A company in the oil and gas industry was looking for a solution to reliably connect remote stations. Using a radio-based system, it was possible to regularly record process data and integrate it into the central control center – without the need for a complex infrastructure.
The system was developed by Schildknecht AG, a manufacturer and system provider for industrial radio data transmission. Its DATAEAGLE radio data transmission system for industrial use is particularly well known.
Connecting remote stations in industrial sectors
The oil and gas company aimed to connect remote stations surrounding several of its plants. The project’s objective was to collect system and process data—such as meter readings, pressure, and temperature. The information was to converge in the company’s central control center. This is where the entire infrastructure is controlled and monitored. The collected data enables the company to ensure safe operation of its facilities and to detect deviations at an early stage.
As is typical in the process industry, individual installations are spread out over a large regional area. In many cases, the distance between the stations and the central hub spans several kilometers. Wiring such locations is cost-prohibitive, making wireless industrial data communication the only viable solution. Common IoT wireless technologies are also unsuitable, as they lack sufficient range and reliability. While setting up a private 5G campus network would be theoretically possible, it is too expensive and technically complex.
In this scenario, mobile radio networks remain the only practical means of industrial data transmission.
Key requirements for the solution
The company required a solution with the following parameters:
- Measurement data had to be transmitted regularly, reliably, and at technically reasonable intervals.
- The solution needed to function without dedicated networks or additional infrastructure.
- Robustness and flexibility were essential to operate efficiently and securely under the given conditions.
- Scalability and adaptability were also important, as additional sites are to be connected in the same way in the near future.
An additional challenge arose from the desired type of data integration. The company did not want to process the data in a cloud environment but within its existing PLC system, which had been tailored to the needs of the company and its plants. The goal was to integrate the data via industrial wireless communication into the existing automation environment—without altering the overall system.
The challenges at a glance
- Collect measurement data over wide areas using industrial wireless communication
- No continuous wireless coverage at remote stations
- No energy supply at remote stations
- License-free radio solutions reach their limits
The solution: Industrial wireless instead of complex networks
To find an alternative approach, the company turned to Schildknecht AG. The specialist for industrial radio data transmission proposed an IoT solution based on mobile radio. As there is no power supply at many locations, battery-powered systems with integrated solar cells are the most suitable.
Hardware and integration in detail
The on-site sensors are standard industrial sensors. They record values cyclically every 15 to 30 minutes and are connected to gateways at the remote stations. Stations with a power supply use DATAEAGLE 7010, all others use the battery-operated DATAEAGLE 7020.
Pre-processing the data in the gateway reduces the data volume. It then sends the information to the Device Cloud via mobile radio, collects it there and then sends it to a DATAEAGLE 7050 IoT Edge Gateway, which is connected to the PLC in the control center. The individual DATAEAGLE components are managed in the cloud.
The amount of data transmitted is low, only a few bytes per measuring point every 15 to 30 minutes. This means that the bandwidth and network quality requirements are low. A 2G fallback ensures that a connection can be established even in regions with weak network coverage. The specific use case is currently limited to Germany. However, international expansion is straightforward thanks to integrated eSIMs.
Tangible benefits for the user
For the company, this application of industrial wireless communication represents a significant improvement over the previous situation. Overall, the solution offers the following advantages:
- The solution enables rapid commissioning. There is no intervention in existing systems. Users only need to set up gateways and connect sensors.
- The DATAEAGLE systems involved can be updated and configured remotely. Diagnostic functions are also available for troubleshooting and maintenance.
- Data from distributed stations is made available directly in the central PLC. Data acquisition is fully transparent and runs in the background.
- The gateways used have integrated eSIMs with worldwide coverage and a standardized tariff. This allows them to work at any location.
- The solution is scalable and can support additional use cases, such as PLC-to-PLC communication.
- Integration into the automation system takes place via familiar interfaces. This means there is no need for training or IT support.
The result: Industrial wireless as a bridge between IT and automation
The solution demonstrates that modern industrial wireless communication can be integrated into existing automation systems without complex IT requirements. The customer benefits from a transparently integrated architecture that seamlessly aligns with existing processes. Configuration is handled by the provider, requiring no specialized knowledge. The modular, standardized architecture enables rapid implementation with simultaneous scalability. This builds a bridge between automation technology and IT.
The systems are ready to use out of the box and require neither dedicated network infrastructure nor deep technical expertise. With this project, Schildknecht has proven that IoT solutions can be easily implemented even in traditional industries with little IT focus. For anyone looking to connect remote industrial stations easily, securely, and without building their own radio network, the Schildknecht solution offers a plug-and-play, future-proof option.
Summary of Results
- Complete solution for industrial wireless communication
- Unified rate plan for global SIM cards
- Rapid deployment is achievable
- Minimal technical expertise required
