RFID and UWB collide to maximize asset tracking efficiency

With Industry 4.0 booming around the world, real-time positioning systems (RTLS) are increasingly recognized as one of the most productive, cost-effective, impactful and least disruptive additional systems in the manufacturing process. With this in mind, many companies are now faced with deciding which RTLS technology, including Wi-Fi, Bluetooth, radio frequency identification (RFID) and ultra-wideband (UWB), best suits their needs.

However, not all of these techniques provide results in the same way. This article will take an in-depth look at the differences between these RTLS technologies and how the combination of UWB and RFID systems can produce results that are greater than the sum of their parts. It will also explore how UWB can be seamlessly integrated into RFID with minimal effort and disruption to ongoing operations.

Choosing the right Asset tracking technology depends on specific needs and end-use goals. Factors to consider include the required accuracy or granularity of location data, the update rate for each monitored asset, the number and value of assets being tracked, the cost or risk associated with asset loss, the physical environment in which tracking occurs, and the technology Ease of use and cost, and requirements for collecting and transmitting data.

Radio Frequency Identification Technology (RFID)

RFID radio frequency identification technology has been widely used in a variety of scenarios, including low frequency (LF), high frequency (HF) and ultra-high frequency (UHF) frequency bands, as well as passive and active systems. Among them, passive RFID can use very small and cheap RFID electronic tags to track various tangible assets.

Advantages of RFID technology include hardware interoperability, inexpensive RFID tags (especially passive RFID electronic tags), a variety of tag types to choose from, and small radio signatures.

However, RFID technology also has disadvantages, such as unstable accuracy, high cost of RFID Readers, complex system installation, limited coverage, and possible interception of wireless signals. RFID systems are a diverse set of technologies whose capabilities vary depending on the RFID reader.

Among them, the combination of handheld readers and passive RFID tags is very common and has extremely low infrastructure requirements. Passive RFID systems utilize very small and inexpensive RFID tags to track a variety of physical assets, from large vehicles and machinery to small hand Tools. These systems are highly scalable, but the tracking intelligence learns about the most recently registered scan points.

In order to achieve real-time positioning, a large number of RFID access gates or RFID fixed readers and RFID Antennas need to be installed throughout the tracking area. In RFID systems, whether passive or active, they work best within line of sight compared to UWB, but have limited range.

Ultra-Wideband Technology (UWB)

UWB technology uses short pulses, low power output, and large bandwidth to transmit data over a wide range of radio spectrum. This low-power method is capable of transmitting large amounts of data, enabling high-precision real-time positioning even without direct line of sight.

UWB offers several advantages, such as the ability to transmit data through walls and obstacles, provide real-time updates, not interfere with most other RF signals and devices, have a unique radio signature, and improve the ability to avoid multipath propagation. The solution therefore works even in cluttered industrial environments where metal surfaces are reflective.

However, UWB also has some disadvantages. It is a newer RTLS technology, so industry standards and protocols for interoperability are less mature and market acceptance is lower.

UWB technology is ideal for use in heavy industrial and GPS-obstructed environments where other wireless technologies often fail. Applications such as tracking high-value assets or scenarios where accuracy is critical, such as safety, security and healthcare, provide the fastest return on investment for UWB.

Its ability to maneuver around and through obstacles provides installation flexibility, including the ability to operate without line of sight between the reader and tracker device. Additionally, its unique radio characteristics make it particularly suitable for use in environments with metal and other reflective surfaces.

Since high-value assets and low-value assets exist at the same time, the combination of RFID technology and UWB technology can meet different tracking requirements. Passive RFID technology, in particular, can provide an effective and affordable solution for tracking many low-value items, while UWB RTLS is often more accurate and can provide line-of-sight, real-time visibility for larger, more valuable items.

RFID and UWB enable tool tracking and management

When a facility has a large number of tools, some smaller and others larger, leveraging passive RFID and UWB technology provides a complete tracking solution.

RFID technology is great for monitoring and managing small items and hand tools in your facility. For example, a toolbox equipped with an RFID reader reads the RFID electronic tag when tools are checked in and out, and records who took the tool.

UWB technology is best suited for larger items such as tool boxes and tools that don’t fit in tool boxes, allowing complete visibility and location tracking anywhere throughout the facility. For facilities without tool boxes, UWB can be used to track calibration tools Stored in closets and check in and out daily, ensuring their whereabouts are always known.

RFID and UWB enable forklift tracking to optimize warehouse operations

By equipping forklifts with RFID readers, pallets with RFID tags can be scanned, and materials can be accurately matched to their respective locations by scanning warehouse shelves. In order to further improve efficiency and optimize route management, it has become a common practice among leading manufacturers to incorporate UWB technology into forklifts to instantly obtain the real-time location and movement history of the forklift.

RFID and UWB enable asset tracking, streamlined linear manufacturing

Tracking vehicles and their components in linear manufacturing using RFID electronic tags affixed to the vehicle chassis can help maximize efficiency in linear manufacturing environments.

With RFID technology, you can identify vehicles and components in each production area through fixed readers with a read range typically less than 3 inches. UWB tags that match the VIN number allow you to fine-tune the location of a specific vehicle in real time, indoors or outdoors, and it's easy to locate once complete. This comprehensive solution ensures complete visibility of vehicles in storage while awaiting components or modifications.

RFID and UWB maximize automotive manufacturing efficiency

Automotive and other heavy equipment manufacturers are using passive RFID tags to track work-in-progress (WIP), scanning it as it is placed on a work truck or station wagon and then leveraging UWB tags to always know its location on the cart.

This is ideal for automotive manufacturing plants, where metal racks hold 25 to 30 parts moved by AGVs or robots. For example, combining UWB and RFID creates a system that can track AGV, part and item-level inventory movements. By tagging more than 5,000 metal racks and using RFID tags for inventory management, the company can increase facility efficiency by enabling real-time visibility of rack location and content as well as other mobile assets (robots, tugs, off-road vehicles, etc.) with tagged content.

As the adoption of asset tracking to improve manufacturing efficiency continues to gain momentum, manufacturers must consider the potential benefits of hybrid solutions that meet their specific needs. By combining RFID-UWB methods, manufacturers can optimize cost-effectiveness and fully enjoy the advantages of asset tracking in their facilities.