Case studies

In today’s dynamic industrial world, the mining industry, especially coal mining, presents numerous technological challenges. Implementing solutions in this context necessitates meeting the highest standards of reliability and safety, particularly in challenging environmental conditions. In this perspective, wireless communication is of paramount importance, but to meet the expectations of the mining industry, it must deliver specific benefits.

Introducing an innovative wireless communication system, developed in collaboration with Elsta Elektronika, a leading provider of comprehensive solutions for the mining industry. This solution not only addresses the challenges of mining but also provides substantial advantages, elevating not only safety standards but also operational efficiency in demanding mining environments.

Challenges Presented by the Mining Industry

The mining industry is an environment that poses exceptionally challenging hurdles for technology. This includes not only extreme working conditions but also the necessity to ensure safety in a potentially explosive environment, with the presence of methane or coal dust. In such a context, wireless communication becomes an exceedingly complex task. The main challenges that technology must face in the mining industry are as follows:

1. Safety threats – the mining industry prioritizes safety above all else. Communication systems must operate intrinsically safely, meaning they are capable of functioning in a potentially explosive atmosphere.
   
2. Working conditions – tight spaces and the presence of numerous electronic devices make radio communication exceptionally challenging. Interference generated by these devices can significantly hinder effective communication.
   

Environmental complexity – mining longwalls are extensive and require monitoring of numerous parameters. This, in turn, necessitates efficient communication with numerous sensors over a vast space. Our collaboration with Elsta Elektronika focused on overcoming these challenges, delivering an innovative wireless communication solution that addressed these hurdles and provided concrete benefits to the mining industry.

Innovation for the Mining Industry

In response to the unique challenges presented by the mining industry, the EMBETECH team, in collaboration with Elsta Elektronika, has developed an innovative wireless communication system that delivers key benefits to mining operations. This solution has been tailored to the specific needs of this sector, taking into account its unique aspects. The key components of this system include:

1. Sensors across vast spaces – in a typical mining installation, there are nearly 1,000 sensors positioned along a long wall. Our system allows these sensors to communicate, automatically forming an organized mesh network using TSCH (Time Slotted Channel Hopping) technique.
   
2. Rapid data transfer – the system can transmit data from any point on the longwall to the central computer in less than 10 seconds, even when utilizing multiple hops. This means that information is available in near real-time, which is crucial in mining.
   
3. Battery-powered sensors – to minimize maintenance requirements, the sensors in the system are battery-powered and have a lifespan exceeding one year. This saves time and costs associated with battery replacement.
   

Intrinsically safety – the solution meets strict safety requirements and is capable of operating in explosive atmospheres, a necessity in mining. The wireless communication system created in collaboration with Elsta Elektronika significantly raises efficiency and reliability standards in the mining industry, delivering concrete benefits for mining operations.

Benefits and Results

The innovative wireless communication system developed by EMBETECH in collaboration with Elsta Elektronika has delivered numerous tangible benefits and achieved impressive results in the mining sector. Here are the key outcomes:

1. Efficient data transfer – thanks to real-time data transfer, the system enables near-instantaneous monitoring and response to changes in mining operations. This enhances operational efficiency and minimizes the risk of potential failures.
   
2. Intrinsically safe – the system fully complies with mining safety requirements and can operate in challenging conditions, including explosive atmospheres. This is crucial for ensuring the safety of mining personnel.
   
3. Maintenance savings – battery-powered sensors with a lifespan of over a year minimize the need for frequent servicing and battery replacements. This translates into significant time and cost savings.
   
4. Extensive application – the solution finds applications in vast mining longwalls, spanning hundreds of meters, allowing the monitoring of various parameters across substantial areas.
   
5. Reliability – the wireless communication system has achieved the highest level of reliability, which is essential for the effective operation of the mining industry, where any failure can be costly and dangerous.
   

This innovative solution, developed in collaboration with Elsta Elektronika, not only met the challenges of the mining industry but also raised the standards in wireless communication technology in demanding mining environments.

Undoubtedly, the mining industry, especially hard coal mining, presents unique challenges to various technologies used in electronic devices, and wireless communication is no exception. The applied solutions must meet the stringent requirements of heavy industry and aim for high reliability. Often, these are intrinsically safe solutions, meaning they can operate safely in explosive atmospheres, in the presence of methane or coal dust. In such conditions, radio communication is particularly challenging due to limited space and the interference generated by the accumulation of high-power electronic devices.

Elsta Elektronika is a leading provider of comprehensive solutions for the mining industry, specializing in the design and production of reliable industrial automation devices. In collaboration with Elsta Elektronika, the EMBETECH team has designed and implemented a wireless communication system tailored to a family of sensors measuring various technical parameters crucial for the proper functioning of mining longwalls.

