Ceramic Production Line
Rugged wireless communication solutions for high-temperature, high-vibration ceramic storage and retrieval lines.
Background
A large ceramic manufacturing facility in China spans approximately 150,000 square meters and is equipped with 6 fully automatic ceramic tile production lines, with an annual output exceeding 30 million square meters. The production process covers the complete workflow including raw material preparation, pressing, drying, glazing, firing, tile storage, and packaging.
In the tile storage and finished goods warehousing stage, the facility is equipped with multiple tile storage RGVs (rail-guided vehicles), shuttle carts, and stacker cranes for automatic transfer of tiles between storage lines, kiln entry/exit points, and packaging lines. However, the ceramic workshop maintains harsh conditions year-round — high dust concentration, high temperatures (localized areas reaching 45°C–60°C), humidity, and abundant ceramic debris. High-frequency electromagnetic noise generated by various electrical equipment causes severe interference to wireless signals. Meanwhile, metal blanks, tile stacks, and steel pillars shield 2.4G/5G RF signals, causing severe signal attenuation during shuttle cart operation, with frequent packet loss, network disconnections, and roaming dropouts — becoming the core bottleneck restricting production line automation efficiency.
The customer urgently needs an industrial wireless communication network with metal-shielding resistance, electromagnetic interference resistance, dustproof and high-temperature resistant capabilities, ensuring real-time, stable communication between tile storage RGVs, shuttle carts, stacker cranes, and the WMS/WCS systems.
The Challenges
Signal Obstruction
Metal blanks, tile stacks, steel pillars, and other obstructions create large signal blind zones. Shuttle carts and stacker cranes experience severe signal attenuation during operation, with frequent packet loss and network disconnections.
Harsh Environment
The ceramic workshop features high dust concentration, high temperatures (45°C–60°C), humidity, and abundant ceramic debris. Traditional networking equipment suffers persistently high failure rates and costly maintenance.
EMI
Dense electrical equipment including variable-frequency drives, motors, and solenoid valves generate high-frequency electromagnetic noise. Traditional wireless solutions lack sufficient anti-interference capabilities, resulting in high network latency, frequent data jitter.
Roaming Dropouts
RGVs frequently switch between APs during movement. Traditional solutions suffer long roaming handover times and frequent dropouts, causing loss of equipment dispatch commands and disrupting continuous production line operations.
Solution Architecture
Full Coverage Layer — KXA5100-5N Industrial Wireless AP
KXA5100-5N industrial wireless APs are deployed at high positions in key areas including tile storage zones, kiln exits, and packaging lines. The product supports 802.11a/n technology with data transmission rates up to 300Mbps. It features 5G dual-network card design, supporting 4900MHz–6100MHz ultra-wide frequency band and DFS dynamic frequency selection, automatically avoiding radar and interference signals. With IP67 protection rating and wide-temperature design (-40℃ to 80℃), it adapts to the high dust, high temperature, and humidity of ceramic workshops. High-gain antenna design effectively penetrates metal blanks and tile stack obstructions, achieving full-area coverage with zero blind spots in tile storage zones.
Vehicle-Mounted Layer — KXC1100-5N Industrial Wireless Client
Each tile storage RGV, shuttle cart, and stacker crane is equipped with a KXC1100-5N industrial wireless client. The product supports 4.9GHz–6.1GHz ultra-wide frequency bands, with MIMO wireless connectivity delivering data rates up to 867Mbps. Built-in client-based fast roaming technology ensures roaming handover time ≤ 100ms, guaranteeing imperceptible handover and zero packet loss as RGVs/shuttle carts move across AP coverage areas. With IP30 protection rating and support for DIN-rail/wall/pole mounting, it adapts to various vehicle deployment requirements.
System Integration & Data Backhaul
PLC controllers, position sensors, limit switches, and other devices on RGVs, shuttle carts, and stacker cranes connect wirelessly to the workshop network via KXC1100-5N clients, uploading equipment status, position information, and task execution feedback to the WMS/WCS systems in real-time. Dispatch commands are delivered from KXA5100-5N APs to client terminals, achieving millisecond-level response between vehicles and systems. Data is aggregated to the central control room via KXS series industrial switches, ensuring full-process data is real-time and controllable.
Recommended Products
KXA5100-5N
- Wireless Access Point
- Data Rate: 300Mbps
- Concurrent: 100unit
- Distance: 200 meters
KXC1100-5N
- Wireless Client
- Data Rate: 300Mbps
- Distance: 100 meters
KXS205
- Industrial Switch
- Non-Managed
- 100Mbps/1000Mbps
POE Optional
KXS208
- Industrial Switch
- Non-Managed
- 100Mbps/1000Mbps
POE Optional
Technological Advantage
Zero-Interruption
- RGV/shuttle cart cross-AP roaming handover ≤ 100ms, zero dropouts and zero packet loss throughout operation
Full Coverage
- High-gain antennas + DFS anti-interference deliver full signal coverage in areas blocked by metal blanks and tile stacks
Environment Adaptability
- IP67 dustproof & high-temperature resistant design extends equipment lifespan by 3x or more
Cost Reduction
Wireless deployment eliminates cabling, maintenance-free later, comprehensive operational costs reduced by 60%
Field Deployment
Get a Tailored Solution
Tell us about your operational environment — our engineers will review your requirements and provide a customized wireless communication solution, typically within 48 hours.
✓ Free site survey support
✓ Solution design included
✓ Samples available upon request
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