IoT-based Truck Overload Detection and GPS-Enabled Alert System

Truck overloading is still common on many highways, and the consequences are steep: higher crash rates, mounting fuel bills, and faster wear on engines, brakes, and tyres. Traditional enforcement the occasional weighbridge or roadside inspection catches a few offenders but leaves most journeys unchecked, giving operators plenty of room to flout weight rules. To close that gap, we built a compact, low-cost IoT kit that watches a truck’s load around the clock. Four strain-gauge load cells ($\pm 0.2 \%$ accuracy) sit beneath the cargo deck and relay amplified signals to an ESP32 microcontroller. The ESP32 pairs those weight readings with live coordinates from a NEO-6M GPS receiver, then pushes the combined data to the Blynk cloud over Wi-Fi. Drivers and fleet managers see every kilogram and every location on a phone dashboard and get a push alert the moment a legal threshold is crossed. In bench tests with staged loads from $0-20 \mathrm{~kg}$, the prototype flagged overload events with $\mathbf{9 9. 1 \%}$ accuracy and issued warnings in 2.3 s on average. Location data stayed within ±3 m of truth. By keeping weight visible mile after mile, the system slashed the need for manual checks by $85 \%$ and helped dispatchers balance loads more efficiently, boosting overall fleet productivity by roughly $\mathbf{4 0 \%}$. Each unit costs under US ${\$}$ 150 and bolts onto an existing truck with minimal wiring, putting real-time weight policing within reach of small and mid-sized operators.