In a typical mining installation, nearly a thousand sensors are distributed along extensive longwalls. These sensors communicate in an automatically organized mesh network using the reliable TSCH (time-slotted channel hopping) technique. This network can transfer data from any point on the longwall to the central computer in just 10 seconds, ensuring high reliability, even when involving several dozen hops. Furthermore, the sensors are battery-powered, boasting an impressive operational life exceeding a year. Given the specific propagation conditions in mining environments, this solution utilizes 16 channels in the 2.4 GHz band.

The partnership between Elsta Elektronika and EMBETECH has introduced a groundbreaking solution that not only overcame the challenges of the mining industry but also raised the standards of wireless communication technology in demanding mining environments.

Railway Safety has a paramount importance. The protection of employees, passengers, goods, and other users of the transport infrastructure constitutes a crucial criterion for the quality of railway services. One of the most contentious aspects of this issue involves railway-road crossings, especially those lacking adequate safeguards. To enhance safety at these locations, automatic warning systems are employed, requiring communication with remote sensors at these crossings. Until now, implementing such a solution has been costly and labor-intensive due to the necessity of installing communication and power lines alongside the tracks.

Thanks to the collaboration with Radionika, a leading producer of reliable wireless communication systems for the railway industry, the EMBETECH team has designed and implemented a dedicated radio communication subsystem for the aforementioned application. A state-of-the-art dual-band radio modem, operating with redundancy using frequencies of 150 MHz and 869 MHz, meeting the highest requirements of ETSI 300 113 and ETSI 300 220 Cat 1 standards, as well as relevant railway regulations, emerged as a pivotal achievement of the project. This device boasts a communication range of up to 2 kilometers with very low power consumption, enabling power supply from renewable sources such as photovoltaic panels. Furthermore, the solution ensures reliable and secure real-time data transmission.

In addition to hardware and software design, the EMBETECH team was responsible for preparing the project for certification tests, meeting the stringent requirements of RED and EMC standards. Currently, the developed communication system is in the pilot implementation phase.

In this case study, we will discuss the groundbreaking solution provided by Radionika, which has significantly improved safety at railway-road crossings while simultaneously eliminating the costly installation of communication and power lines. The commencement of the deployment of this system marks a milestone in the construction of a secure railway infrastructure, opening new possibilities and elevating standards in the field of railway transport.

Challenges associated with existing systems

While safety in railway transport is an absolute priority, existing systems sometimes present significant challenges.

1. The need for sensory communication at crossings:
   
   • Existing solutions often fail to provide sufficient sensory communication at railway-road crossings, especially those lacking adequate safeguards;
     
   • inadequate communication can lead to delays, errors, and safety hazards.
     
2. The costs of installing communication and power lines:
   
   • implementing traditional communication systems requires costly installation of communication and power lines alongside the tracks;
     
   • such investments would pose a substantial financial burden for railway operators.
     

Radionika solution

A key element of our success in improving safety at railway-road crossings is the unparalleled solution provided by Radionika.

1. Development of radio communication subsystem:
   
   • radionika has developed a dedicated radio communication subsystem designed for use at railway-road crossings;
     
   • this system is a crucial component enabling efficient data transmission and sensory communication in real-time.
     
2. High-quality dual-band radio modem:
   
   • the dual-band radio modem developed by Radionika boasts exceptional quality;
     
   • it operates with redundancy on frequencies of 150 MHz and 869 MHz, ensuring reliability in all conditions.
     
3. Compliance with ETSI 300 113, ETSI 300 220 Cat 1 and railway standards:
   
   • Radionika’s solution meets the highest quality and safety standards, including ETSI 300 113 and ETSI 300 220 Cat 1 standards;
     
   • In addition, it complies with railway regulations, which are vital in the railway industry.
     
4. Communication range up to 2 kilometers with low power consumption:
   
   • Radionika’s radio modem allows effective communication over a distance of up to 2 kilometers, providing coverage over a large area;
     
   • equally important, it features minimal power consumption, enabling power supply from renewable energy sources such as photovoltaic panels.
     
5. Capability for power supply from renewable energy sources:
   
   • thanks to low energy consumption, Radionika’s solution allows power supply from renewable sources;
     
   • this eco-friendly approach aligns with sustainability trends and efficient resource utilization.
     

With these innovations, Radionika opens new horizons in railway-road crossing safety by eliminating the need for costly installation of communication and power lines. The solution not only raises industry standards but also paves the way for a more environmentally friendly future of railway transportation.

