IIoT Increases Transparency in Materials Testing

To transparently track the path of samples between production and the lab, the transport containers were equipped with Bluetooth beacons. The beacons transmit a unique identifier at short intervals. Fixed scanners at the sampling stations and in the approach zone of the sample processing area capture these signals. The relevant information is centrally provided and processed via the IIoT (Industrial Internet of Things) infrastructure.
Technically, this combines the strengths of two wireless technologies: Bluetooth is suitable for the energy-efficient identification of objects at close range. LoRaWAN (Long Range Wide Area Network) is a low-power wide-area architecture designed for transmitting small amounts of data over long distances and for scalable IIoT networks. The technology enables battery-powered devices with low energy requirements to be wirelessly integrated into extensive IIoT networks that can be expanded as needed.
The solution implemented deliberately does not rely on continuous, meter-accurate tracking. Instead, it reliably records when a tagged transport container arrives at or departs from a defined station. The arrival and departure times of the container are derived from the received signals. Since the sampling event is also recorded digitally at the same time, the respective sample sheet can be uniquely assigned to its transport container. The container thus serves as the digital link between the manufactured part, the sampled sheet, and the subsequent inspection.
The system integration of the Bluetooth components, as well as the development of a dashboard for monitoring the IIoT infrastructure, were carried out by our sister company, Salzgitter Digital Solutions GmbH. By combining expertise in materials testing and process engineering with the Group’s internal digitalization and integration capabilities, a comprehensive solution tailored to operational requirements was created.

Our customers benefit from indirect added value, primarily through greater transparency throughout the entire testing process. The status of a sample is visible not only upon its arrival at the laboratory. The transition between sample collection, internal transport, and sample preparation is already digitally tracked. This allows delays and unplanned downtime to be identified more systematically and analyzed in a targeted manner.
The recorded timestamps also create a robust data foundation for the continuous optimization of the process chain. Transport cycles, handoff processes, and the preparation of samples for testing can be objectively evaluated. The goal is to further shorten the turnaround time from sample collection to the availability of test results. Faster test results, in turn, support early material release and thus reliable processes for shipping, certificate issuance, and invoicing.
The central dashboard for monitoring the technical status of the IIoT infrastructure also provides a quick overview of component availability and, for example, alerts users early on to low battery levels in individual beacons. This allows for the planning of necessary battery replacements before traceability is compromised.