DeltaPro – Precise process monitoring using radio signals

Production processes are often complex, especially in small and medium-sized enterprises. Many processes are partially manual, documented only randomly or not recorded at all. This makes it difficult to optimise quality, throughput time and resource utilisation in a targeted manner.

DeltaPro provides a solution: the system monitors production processes in real time – contactlessly, comprehensively and without additional sensors. It is based on the evaluation of signal parameters from existing wireless networks such as UWB, WiFi 6 or 5G.

Intelligent signal analysis instead of additional sensors

DeltaPro uses existing communication infrastructure as a sensor network.

The system detects movements, deviations and changes in the production environment via shadowing and reflections in the radio signal.

Machine learning methods are used to derive patterns, process states and anomalies from this data. This enables continuous process monitoring without having to intervene in existing processes.

The system detects deviations before they affect product quality or throughput times. Anomalies are automatically flagged and displayed with a spatial classification.

This allows those responsible to react immediately, identify causes and initiate corrective measures – before rejects or downtime occur.

• Real-time detection of process deviations
• Use of existing radio infrastructure
• No additional sensors or complex data collection
• AI-supported analysis and visualisation
• Easy integration into existing manufacturing environments
• Ideal for SMEs with a high proportion of manual manufacturing

In order to test DeltaPro's approach under realistic conditions, a test setup was set up at the L.I.N.K. test and application centre. The test environment offers a flexible Industry 4.0 infrastructure in which production processes can be simulated and analysed in a realistic manner.

This setup demonstrates how processes can be monitored contactlessly and in real time by evaluating UWB (ultra-wideband) signals. The UWB Roundview method is used, which captures signals from multiple directions and combines them into a comprehensive process image. This allows movements, changes or deviations to be reliably detected – without additional sensors or interference with existing processes.

DeltaPro uses processes that will be an integral part of 6G communication systems in the future. Even today, the approach shows how communication and sensor technology are converging – into a tool for precise, data-driven process monitoring.

DeltaPro is thus already making future technology usable in industry today.