Design and certification

The partnership between Radionika and EMBETECH extended beyond the mere implementation of the solution. Our involvement in design and certification played a pivotal role in Radionika’s success, bringing numerous benefits.

1. Hardware and software design work:
   
   • the EMBETECH team was actively engaged in the design of hardware and software for the radio communication system;
     
   • our advanced engineering approach allowed us to tailor the solution to the specific needs of the railway industry.
     
2. Preparation for certification tests in compliance with RED and EMC standards:
   
   • our company played a critical role in preparing the project for rigorous certification tests, in accordance with RED (Radio Equipment Directive) and EMC (Electromagnetic Compatibility) standards.
     
   • as a result, Radionika’s solution met the highest standards of quality and safety, contributing to gaining the trust of customers.
     
     

EMBETECH’s actions within the project significantly expedited the implementation process of Radionika’s solution. Our engineering expertise and full commitment to the project allowed us to adapt the technology to the unique needs of the railway industry.

The benefit for Radionika is that through the collaboration with EMBETECH, their solution not only meets but exceeds the most stringent standards of quality and safety. This has led to customer satisfaction and positioned Radionika as a leader in the field of reliable radio communication systems in railway transportation.

Implementation of the Radionika Communication System

Following the successful design and certification phase, it was time for the practical implementation of the innovative Radionika communication system. This phase brought even more benefits and confirmed the strength of our collaboration.

Pilot implementation

• Radionika’s solution was introduced in a pilot implementation, allowing for precise testing at real railway-road crossings;
  
• the pilot phase served as a crucial stage for validating the effectiveness and reliability of the communication system in real-world conditions.
  

The pilot implementation of the Radionika communication system has yielded numerous advantages. Firstly, it enabled a genuine evaluation of the system’s performance under „field” conditions, facilitating adjustments to suit the specific needs of railway infrastructure. Secondly, the pilot phase provided an opportunity to assess the solution’s effectiveness in practice and gain the trust of customers and industry partners.

The pilot implementation of the Radionika communication system marks another milestone in the ongoing revolution in railway-road crossing safety. Thanks to practical tests and positive results, this solution is gaining increasing recognition in the railway industry.

Benefits for Radionika

Thanks to the advanced Radionika communication system, remarkable results have been achieved, leading to significant benefits that have had a positive impact on the safety of railway-road crossings and the efficiency of the entire railway system.

1. Communication range up to 2 km with high-quality service – Radionika’s solution not only provides an extensive communication range but also maintains high-quality communication services, a crucial factor for ensuring effective communication at railway-road crossings.
   
2. Complete elimination of costly cable management work – traditional communication systems often necessitate expensive earthworks related to cable installation. Radionika’s solution eliminates these costs, resulting in substantial savings.
   
3. Low power consumption enabling renewable energy supply – the Radionika system features low energy consumption, enabling power supply from renewable sources like photovoltaic panels. This eco-friendly approach addresses sustainability challenges.
   
4. Real-time data transmission with high redundancy – Radionika’s solution facilitates real-time data transmission from multiple sources with high redundancy. This means that even in the event of a source failure, communication remains uninterrupted.
   
5. High reliability – Radionika meets the highest reliability standards, contributing to the safety and effectiveness of the entire railway infrastructure.
   

The project’s results and the benefits derived from the implementation of the Radionika communication system are undeniably favorable, positioning this solution as a revolution in railway-road crossing safety. This case exemplifies a successful collaborati

One of the essential elements of building automation is emergency lighting. Today, most systems of this type use wired communication to perform regulatory self-diagnosis. This, however, comes with an additional wiring cost and makes the installation process more difficult. For this reason, AWEX, which is one of the leading suppliers of this type of systems and has extensive experience in their design and implementation, has decided to implement the embeNET wireless network in its products.

The challenge for a wireless network in building automation is to provide reliable two-way communication in a large installation of thousands of devices. This requirement could not be met by using competitive open-source solutions, therefore AWEX decided to use professional products and services provided by EMBETECH.

Our team demonstrated the initial operation of the embeNET product in the customer’s existing devices. Then, we developed a universal radio module for the 863-870 MHz band and performed pre-compliance tests for compliance with the requirements of the RED directive and relevant ETSI standards. The next stage  included the integration of the wireless system and the development of functionalities enabling the use of a wireless network as a replacement for a wired connection in the customer’s existing product. EMBETECH delivered the networking stack for radio modules, a library for interfacing radio modules with the client’s devices and a library for managing the network of lighting fixtures on the control panel side. The embeNET network implements two-way radio communication with 250 devices within one mesh subnetwork with the possibility of routing packets up to 8 hops. The network builds up autonomously and natively supports device encryption and authentication, as well as software updating.