UWB Positioning and Management System Solution for Segment Beam Storage Area in Beam Fabrication Plant

I. Project Background and Construction Objectives

To address the positioning management needs of the segmental beam storage yard in beam prefabrication plants, this solution utilizes UWB (Ultra-Wideband) ranging technology to build an intelligent management system integrating rapid tag binding/unbinding, real-time positioning of segmental beams, and precise rapid searching. Through the cable-free deployment of long-endurance UWB tags and solar-powered 4G+ base stations, it solves the difficulties in positioning and low search efficiency of large prefabricated components during the storage phase, achieving a digital upgrade for the entire lifecycle storage management of segmental beams.

II. Advantages of Core Technology Selection

2.1 Advantages of UWB Ranging Technology

• Centimeter-level Positioning Accuracy: Ranging error ≤30cm, meeting the need for precise differentiation of segmental beams by row, column, and layer.
• Strong Anti-interference Capability: Highly adaptable to metal components and dusty environments, suitable for complex scenarios in beam prefabrication plants.
• Good Penetration: Can penetrate non-metallic obstacles, suitable for tag signal transmission through the hollow structure of segmental beams.
• High Ranging Stability: Utilizes Time Difference of Arrival (TDoA) technology to avoid environmental reflection interference.

2.2 Hardware Solution Features

• Long-endurance UWB Tags: Battery life ≥3 years (default reporting cycle 30 minutes), IP67 waterproof rating, suitable for outdoor storage environments.
• Solar-powered 4G+ Base Stations: 60W high-efficiency photovoltaic panel + 24Ah lithium battery, supports continuous operation for ≥72 hours in overcast/rainy weather.
• Cable-free Deployment: 4G full-network transmission, no on-site cabling required, installation cycle shortened by 60%.

III. System Core Functions and Technical Implementation

3.1 Rapid Tag Binding and Unbinding Function

3.1.1 Binding Mechanism

• Convenient Binding Process: Scan the segmental beam's identity QR code and the tag ID via a mobile terminal (PDA / mobile app) to complete the association with one click.
• Information Entry: Key information such as beam model, production batch, and strength grade can be entered during binding.
• Batch Operations: Supports batch binding when new beams are stored (via table import processing).

3.1.2 Unbinding Mechanism

• Single Beam Unbinding: When a segmental beam is dispatched, disassociate the tag from the beam via the management platform or mobile terminal.
• Batch Unbinding: Supports batch unbinding operations when entire rows/columns of beams are dispatched centrally.
• Tag Recycling: Unbound tags automatically enter an available state for reuse.

3.2 Real-time Positioning Function

3.2.1 Hardware Deployment Plan

• Base Station Layout: For example, if the storage yard has 6 columns of beams, install 6 corresponding UWB ranging base stations, mounted on the end pillars of each column at a height of 3-4 meters.
• Tag Installation: After the segmental beam is prefabricated, fix the UWB tag in the center of its hollow bottom, ensuring the tag faces the base station direction.
• Power Supply & Transmission: Base stations use solar panels + lithium batteries for power and 4G wireless transmission to send data to the management platform.

3.2.2 Positioning Algorithm Implementation

1. Column Positioning:
   • Each tag periodically (default 30 minutes) sends ranging signals to all base stations.
   • The system collects distance data from the tag to the 6 base stations (D1-D6).
   • The column corresponding to the base station with the minimum distance value determines the beam's column (e.g., if D3 is minimum, then it's in the 3rd column).
2. Row Positioning:
   • Using the base station of the identified column as reference, obtain the lateral distance (L) from the tag to that base station.
   • Combine with preset parameters (single beam width + gap = 1.5 meters, customizable).
   • Row number calculation formula: Row Number = INT(L/1.5) + 1 (e.g., L=4.2 meters -> 4.2/1.5=2.8 -> INT(2.8)=2 + 1 = 3rd row).
3. Layer Positioning:
   • Based on the tag installation height and the signal angle difference during base station ranging.
   • Combined with the height difference between double-layer beams (preset 2.5 meters), automatically determine if it's the upper or lower layer.

