How to Transform Industrial Automation Using Real-Time Locating Systems (RTLS)

Real-Time Locating in Industrial Environments

Tracking mobile and stationary assets such as manufactured goods, transport vehicles, machines, tools or containers is a key prerequisite for the automation and optimization of logistics and production processes in Industry 4.0. To reliably orchestrate complex operations in industrial environments, the location and status of involved objects must be continuously tracked. Real-Time Locating Systems (RTLS) consisting of sensors, receivers, network and control systems provide the technical infrastructure for automated, continuous monitoring.

What is a Real-Time Locating System (RTLS)?

Real-Time Locating Systems (RTLS) are a key technology for the automated localization and tracking of objects in real time, usually within a specific business area, e.g. industrial production or warehouse. Combining wireless communication, localization algorithms and centralized monitoring, RTLS provides accurate real-time data on the positions of tagged objects, enabling businesses to effectively track and manage their assets and processes. This makes RTLS a key prerequisite for industrial process optimization and automation.

How does RTLS work?

RTLS typically uses radio frequency signals such as BLE, GPS, RFID, UWB or WiFi technology to locate assets in a defined area. Each asset to be tracked is equipped with a sensor that emits radio signals. These signals are collected by a series of receivers located throughout the monitoring area. The receivers triangulate incoming signals to determine the exact location of each object using localization algorithms. Depending on business requirements, the position of each tagged object can be precisely calculated.  

RTLS Tracking: Bluetooth/BLE, GPS, RFID, UWB, WiFi

Various technologies are available to enable effective communication between hardware and software components in industrial object tracking systems, depending on the specific requirements. Whether a technology is suitable for a particular application essentially depends on whether objects need to be tracked continuously or just from time to time, whether this process needs to be automated and how accurate the localisation needs to be.

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‍Common tracking technologies in a nutshell

• Bluetooth Low Energy (BLE) offers low-power communication over short distances and is usually used indoors. It is very suitable for frequent updates without reducing battery life and is therefore suitable for warehouses and factories.
• Global Positioning System (GPS) enables accurate tracking outdoors using satellite signals. It is particularly suitable for monitoring vehicles and shipments in large areas, but is less effective indoors due to signal obstructions.
• Radio Frequency Identification (RFID) uses electromagnetic fields to track tags on objects. Active RFID tags have their own power source for communication over longer distances, while passive tags rely on signals from connected readers.
• Ultra-wideband (UWB) provides high-precision indoor tracking with high accuracy. Its wide frequency range minimizes interference, thus making it the ideal choice for manufacturing, asset tracking and automatic vehicle navigation.
• WiFi-based tracking uses existing WiFi infrastructure to track devices and assets. It offers a good balance between accuracy and cost and is suitable for industrial environments with extensive, seamless WiFi coverage.

With the growing demand for more accurate, comprehensive and immediate data, businesses are adopting Real-Time Locating Systems (RTLS) to complement or replace their RFID solutions. UWB is recognised as the most accurate, reliable and dynamic locating technology and is therefore the gold standard for ultra-precise RTLS. The following comparison highlights the differences between RFID and UWB.

What Is the Difference between RFID and UWB RTLS?

RFID has been a key technology for wireless object identification in industrial environments for decades. With an increasing number of industrial assets and people moving through factories and warehouses, UWB-based real-time localization has become a more powerful alternative to RFID. The main difference between (passive) RFID and UWB RTLS is in the localization data they generate: while RFID provides selective point-to-point data, UWB is designed to deliver continuous, seamless real-time data across a defined space.‍

Key benefits of UWB technology:

• Accuracy: high-precision localization technology
• Responsiveness: real-time capability
• Stability: no interference with WiFi or BLE versions commonly used in the industry
• Flexibility: various use cases within one infrastructure
• Robustness: long-term operation without maintenance intervention

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RTLS Localization: TWR, TDoA, AoA and PDoA

UWB combines short light-speed pulses and accurately measures signal arrival time over a wide bandwidth for high-precision transmitter positioning, reaching distances of up to 200 meters in line-of-sight. There are various methods available to achieve this, which differ in their accuracy, energy consumption and suitability in fast environments with a large number of assets to be tracked. The most common methods are presented here.

‍Two-Way Ranging (TWR): Using TWR the highest precision and position stability can be reached. This method is preferred for localization of people and tools. It is furthermore the go to method for navigation of driverless automatic guided vehicles (AGV).

Time Difference of Arrival (TDoA): Localization using TDoA is characterized by the lowest power consumption compared to the other methods. In an industrial environment TDoA is primarily used with larger numbers of objects.

Angle of Arrival (AoA): Calculating the position based on the angle of arrival, the direction of the signal relative to the anchor and the signal strength allows greater precision with minimum infrastructure. 

Phase Difference of Arrival (PDoA): Determining the sensor position based on the phase difference between the received signals at both anchor antennas and the angle of the signal relative to the anchor allows the RTLS to be implemented in restricted infrastructures.

Modern RTLS systems for high-precision real-time positioning combine various localization methods to achieve the best results in industrial environments. KINEXON RTLS uses TWR and TDoA to provide maximum accuracy and energy efficiency.

RTLS Hardware: Tags and Anchors

The hardware components of an industrial RTLS include tags and anchors - mobile devices attached to assets to be tracked that transmit signals and static ones that receive these signals, determine asset positions in real time and forward them for processing.

RTLS Tags: Mobile sensors that are attached to the objects to be tracked. Tags emit signals received by the so-called anchors. There are different types of tags, including active tags with their own power source, e.g. a battery, that can transmit signals over long distances, and passive tags, relying on an external power source, e.g. a reader. There are also tags with and without a user interface, e.g. a small screen to display the current asset status.

