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LoRaWAN UWB Solution for Anti-Collision in Industrial Environments

LoRaWAN UWB Solution for Anti-Collision in Industrial Environments

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Case Study: Lansitec’s LoRaWAN UWB Solution for Anti-Collision in Industrial Environments
Case Study: Lansitec’s LoRaWAN UWB Solution for Anti-Collision in Industrial Environments

Client: SAMKING Solar Pumps Manufacturing Plant
Industry: Heavy Machinery & Industrial Manufacturing

SAMKING Background

SAMKING operates a sprawling 800,000 sq. ft. manufacturing facility, housing automated assembly lines, CNC machines, and overhead cranes. With 200+ workers and 50+ heavy machines operating in close proximity, the plant faced critical safety challenges:

  • Frequent near-miss incidents between workers and moving machinery.
  • Unauthorized entries into restricted high-risk zones (e.g., robotic welding areas).
  • Rising insurance premiums due to workplace injuries and OSHA violations.

Existing infrared sensors and manual signage failed to provide real-time alerts, leading to three worker injuries in 2023.

Challenge

Collision Risks: Workers often entered blind spots of cranes and forklifts, resulting in accidents.
Restricted Area Breaches: Unauthorized personnel entered hazardous zones, risking electrocution or equipment damage.
System Limitations: Legacy proximity sensors (2m accuracy) could not distinguish between static obstacles and humans.

Implementation

Collision Risks: Workers often entered blind spots of cranes and forklifts, resulting in accidents.
Restricted Area Breaches: Unauthorized personnel entered hazardous zones, risking electrocution or equipment damage.
System Limitations: Legacy proximity sensors (2m accuracy) could not distinguish between static obstacles and humans.

Solution: Lansitec’s Multi-Use UWB-LoRaWAN Safety Ecosystem

SAMKING deployed Lansitec’s UWB-anchor and UWB Badge Tracker across three key applications:

1. Heavy Machinery Anti-Collision

  • Workers wore UWB Badge Trackers, broadcasting their real-time locations via UWB(up to 20m range in open areas).
  • UWB-anchorsmounted on cranes, forklifts, and robotic arms provided 10–20 cm precision It also reports the proximity actions to the server via LoRaWAN.

Customizable Danger Zones:

  • 1–5 meters around moving machinery triggered alarms (beeping + LED flashes) on both the UWB-anchor and the worker’s badge.
  • 5–10 meters for slow-moving cranes, giving operators advanced warnings.

2. Restricted Area Monitoring

UWB-anchors installed at entry points to hazardous zones (e.g., high-voltage panels, chemical storage).

Unauthorized personnel entering these zones triggered:

  • Local Alerts: Flashing LEDs and alarms on the anchor.
  • Central Alerts: The anchor will send all the notifications to the APP via LoRaWAN.

3. System-Wide Benefits

  • Full Battery-Powered System: Anchors and badges are battery-powered, with anchors lasting for up to 5 years and badges lasting 6 months per charge.
  • Low Power, High Scalability: The LoRaWAN gateway supports 500+ devices
  • Interference Resistance: UWB’s 5GHz–7.5GHz bandwidth avoided clashes with Wi-Fi/Bluetooth.
  • Data Logging: Incident reports (time, location, personnel) were integrated into Samking’s safety compliance software.

Implementation

  • Phase 1 (3 weeks): Installed 80 UWB-anchors on machinery and restricted zones; distributed 250 badge trackers.
  • Phase 2 (2 weeks): Calibrated danger zones using Samking’s cloud-based software (e.g., 2m radius for robotic arms, 8m for crane paths).
  • Training: Workers received briefings on badge protocols while machine operators practiced emergency stop procedures during alerts.

Challenges Overcome:

  • High Noise Environments: UWB’s short pulses excelled in metal-dense areas where traditional RF failed.
  • Dynamic Workflows: Adjustable zones accommodated shift changes (e.g., expanding danger area during maintenance).

Results

90% Reduction in Near-Miss Incidents involving heavy machinery within 4 months.
Zero Restricted Zone Breaches post-deployment, compared to 8 incidents quarterly in 2023.
Insurance Savings: 25% lower premiums due to improved OSHA compliance.
Operational Efficiency: 15% faster machine throughput as operators worked confidently with real-time alerts.

Worker Feedback:
“The anchor alarms make me hyper-aware of my surroundings. I feel safer working when the forklift is near the workers now.”
— Shu LEE, Forklift driver

Management Insight:
“Lansitec’s system didn’t just prevent accidents—it gave us data to redesign high-risk workflows.”
— Zhen Wang, Plant Safety Director

Conclusion

SAMKING’s deployment highlights Lansitec’s versatility in addressing industrial safety challenges, from anti-collision to access control. By combining UWB’s pinpoint accuracy with LoRaWAN’s robust connectivity, the solution creates a proactive safety net adaptable to diverse environments.

Future Expansion, Samking plans to:

  1. Integrate UWB-anchors with emergency shutdown systems for automated machine halting.
  2. Deploy wearable “smart helmets” with embedded UWB trackers for high-risk roles.

Explore Lansitec’s Safety Solutions:

Lansitec—Engineering Safer Workplaces Through Innovation.

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Technically reviewed by Liancheng Su, IoT Hardware Engineer at Lansitec

This article has been reviewed by our engineering experts with extensive experience in BLE, LoRaWAN, and Industrial IoT solutions to ensure technical accuracy and reliability.

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