Prefabricated Beam Yard Production Process Identification and Statistics Solution

To address the intelligent management requirements for precast beam yard production processes, we present a case study involving close-range identification (within 2 meters) for 8 production lines (comprising 8 pouring zones, 8 steam curing zones, 8 curing zones, and 8 tensioning/grouting zones, totaling 32 process areas) and 32 thirty-meter mobile trolleys. Considering the functional requirements for identifying process names, project area names, mobile trolley names, trolley dynamic/static status, production line names, and time statistics, we recommend implementing a customized solution utilizing ZigBee semi-active positioning technology. This technology, with its advantages of low power consumption, precise close-range identification, strong anti-interference capability, and dynamic perception, comprehensively meets the core needs of your multi-dimensional management scenarios in the production area.

I. Hardware Deployment: Precise Perception, Building a Digital Correlation Network for Production Elements

1. ZigBee Low-Frequency Signal Source Deployment: The "Intelligent Identity Carrier" for Mobile Trolleys

Equip each of the 32 mobile trolleys with one industrial-grade ZigBee low-frequency signal source. The signal source features an IP67 high-protection design, capable of withstanding dust, vibration, temperature variations, and humid environments in the production area (specifically optimized for the high-temperature and high-humidity environment of the steam curing zone). Power supply utilizes solar panels and DC power. Each signal source contains a unique ID code, pre-bound with key information through system configuration:

• Basic Identity Information: Mobile trolley name (e.g., "Trolley01", "Trolley32"), affiliated production line name (e.g., "Line2", "Line8"), ensuring unique and traceable trolley identity;
• Dynamic Monitoring Function: The low-frequency signal source is bound such that movement from the first ZigBee semi-active tag position in a process to the second ZigBee semi-active tag position, and from the third ZigBee semi-active tag position to the first ZigBee semi-active tag position of the next process area, is identified as motion status. If persistently identified at the second semi-active tag position, it is classified as static status.

The low-frequency signal source is installed on the front side of the trolley, 1.2 meters above the ground, using a combination of magnetic adsorption and screw fixation. The signal transmission direction faces the interior of the area, ensuring stable communication with ZigBee semi-active tags. Solar power provides long-term operational endurance, eliminating power supply concerns.

2. ZigBee Semi-Active Tag Deployment: The Regional "Data Collection and Attribute Correlation Hub"

For the 32 production areas (8 pouring zones, 8 steam curing zones, 8 curing zones, 8 tensioning/grouting zones), adopt the precise deployment principle of "three tags per area" to directly correlate area attributes with processes:

• Each functional area: Install 1 ZigBee semi-active tag on the ground inside the area entrance; install 1 ZigBee semi-active tag on the ground inside the trolley parking stop point at the area exit; install 1 ZigBee semi-active tag on the ground 2-3 meters outside the area exit. ZigBee semi-active tags are pre-bound in the software system with core regional attributes: process name (e.g., "Pouring Process", "Steam Curing Process"), project area name (e.g., "Line 3 – Curing Zone 05"), production line name (e.g., "Line 3");
• Total deployment across the production area: 96 ZigBee semi-active tags correspond one-to-three with the 32 areas.

3. Reader Deployment: Strategic Placement Based on Site Area for Complete Coverage

All reader base stations utilize directional precision identification antennas with a recognition range of 100 meters. Installed on walls on both sides of the production area at a height of 3 meters, they maintain an unobstructed line of sight with the ground-level semi-active tags. Directional signal coverage ensures 100% trigger identification of all tags within the recognition area, preventing missed reads. Reader base stations connect to the workshop LAN via industrial POE/Ethernet, supporting real-time data upload and local caching (data is automatically cached during network fluctuations and synchronized upon recovery), ensuring no data loss.

