The Challenge: Empty Boxes Disrupt Production Flow
At the German site of the aerospace group, assembly teams receive components delivered in boxes. Once the parts are installed, the empty containers must be removed quickly. Previously, this step was initiated manually by pressing a button to request driverless transport systems (DTS). This was inefficient and frequently interrupted the tightly synchronized assembly line.
The Solution: Automated Empty Container Handling with LoRaWAN
Today, this process runs automatically – enabled by wireless ultrasonic sensors and reliable LoRaWAN communication. Once a predefined height of stacked empty boxes is detected, the system autonomously triggers the DTS. The containers are picked up, and an empty trolley is provided – with no manual interaction required.
LoRaWAN has proven to be an ideal technology for such scenarios. It is energy-efficient, offers reliable building penetration, and can be easily integrated into existing IT systems – making it especially suitable for industrial indoor use.
Note: Ultrasonic sensors operate using sound waves above 20 kHz and determine distances by measuring the time delay of reflected signals. They detect objects regardless of color, material, or lighting conditions and are ideal for industrial environments.
Focus on WILSEN.sonic – The Sensor Solution from Pepperl+Fuchs
The key to automation lies in WILSEN.sonic ultrasonic sensors. Developed specifically for industrial IoT applications, they offer:
- Accurate measurement even with changing lighting or surface conditions
- Battery-powered operation for up to ten years – ideal for autonomous deployment
- Rugged design compliant with IP66/67 – reliable in harsh industrial environments
- Full connectivity via LoRaWAN – no external power or network wiring required
- Remote configuration via downlink – adjustments can be made from anywhere
Why the System Stands Out
- Reduced manual workload: No more pressing buttons – the system takes over.
- Increased production reliability: Empty containers no longer obstruct workspaces.
- Retrofit-ready: Wireless sensors require no structural modifications.
- Scalable implementation: Can be deployed wherever empty containers occur.
“Install, Activate, Unburden” – Interview with Daniel Möst, Pepperl+Fuchs
Daniel Möst, Technology Manager at Pepperl+Fuchs, shares insights into real-world application:
What makes WILSEN.sonic particularly suitable for industrial use?
Daniel Möst: Our sensors operate reliably, energy-efficiently, and completely autonomously – which is a huge advantage in industrial settings. They can be installed where other solutions fail due to the need for power supply or cabling. Thanks to precise measurement data, the system reacts exactly when it should – not earlier, not later.
Our sensor solution delivers where others fail – fully autonomous, precise, and seamlessly integrated into existing processes.
How does the solution integrate into existing infrastructure?
Daniel Möst: The sensors connect directly to existing LoRaWAN networks – no extra software licenses or infrastructure costs. They can also be configured and monitored remotely, saving time and enabling full control even across complex production sites.
Conclusion: Rethinking Industrial Empty Container Management
This implementation shows how wireless sensor technology solves real-world challenges. The management of empty load carriers becomes automated, ensuring uninterrupted production flow. The combination of LoRaWAN and WILSEN.sonic not only delivers technical reliability but also economic value – a clear step toward smarter industrial logistics.
