LoRaWAN® Gateway Integration for Industrial Parking Management

Industrial facilities often face significant challenges in managing parking for industrial vehicles. These challenges are even greater in remote locations like oil rigs, mining sites, and steel manufacturing facilities, where traditional network infrastructure is limited and environmental conditions are harsh.

TEKTELIC recently partnered with a leading global Industrial Control Systems Provider (referred to as “the customer” due to NDA terms) to deliver an innovative LoRaWAN®-based solution for industrial parking management. This case study highlights the deployment process, the solutions provided, and the transformative outcomes achieved.

The Challenge

Managing industrial parking in steel manufacturing facilities came with several issues:

• Limited real-time visibility: Existing systems could not provide accurate, real-time data on industrial vehicle parking and status.
• Integration difficulties: The customer’s infrastructure relied heavily on PLC (Programmable Logic Controller) systems, requiring seamless integration to avoid disruptions.
• Harsh environments: The facilities were in remote areas with challenging RF conditions, high levels of dust, and no reliable internet connectivity.
• Need for scalability and durability: The solution had to support a large number of IoT sensors and withstand tough conditions.

Solution

To meet these challenges, the customer needed to make the right choice to ensure success. For this deployment, the KONA Enterprise Gateway was selected as the core product for the LoRaWAN® network. This gateway provided a reliable communication link and integrated seamlessly with the customer’s existing setup.

Additionally, the solution incorporated the Sky Light Parking Sensors, which enhances vehicle detection accuracy and supports energy-efficient data transmission.

Here’s how the solution was implemented:

1. Gateway Integration with PLC Systems

The KONA Enterprise Gateway’s embedded Network Server allowed efficient communication with third-party parking sensors installed across the facility. The gateway connected with the customer’s PLC system using MODBUS/TCP protocol, enabling real-time data flow without requiring significant changes to the existing setup.

2. Optimized IoT Communication

The parking sensors were configured to send data only when necessary, reducing network traffic. This approach ensured efficient use of limited network resources, especially in remote areas.

3. Robust and Reliable Design

The KONA Enterprise Gateway’s IP67 rating made it highly durable in tough environments. It was resistant to dust, moisture, and extreme temperatures. The solution supported up to 100 LoRaWAN® sensors with a single gateway, making it easy to expand in the future.

Future enhancements to the gateway include the integration of a highly available LTE modem, which will ensure reliable backhaul connectivity and facilitate efficient data transmission in remote locations. Additionally, planned improvements such as satellite backhaul support, expected to be integrated by early 2025, will further strengthen the solution’s ability to operate in the most challenging environments.

The Results

A Proof of Concept (PoC) showed immediate and meaningful results:

• Better Operational Efficiency: Real-time monitoring improved parking space usage, reduced vehicle downtime, and streamlined logistics.
• Easy Scalability: The solution could handle large-scale sensor deployments, making it ideal for expansion to other sites.
• Seamless Integration: The gateway’s compatibility with MODBUS/TCP ensured smooth operation within the customer’s PLC network without disrupting existing processes.
• Resilience in Tough Conditions: Despite challenging RF environments and no internet access, the solution worked reliably, showcasing TEKTELIC’s ability to deliver dependable IoT solutions.

Future Opportunities

After the success of the PoC, the customer plans to roll out the solution at more facilities, including remote oil rigs and mining sites. The scalable and reliable nature of TEKTELIC’s solution makes it a valuable tool for improving operations in various industrial settings. This collaboration highlights TEKTELIC’s commitment to providing effective IoT solutions that enhance efficiency and drive innovation.