Use Case — Intralogistics

Transfer Vehicles – Uninterrupted Loading and Unloading Operations in Critical Environments

R3 Solutions provides the wireless technology that reliably controls transport and transfer vehicles even under extreme conditions—where heat, movement, or structural constraints make a wired connection impossible.

Overview

In many production processes, transfer vehicles move workpieces through environments where traditional cable connections are difficult or impossible to implement. High-temperature zones such as drying ovens or furnaces, corrosive areas, strong vibrations, or constantly moving plant components place heavy strain on mechanical and electrical connections.

Under these conditions, power and data cables wear out quickly, causing recurring failures and high maintenance costs. In some cases, continuous cabling is physically impossible. A wireless control system circumvents these problems but must offer the same reliability and real-time capability as a wired connection—even under the most adverse environmental conditions.

Typical Industry Challenges

Extreme Environmental Conditions

High temperatures, extreme temperature fluctuations, vibrations, or corrosive atmospheres place heavy strain on wired connections and lead to recurring failures

Cable connection not feasible

For moving vehicles in enclosed or thermally stressed process areas, continuous cabling is often physically impossible.

Mechanical connections require a great deal of maintenance

Trailing cables and wires are subject to wear and tear. Replacing them causes downtime and costs, sometimes in hard-to-reach or hazardous areas.

Real-Time Process Control

Precise loading and unloading, as well as process synchronization, require deterministic, delay-free data transmission to the central control system.

Seamless integration into the existing control system

The wireless solution should integrate seamlessly into the existing PLC and protocol environment without interfering with the higher-level control architecture.

How R3 Solves the Challenges

The R3 product portfolio is tailored to the requirements of transfer vehicles in demanding production environments. From real-time, deterministic control to wear-free connections in places where cables cannot be used.

Edge X

For advanced requirements that demand higher bandwidths and the integration of different protocols.

Edge X by R3 Solutions

Bridge E

For safety and control applications with real-time requirements and high synchronization.

  • Determinism: Time-slot-based signal transmission, packet loss rate of 0.000000001 %.
  • Real-time communication: Latencies of up to 2 milliseconds are possible.
  • Safety-compliant: PROFIsafe, CIP Safety, and others are transmitted transparently.
  • Proven in practice: Years of use by European and American OEMs.

Typical Project Workflow

Project Assessment

Project analysis, functional safety requirements, protocol selection.

Network Solution Plan

Traffic analysis, channel planning, configuration details.

Deployment

Installation, functional safety testing, acceptance testing.

Support & Maintenance

Monitoring, firmware updates, and enhancements.

Success Stories

Wireless Robot Control for Auto Body Shops

In auto body manufacturing, robots equipped with grippers perform key work steps. The gripper control system relies on cables and connectors that are subject to regular wear and tear. If these fail during continuous operation, the system comes to a standstill, resulting in enormous follow-up costs.

Read Success Story

Wireless Safety for AMRs at the Goods Transfer Station

An automotive plant operates around the clock and has several production lines that are supplied by autonomous mobile robots (AMRs). The transfer station serves as the central interface between the warehouse and the production line. Hundreds of transfers are handled here per shift.

Read Success Story

Wirelessly Controlled Monorail System

A Canadian automotive supplier operates a monorail suspension system at its plant in the U.S., which plays a key role in ensuring smooth production and logistics. The control system for this system was to be implemented via radio.

Read Success Story

Daniel Thiel

Wireless Solutions Expert

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