3.3 Rapid Search Function

3.3.1 Search Process

1. The user enters the segmental beam number or scans its QR code in the management platform.
2. The system immediately retrieves the current positioning data (row, column, layer) for that beam.
3. The platform's electronic map displays the precise location.

3.3.2 Technical Support

• Positioning data updates in real-time (latency ≤2 seconds).
• Supports simultaneous multi-target search, displayed distinctly on the map.
• Search results include additional information like beam storage-in time and estimated dispatch time (reserved).

IV. System Architecture Design

4.1 Perception Layer

• UWB Asset Tags: Installed on the bottom of segmental beams, actively send ranging signals, battery life ≥3 years.
• UWB Ranging Base Stations: 6 units, one per column, responsible for receiving tag signals and calculating distances.

4.2 Network Layer

• Solar Power Supply System: MPPT intelligent charge management, with overcharge and over-discharge protection.
• 4G Wireless Transmission: Supports Mobile/Unicom/Telecom full-network access, data encrypted transmission.

4.3 Application Layer

• Data Processing Server: Receives base station data, runs positioning algorithms, and resolves beam locations.
• Management Platform: Web-based visual interface, accessible via PC/mobile devices.
• Database: Stores beam information, positioning data, operation logs (data retention ≥3 years).

V. Core Functional Modules

1. Tag Management Module
   • Tag status monitoring (battery level, binding status)
   • Rapid binding/unbinding operation interface
2. Real-time Positioning Monitoring Module
   • Real-time display of the storage yard electronic map
   • Dynamic update of beam positions (column, row, layer)
   • Statistics on the number of beams in the area and distribution heat maps
3. Rapid Search Module
   • Multi-criteria search (number, model, batch, etc.)
   • Visual display of positioning results
4. System Management Module
   • Base station equipment status monitoring
   • Positioning parameter calibration (beam width, gap, etc.)
   • Operation permission management and log query

VI. Key Points for Implementation and Deployment

6.1 Base Station Installation Specifications

• Install base stations for each row on the end pillars, ensuring an unobstructed view towards the beam tags.
• Solar panels tilted 30° facing south (optimal angle for Dongtou area) to ensure sufficient sunlight.
• Base station spacing evenly distributed according to storage yard length, maximum spacing ≤50 meters.

6.2 Tag Installation Requirements

• Tags fixed in the center of the hollow bottom of the beam using strong magnets or bolts.
• Ensure no metal obstruction on the tag surface, signal transmission direction faces the base station.
• Conduct signal test after installation; RSSI value ≥ -85dBm is qualified.

6.3 System Debugging Standards

• Positioning Accuracy: Row identification accuracy 100%, column identification error ≤1 column, layer identification accuracy 100%.
• Response Time: Time from search request initiation to result display ≤5 seconds.
• Data Update: Position information refresh cycle ≤30 minutes (configurable).

VII. Project Expected Benefits

1. Management Efficiency Improvement
   • Segmental beam search time reduced from an average of 30 minutes to within 5 minutes.
   • Tag binding/unbinding efficiency increased by 80%, reducing manual operations.
   • Achieves dynamic inventory management, reducing mis-shipment and omission risks.
2. Cost Savings
   • Solar 4G base stations eliminate cabling, reducing construction costs by 60%.
   • Reusable tags reduce total lifecycle cost by 50%.
   • Reduces staffing needs by 3-5 dedicated management personnel.
3. Management Level Enhancement
   • Achieves digital recording of the entire segmental beam storage process.
   • Provides accurate inventory data support for production scheduling.
   • Forms traceable storage management archives.

This solution, tailored to the positioning and search management characteristics of segmental beam storage yards in beam prefabrication plants, utilizes UWB precise ranging technology and a cable-free base station design. It perfectly solves the challenges of locating and finding large components. The system features easy deployment, simple maintenance, and high cost-effectiveness, providing strong support for the intelligent management of beam prefabrication plants.