II. Solution Topology

III. System Core Functions: Full-Element Identification + Full-Cycle Statistics, Enabling Transparent Production Process Management

1. Multi-Dimensional Element Automatic Identification: Real-time Production Information Correlation

• Process Name Identification: ZigBee semi-active tags are pre-bound with the corresponding process type for their area. When a trolley's low-frequency signal source enters the area, the system automatically reads the process information bound to the ZigBee semi-active tag (e.g., pouring zone corresponds to "Pouring Process", tensioning/grouting zone corresponds to "Tensioning/Grouting Process"), achieving precise identification and correlation of process names;
• Project Area Name Identification: ZigBee semi-active tags are bound with unique area codes (e.g., "Line1 – Pouring Zone02", "Line 6 – Steam Curing Zone07"). Upon entry of a low-frequency signal source, the system immediately records the area name, clarifying the trolley's specific location;
• Mobile Trolley Name Identification: Through the trolley name information pre-bound to the low-frequency signal source, the system displays the identity of the trolley currently in the area in real-time (e.g., "Line4 – Tensioning/Grouting Zone03 Current Trolley: Trolley15"), supporting quick location retrieval by trolley name;
• Mobile Trolley Dynamic/Static Status Identification: The tag's motion sensor collects acceleration data in real-time, uploaded to the system via the coordinator. When acceleration ≤ 0.1g and persists for 30 seconds, it is judged as "Static"; when acceleration > 0.1g, it is judged as "Moving". Status changes are updated in real-time on the management interface;
• Production Line Name Identification: Dual verification is performed using the production line information pre-bound to the low-frequency signal source and the production line attribute of the area bound to the ZigBee semi-active tag, ensuring error-free production line name identification (e.g., "Line5"), enabling centralized management by production line dimension.

2. Full-Cycle Time Statistics: Automatic Generation of Process Flow Data

The system automatically records the complete time nodes of trolleys in each process, forming a closed-loop statistical chain:

• Process Entry Time: When the trolley's bound low-frequency signal source enters the area and is first stably identified by the first ZigBee semi-active tag, the system precisely records the time (accurate to the second), e.g., "2025-09-02 09:05:12 Entered Line 5 – Pouring Zone 04 (Pouring Process)";
• Process Working Time: The system automatically calculates "Exit Time – Entry Time". Even if the trolley moves briefly within the area (e.g., minor position adjustments), the continuous stay duration is still counted, e.g., "Steam Curing Process Working Time: 8 hours 30 minutes";
• Process Exit Time: When the trolley's bound low-frequency signal source begins to leave the area and is first stably identified by the third ZigBee semi-active tag, the exit time is recorded. If the trolley proceeds directly to the next process, the system reverse-calibrates the exit time using the first identification time in the next area, ensuring data accuracy, e.g., "2025-09-02 17:35:12 Left Line 5 – Pouring Zone 04".

All time data is automatically synchronized to the system database, supporting filtered export of Excel reports by process, production line, trolley, etc.

3. Visual Management and Dynamic Monitoring: Intuitive Presentation of Production Status

Through the visual interface of the management backend, achieve multi-dimensional real-time monitoring:

• Area Monitoring Dashboard: Displays the trolley distribution across the 32 areas in real-time, including current trolley name, dynamic/static status (static trolleys marked green, moving trolleys marked yellow), entry time, etc. Clicking on an area reveals detailed data;
• Production Line Monitoring Dashboard: Displays the number of trolleys in each process categorized by production line (e.g., "Line 7 Currently: 2 trolleys in Pouring Zone, 3 in Curing Zone, 1 in Tensioning/Grouting Zone"), intuitively presenting production line load balance;
• Trolley Trajectory Tracking: Input a trolley name to query its historical flow trajectory with one click, including entry/exit times, working durations, and status change records for each process (e.g., "Trolley 22 entered Curing Zone at 10:00 on Sep 2, remained static for 24 hours, then moved to Tensioning/Grouting Zone").

