Abstract
In many areas, public transportation-especially minibus services-is an essential mobility alternative, yet overloading remains a prevalent safety hazard. Vehicle stability is jeopardized, road deterioration is accelerated, and the likelihood of accidents is increased when allowable weight limits are exceeded. For the reason that to address these issues, this study suggests an integrated, real-time driver support system that operates to detect instability in minibuses thereby preventing overloading. To continually track vehicle weight and dynamic load transfer, the system makes use of leaf spring strain gauges and chassis-mounted load cells. A fuel cutoff solenoid deactivates and stops engine operation when the gross vehicle weight is surpassed. A strain threshold (ε = 0.03) detects instability during motion, triggering audiovisual warnings and, if required, sending location-based alerts to authorities via GSM/GPS. A Toyota HiAce (LH172V) van's maximum safe running speed of 24.37 km/h and wheel load capabilities of 10.24 kN (front) and 11.52 kN (rear) were determined through analytical and experimental research. By minimizing rollover danger, preserving stability under a variety of driving circumstances, and alleviating accidents ascribed to overload-induced instability, attributable to overload-induced instability.