Soaring to New Heights in Aircraft Weighing

How a wireless telemetry system transformed aircraft weighing operations.

Jackson Aircraft Weighing Service (JAWS), a full-service aerospace weighing company based in West Palm Beach, Florida, was struggling with outdated wired sensor setups for weighing aircraft. It needed a solution to eliminate the extensive setup and calibration times, which often caused significant downtime and operational inefficiencies. To enhance accuracy, reliability and efficiency, JAWS partnered with wireless measurement expert Mantracourt to integrate its T24 wireless telemetry transmitter into JAWS's weighing systems, creating a wireless aircraft weighing solution. 

Precise aircraft weighing is vital for safety and performance, ensuring correct centre of gravity for control, optimal fuel efficiency, structural integrity, accurate performance calculations, regulatory compliance and safe passenger and cargo management. It prevents overloading, reducing maintenance costs and enhancing the aircraft’s operational lifespan and reliability. 

According to the FAA’s Weight and Balance Handbook, weight and balance holds vital importance to each FAA certificated mechanic or repairman maintaining an aircraft. Consequently, they must be fully aware of their responsibility to provide the pilot with current and accurate information for the actual weight of the aircraft and the location of the centre of gravity (CG). 

JAWS offers comprehensive services, including sales, calibration, on-site weighing and rental scales. Its expertise covers a range of aircraft types, from small planes to commercial jets, helicopters, unmanned aerial vehicle (UAVs) and electric aircraft. The increasing complexity of modern aircraft necessitates a more efficient and reliable weighing solution. 

Historically, weighing systems relied on wired technology, which are less flexible in terms of placement and movement, making it harder to adapt to different aircraft types and configurations. Additionally, wired systems typically experience more wear and tear than wireless systems. The physical cables and connectors are prone to damage from frequent handling, environmental exposure, and mechanical stress. Over time, this can lead to connectivity issues and require frequent repairs or replacements.  

Early attempts at wireless systems often failed due to weak signals and unreliable performance, making customers hesitant to adopt them. 

"Knowing that we needed to upgrade from wired systems, we set out to find a high-precision wireless solution. We tested various systems extensively to ensure reliability and accuracy, ultimately partnering with Mantracourt,” said Larry Jackson, general manager of Jackson Aircraft Weighing Systems. “Its T24 wireless telemetry transmitter stood out for its robust performance and reliability." 

Navigating challenges 

Transitioning to a wireless system posed several challenges. For example, the aviation industry has stringent requirements for weighing aircraft, with the FAA’s Weight and Balance Handbook stating “Weighing aircraft with accurately calibrated scales is the only sure method of obtaining an accurate empty weight and CG location”. 

This meant that any new technology had to be exceptionally accurate, reliable and durable. The T24 system, with its high-quality 17-4 stainless steel construction and IP67 rating, met these demands, offering resistance to dust and water and ensuring durability in harsh environments. 

One significant advantage of the T24 system was its ability to provide reliable wireless communication up to 800 metres without signal interference, proving useful for large aircraft. This system allowed real-time data transmission, enabling accurate and efficient monitoring and recording of weight measurements. 

JAWS developed a modular wireless telemetry system using Mantracourt's technology, capable of handling multiple data points in real time. This system included a range of transmitters, interfaces, displays and output modules, configurable for various applications.  

The flexibility of the T24 system allowed JAWS to design custom solutions for different aircraft types, including small aircraft with non-retractable landing gear, larger aircraft, commercial jets such as the A320, 737, A330 and 767, as well as helicopters, UAVs, and electric aircraft. 

Simple yet effective 

The integration of the T24 system brought significant benefits. The wireless setup eliminated the physical constraints of wired systems, allowing for greater flexibility in sensor placement and more accurate measurements, especially for large commercial jets. The system's robust construction ensured longevity and reduced maintenance intervals crucial for equipment subjected to harsh use. 

The custom software developed in collaboration with Mantracourt enhanced usability, offering sophisticated data logging and visualisation. Clients could monitor up to 100 channels simultaneously, set alarms for under and over-range conditions and receive alerts for communication or battery issues. These features ensured accurate, real-time data for informed decision-making. 

“Our wireless is so strong, it can even be used in between brake housings with no signal interference,” explained Tom Lily, product manager at Mantracourt. “Custom computer readouts with visual loading take all the guesswork out of weighing a large jet.” 

Overcoming scepticism 

Convincing customers to switch from wired to wireless systems required demonstrating the new system's reliability. JAWS conducted extensive field tests and demonstrations, showcasing robust performance in demanding environments. They also developed retrofit kits for existing wired systems, making the transition seamless and efficient. 

“We chose to offer wireless systems only after complete testing and development,” said Jackson. “The performance and reliability of Mantracourt’s system were unmatched, providing the robust solution we needed.” 

Training programs were implemented to ensure clients could operate the new system effectively and troubleshoot any issues, building confidence in the technology and ensuring smooth adoption. 

Soaring to new hights 

The successful deployment of the T24 wireless telemetry system transformed JAWS’s operations. The system's high precision and reliability ensured accurate weight measurements, reducing setup times and increasing operational efficiency. The substantial reduction in downtime during weighing operations translated into cost savings and increased productivity for clients. 

Jackson concluded: “The efficiency and accuracy of the system have set a new standard in the industry. The ability to perform critical maintenance checks without compromising on safety or precision has transformed our operations.” 

The positive feedback and successful adoption of the wireless system validated JAWS's decision to transition to wireless technology, reinforcing its reputation as a leader in the aerospace weighing industry. 

For more information about Jackson Aircraft Weighing Service’s innovative wireless weighing solutions, visit www.aircraftscales.com.

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