At Ursa-Chemie, we rely on networked drones to transport samples between our production facility and our laboratory. This project is supported by Deutsche Telekom, which provides us with IoT expertise and drone technology.
As specialists in contract manufacturing of chemical products, we operate two factory sites in Montabaur, which are located approximately 700 metres apart as the crow flies. For quality assurance purposes, it is essential to regularly transport samples between the production facility and the laboratory. Until now, a laboratory assistant has been performing this task several times a day by car.
‘This process is naturally time-consuming,’ explains our managing director Andreas Möller. ‘We were looking for an innovative solution that would not only optimise sample transport, but also demonstrate our pioneering spirit as a medium-sized company.’
Smart drone technology for sample transport
In search of a suitable solution, we turned to Deutsche Telekom, our long-standing IT service provider. ‘It was a shot in the dark,’ recalls Möller, ‘but the people we spoke to at Telekom were immediately very motivated to implement this project.’
In collaboration with Droniq, a joint venture between Telekom and Deutsche Flugsicherung (DFS), we have implemented a drone system for sample transport. Droniq supported us with the complex approval process for the project and with training our employees, who now have drone pilot licences.
Our DJI drone can carry up to 3 kg of payload and flies in an approved corridor of approximately 850 metres between our two factory sites. Flying over populated areas has been deliberately avoided. The samples, with a volume of up to 250 ml, are attached to the drone in a secure container.
The current solution is based on a pre-programmed route that the drone automatically flies at the touch of a button. As the flight path crosses a hill and visual contact is lost at times, two employees currently monitor the flight by remote control at the start and end points.
Future prospects: IoT mobile communications enable autonomous flights
‘At the moment, manual control still serves as a backup,’ says Möller. ‘Our goal is to carry out fully autonomous flights in the future.’
For the next stage of development, we therefore plan to equip the drone with a 5G mobile communications module from Telekom. This will enable drone flights without visual contact (Beyond Visual Line of Sight / BVLOS).
To this end, Telekom and DFS have developed a technology that enables unmanned aircraft systems (UAS) to be tracked via the mobile network. The drone’s position data can be used to create a complete air situation picture for safe flight in German airspace.
The hardware for this future-proof solution consists of a special transponder modem with an integrated SIM card from Telekom. This device not only transmits the drone’s position and identification via fast 5G mobile communications, but also enables the transmission of additional information such as image and measurement data in real time.
‘This advancement will ensure even safer operations in German airspace and enable autonomous flights,’ says Daniel Pohl, Sales Account Manager IT at Deutsche Telekom. ‘An employee in production can launch the drone, which then flies autonomously to its destination and lands there. This means that no personnel are required for control.’
Further application possibility: factory monitoring by drone
In addition to autonomous sample transport, we are also considering other possible applications for drone technology – such as factory surveillance.
Möller: ‘When constructing our second factory premises, we installed external video surveillance on one building. However, monitoring both factory premises completely by video would be very costly and technically complex. Since we already have approval for drone flights, it makes sense to use this technology for security purposes as well.’
Our concept involves equipping the factory premises with sensors. When a sensor triggers an alarm, a drone will automatically take off and inspect the area in question. To this end, we are planning to use a “drone-in-a-box” solution that can take off independently from its small hangar.
This solution offers several advantages: in the event of an alarm – for example, due to fire or burglary – the drone could fly from one plant to another within a minute and provide camera footage. A central control centre could then take over control and even track potential intruders if necessary.
Pohl: ‘We are currently examining whether our own control centre service, which is currently responsible for Telekom shops, could also take on this task.’
In addition, the drone could carry out irregular surveillance flights as a deterrent.
IoT as a pioneer for efficiency and innovation
The use of drone technology brings us several advantages at Ursa-Chemie: drone transport saves about an hour per day compared to car transport. Automation allows our laboratory technicians to focus more on their core tasks.
Last but not least, the system forms the basis for further innovations.
‘Our goal is to use technology where it makes people’s lives easier,’ says Möller. ‘This drone case fits perfectly with our pioneering spirit at Ursa-Chemie. It also attracts attention – not only within the industry, but also among new applicants.’
Our project demonstrates how IoT technologies and drone systems can open up new opportunities even in traditional industries.
By collaborating with Deutsche Telekom and Droniq, we have not only optimised our internal processes, but also positioned ourselves as an innovation leader in the chemical industry.
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