Solution Background:

A manufacturing plant was experiencing poor wireless network performance, resulting in frequent disconnections, lag, and instability for AGV carts, barcode scanners, and PCs during operation.

Key Customer Challenges:
  • AGV Interruptions: AGV carts frequently stopped during travel due to wireless signal loss, negatively impacting production efficiency.
  • Poor Terminal Performance: Legacy terminals suffered from channel conflicts, poor compatibility, and inability to intelligently switch between APs, leading to degraded wireless experience.
  • Ineffective Network Planning: AP placement did not follow wireless coverage standards, resulting in dead zones and signal overlaps, and interference sources were not properly identified or mitigated.

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Solution Overview

By using Ekahau & Sidekick professional wireless site survey tools, the following optimization steps were implemented:

Wireless Survey & Analysis

  • Performed full-site signal coverage testing using integrated devices (Wi-Fi module + spectrum analyzer).
  • Identified coverage gaps and interference sources (e.g., non-Wi-Fi devices).
  • Generated heatmaps to assess AP layout, redesigned AP placement, and optimized power settings.

Channel & Interference Optimization

  • Analyzed 2.4GHz and 5GHz channel usage; adjusted channel allocation to avoid co-channel interference.
  • Upgraded wireless adapters to support newer protocols (e.g., Wi-Fi 6) for better compatibility with legacy devices.

Terminal Roaming Optimization

  • Adjusted adjacent AP power levels and coverage areas to enable seamless roaming for AGVs and mobile terminals, ensuring uninterrupted connectivity to the optimal signal source.

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Key Features & Advantages

Professional Tool Support
  • Ekahau supports full-band spectrum analysis (2.4/5GHz), automatically identifying interference sources such as Bluetooth devices and microwave ovens, with industry-leading accuracy.
  • Compatible with all Wi-Fi standards (including 802.11ax/Wi-Fi 6) and thousands of antenna models—ideal for complex environments.

Comprehensive Optimization Capabilities

  • Heatmap visualization reveals coverage defects and provides AP adjustment recommendations for standardized wireless coverage.
  • Dynamic channel allocation and power tuning reduce co-channel interference and improve channel efficiency.
  • Adapter upgrades extend the lifespan of older devices through enhanced compatibility.

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Customer Pain Points

  • AGV Downtime: Signal drops and lack of intelligent AP switching led to frequent AGV halts and logistics disruptions.
  • Terminal Instability: High channel occupancy (especially in 2.4GHz), frequent disconnections, and lack of intelligent AP roaming.
  • Network Design Flaws: Unoptimized AP distribution with dead zones or overlapping coverage; unresolved interference sources.

Customer Benefits

  • AGV Performance Boost: Optimized AP power and seamless handoff strategy significantly improved AGV navigation smoothness, reducing production interruptions.
  • Enhanced Terminal Stability: Channel efficiency improved post-optimization, boosting terminal connection stability, reducing interference, and accelerating business app responsiveness.
  • Increased Network Reliability: Rational AP layout achieved standardized coverage, while interference resolution and terminal upgrades improved wireless availability to over 99%.
  • Long-Term Cost Savings: Prevented downtime losses due to network failures and reduced costs associated with frequent legacy device replacements.