertain to making the label.
6. The customer has 2 labels. This determines which one will be printed and for which fields we need to prompt.
7. We prompt for the “part #” so it can be printed on the label. This is the only ID field on the “SHIPPING” label.
8. This is our last chance to be sure everything is right before making the label.
9. The label printed and we have 4 choices:
  • “MORE?” for same item, different count
  • “ENDRPT” starts from the beginning
  • (1) and “MORE” lets you retype your Ids in case you found you made a mistake
  • (2) and “MORE” is for the same part so you do not have to resample, but starts from the 6th screen above (shipping or incoming)


These are just some examples of applications we have met for some customers. Please contact us about your applications. You may only require a simple scale and that is OK too.

Contact us about your application needs. or call 1-800-696-8282 then press 1.
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