RTLS Anchors: Stationary receivers that are placed across the industrial environment to receive signals from the installed tags. These anchors collect data on the arrival time, strength and angle of the signal and then transmit this information to the RTLS software for centralized processing and control. RTLS anchors usually have their own power supply, e.g. through integration into a Power-over-Ethernet (POE) infrastructure or regular power grid.

RTLS Software: Control Center and Coordinator

While hardware, anchors and tags, is an essential component of RTLS systems, any smart solution requires powerful software to unlock the true value of location-based process automation - regardless of the technology used to generate real-time location data. A sophisticated RTLS software platform integrates tracking technologies and location data, enabling operators and decision makers alike to automate operations and gain actionable insights from location data.

Coordinator: Software that runs on a server or on a Virtual Machine (VM) to which the anchors are connected. The coordinator controls the synchronization of anchors and tags and processes the anchor data to create position data in real time.

Control Center: User interface for the RTLS, which in modern systems is a web-based application. All relevant information, such as the current system status, the available devices or the current system settings, is displayed in the Control Center.

What Is the Difference between IPS and UWB RTLS?

The terms Indoor Positioning System (IPS) and Real-Time Locating System (RTLS) are often used synonymously. In fact, both refer to systems that are designed for tracking and monitoring moving or stationary objects in industrial environments. In addition, both are mostly used for indoor production and intralogistics applications.

At a technical level, IPS and RTLS differ in one key feature:

• RTLS solutions are network-centric systems where the location of assets is tracked and reported to the back-end server and control software, providing this information to the user. Typical application: Locating e.g. goods, tools etc.‍
• IPS solutions are device-centric systems, telling the asset its location and reporting the location to the user of the device (usually via a smartphone app). Typical application: Navigating e.g. driverless vehicles (AGV), for example.

Industrial Applications for RTLS

Real-Time Locating Systems (RTLS) are taking industrial processes to the next level by providing businesses with high-level visibility and control over systems and processes, unlocking a great potential for automation. From industrial asset and production order tracking to assembly line control, RTLS enables businesses to increase efficiency, productivity and safety while reducing operating costs. As industries continue their digital transformation, the adoption of RTLS will undoubtedly play a crucial role in a company’s future success.

Order Tracking & Process Management

Automated order tracking and process management helps optimize industrial operations and reduce costs. Companies achieve maximum order transparency and track production orders in real time. Accurate insights into physical production processes allow for effective quality control and automatic material replenishment.

• Real-time Order Tracking: Automate processes by eliminating manual bookings and scans to save time and costs.
• Automated Quality Control: Increase production and process quality with real-time monitoring and timely alerts of errors and bottlenecks.
• Efficient Material Replenishment: Avoid material shortages and process idle times by optimizing just-in-time delivery of material to the production lines.

Learn more about Order Tracking & Process Management with KINEXON

AMR & AGV Fleet Management

The level of automation can be further increased by combining AMR/AGV control with real-time location systems. With KINEXON OS & KINEXON IIoT devices, companies connect and manage resources beyond mobile robots. By combining both solutions, further manual effort is eliminated and operational efficiency is increased.

• Process stability with real-time manufacturing monitoring: RTLS enables real-time monitoring of manufacturing processes, improving stability and increasing efficiency.
• Automate order creation process: RTLS minimizes setup times and simplifies order creation for faster turnaround times.
• Transport safety of autonomous vehicles: RTLS prevents collisions between autonomous vehicles and forklifts, ensures safe transport processes.

More about AMR & AGV Fleet Management with KINEXON

Asset Tracking in industrial environments

Industrial Asset Tracking enables businesses to efficiently manage materials, tools or semi-finished goods. Movable assets are digitized to easily track their location and improve transparency for employees. Automated flows of tagged assets can be managed more efficiently to identify and reduce bottlenecks.

• Inventory Management: Eliminate search times and increase industrial asset visibility to save operational costs.
• Process Flow Management: Manage and optimize the work-in-process status of any industrial assets involved in production processes.
• High-value Asset Tracking: Efficiently monitor and manage high-value assets with greatest precision and reliability.
• Specialty Equipment Tracking: Receive real-time notifications and documentation of rule violations related to the movement and quantity of speciality equipment.

Explore more about Asset Tracking with KINEXON

Assembly Line Control

Using RTLS, businesses reach the next level of flexible and efficient assembly automation. By tracking the location of vehicles and tools in real time, manual assembly processes can be automated and production managers enabled to intervene immediately in emergencies.

• Automated Vehicle Identification: Accelerate assembly by eliminating manual scans for vehicle identification.
• Automated Tool Approval: Increase assembly quality by controlling manual assembly tool operations.
• Assembly Line Operator: Leverage flexibility of assembly processes to seamlessly apply new requirements.

Discover more about Assembly Line Control with KINEXON

How KINEXON Helps Unleash the Power of RTLS

The KINEXON Real-Time Locating System is designed for fast update rates and maximum positioning accuracy. Thanks to the versatile portfolio of sensors (tags), the KINEXON RTLS Pro is able to cover a wide range of application scenarios, including order tracking & process control, asset tracking and automated assembly line production.

The KINEXON RTLS Pro system provides businesses with all the hardware and software components they need to efficiently automate their industrial processes. The latest UWB technology ensures maximum performance and reliability. In addition, the system is highly scalable and can be easily expanded by adding further anchors as required.

Learn more about the KINEXON RTLS Pro

The KINEXON OS platform collects and processes location data in real time to respond flexibly to production and logistics operations and enable intelligent decisions for key processes. The platform is highly flexible, scalable and allows businesses to aggregate location and identification data from various sources and complements contextual information from third-party IT/OT systems such as ERP (Enterprise Resource Planning), MES (Manufacturing Execution System) and WMS (Warehouse Management System).

‍Read more about KINEXON OS

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