4. Exception Alerts and Data Analysis: Facilitating Production Decision Optimization

• Intelligent Exception Alerts: Supports custom alert rules, such as "Trolley static in Curing Zone for over 36 hours", "Trolley moved but did not enter the next process area within 30 minutes", etc. When triggered, alerts are immediately sent via workshop audible/visual alarms and push notifications to managers' mobile apps, ensuring timely problem resolution;
• Core Data Reports:
  • Process Time Analysis Report: Statistics on average working duration, longest/shortest time consumption by process type, generating efficiency variance analysis compared to standard工时, providing basis for process optimization;
  • Trolley Status Report: Statistics on the proportion of static/moving time for each trolley, analyzing equipment utilization rate, identifying idle trolleys;
  • Production Line Efficiency Report: Statistics on daily/weekly process completion volume and area utilization rate by production line, aiding production capacity planning and scheduling optimization.

IV. Solution Value: Full-Process Digitalization, Driving Production Management Efficiency Improvement

• Comprehensive Multi-Dimensional Identification Meets Fine-Grained Management Needs
  Accurately achieves identification of process, area, trolley, production line names, and trolley dynamic/static status monitoring, replacing traditional manual recording methods. Data accuracy reaches 100%,彻底 solving problems of information fragmentation and significant recording errors.
• Automated Time Statistics, Traceable Process Flow
  Automatically records entry, work, and exit times, forming a complete "Trolley – Process – Time – Status" data chain, supporting full-process traceability, and providing precise data support for production cycle analysis and process optimization.
• Real-time Status Perception, Enhances Production Scheduling Efficiency
  Through real-time monitoring of trolley dynamic/static status, dispatchers can quickly identify trolleys ready for transfer (e.g., "Trolleys static for over 2 hours"), dynamically adjust production plans,预计 increasing production flow efficiency by over 30%.
• Low Power Consumption, Stable, Easy Maintenance, Adapts to Complex Production Scenarios
  Zigbee semi-active tags have a battery life of 3-5 years. Readers support Bluetooth configuration management. Deployment and debugging for 32 areas can be completed within 1 day. Hardware investment cost is lower than comparable technical solutions, with very low后期 maintenance costs.

V. Hardware Product List and Costs

Provided separately in the attachment.

VI. Full-Process Service Assurance: Worry-Free from Deployment to Operation & Maintenance

1. Customized Preliminary Preparation
   Provides free on-site survey services, conducting a comprehensive assessment of the layout and signal environment of the 32 areas (focusing on testing signal stability in the steam curing zone), optimizing tag and coordinator installation locations; provides pre-entry services for low-frequency signal source information, ensuring complete alignment with your trolley naming and production line division rules.
2. Professional Installation and Debugging
   Technical team performs on-site equipment installation, precisely binding trolley low-frequency signal sources to trolley names, and ZigBee semi-active tags to area attributes, followed by a 72-hour continuous operation test:
   • Verifies accuracy of trolley dynamic/static status identification (static/moving judgment error ≤5 seconds);
   • Ensures time statistics accuracy (error compared to standard time ≤1 second), guaranteeing data reliability.
3. Comprehensive Training Support
   Provides tiered training services (administrator, dispatcher) and detailed operation manuals, focusing on explaining:
   • Multi-dimensional data query and filtering (by process / production line / trolley);
   • Exception alert rule setting and handling procedures;
   • Report export and production data analysis methods.
4. Long-Term Operation & Maintenance Assurance
   Provides 1 year of free equipment maintenance + 7×24 hour technical support, supports free system upgrades, and allows flexible expansion based on later additions of areas or functional requirements.

We look forward to in-depth communication (Contact: Wang Yunhu Tel: 13818128296) to build a production management system for your precast beam yard characterized by "Full Element Identification, Full Status Perception, Full Time Statistics, Fully Intelligent Scheduling". Let every trolley's flow be more efficient, and the management of every process be more precise, injecting digital power into production capacity enhancement.