Load Cell

Load cells measure force/weight to detect object presence, evaluate structural loading, or monitor mechanical stress. The system supports a dual load cell configuration, each read through its own HX711 24-bit ADC using GPIO bit-banging. This is the most complete sensor driver on the board: it talks to real hardware with no compile gate.

Hardware Specifications

Wiring and Pin Map (from firmware.ioc)

Data Structure

typedef struct {
  int32_t raw_counts;               /* 24-bit two's complement reading */
  float force_newtons;
  float mass_grams;
  float scale_newtons_per_count;    /* default 1.0 (passthrough) */
  int32_t tare_offset_counts;
  bool is_calibrated;               /* true once load_cell_set_scale() called */
  bool read_ok;                     /* true if the last poll succeeded */

  /* HX711 hardware binding (set by load_cell_sensor_init_hw) */
  GPIO_TypeDef *dout_port;
  uint16_t dout_pin;
  GPIO_TypeDef *sck_port;
  uint16_t sck_pin;
  uint8_t gain_pulses;
} load_cell_data_t;

Initialization

Initialize Load Cells (as in main.c)

load_cell_data_t load_cell_data[2];

/* Unit 0: DOUT = PA5, SCK = PC7. Unit 1: DOUT = PA6, SCK = PB5. */
load_cell_sensor_init_hw(&load_cell_data[0], GPIOA, GPIO_PIN_5, GPIOC, GPIO_PIN_7);
load_cell_sensor_init_hw(&load_cell_data[1], GPIOA, GPIO_PIN_6, GPIOB, GPIO_PIN_5);
/* init_hw powers up the HX711 and auto-tares */

/* Alternative: load_cell_sensor_init(&data) zero-initialises WITHOUT a
 * hardware binding; poll() then returns RESULT_ERR_UNIMPLEMENTED */

Poll Load Cell Sensor

result_t lc_result = poll_load_cell_sensor(&load_cell_data[i]);

Data Access Functions

float force, scale;
float mass;
int32_t counts, tare;
bool valid;

load_cell_get_force_newtons(&cell, &force);
load_cell_get_mass_grams(&cell, &mass);
load_cell_get_raw_counts(&cell, &counts);
load_cell_get_calibration(&cell, &scale, &tare);
load_cell_sensor_is_valid(&cell, &valid);

Calibration Procedure

Two-Step Calibration

Step 1: Tare (Zero Load)

/* With nothing on the cell: average N raw reads and store as zero offset.
 * init_hw already does this automatically at startup. */
load_cell_tare(&cell, 10);

Step 2: Span (Known Weight)

/* Place a known mass, read raw counts, then:
 *   scale = known_force_newtons / (raw_counts - tare_offset_counts)   */
load_cell_set_scale(&cell, newtons_per_count);   /* sets is_calibrated = true */

Measurement Formulas

force_newtons = (raw_counts - tare_offset_counts) × scale_newtons_per_count
mass_grams    = force_newtons / 9.81 × 1000

Note: before calibration the default scale is 1.0 (passthrough): raw_counts is trustworthy but force_newtons and mass_grams are not physical units yet.

Protobuf Message Format

message SensorBoardLoadCellInfo {
    uint32 sensor_index;            /* 0 or 1 */
    float force_newtons;
    float mass_grams;
    int32 raw_counts;
    float scale_newtons_per_count;
    int32 tare_offset_counts;
    bool is_calibrated;
    SensorState state;
    LoadCellErrorCode error_code;   /* NO_ERROR, COMMUNICATION_FAILURE, INVALID_DATA */
}

Unit Conversions

Integration Notes

• Two independent units polled every main loop iteration; each is transmitted in its own envelope with its sensor_index
• Each sensor maintains separate calibration (tare + scale) and independent error reporting
• HX711 gain/channel is selected by extra SCK pulses after the 24 data bits (1 = channel A gain 128, 2 = channel B gain 32, 3 = channel A gain 64)
• The blocking wait for data-ready can take up to 200 ms per cell per poll; keep this in mind when reducing the loop interval
• A failed read maps to state ERROR with LOAD_CELL_COMMUNICATION_FAILURE; a read with implausible data maps to LOAD_CELL_INVALID_DATA