Resolving GSM connectivity issues in industrial predictive maintenance
We supported Balluff, a leading German manufacturer of industrial automation solutions, in resolving GSM connectivity issues affecting its PM Sys monitoring device outside Germany. What initially appeared to be a network communication problem led to the discovery of underlying software-related factors, resulting in a comprehensive firmware redevelopment that improved device stability and communication reliability.
Services
Technologies
Challenges and business needs
One of the solutions offered by Balluff, the PM Sys device, supports predictive maintenance by monitoring machines and equipment in industrial environments. It monitors vibration to assess the machine’s condition and detect anomalies that may lead to equipment failure. The generated data are collected in the Microsoft Azure cloud and can also be used in internal systems and for other analyses. This kind of monitoring enables end-users to perform predictive maintenance on their production lines and utilise their machines and sub-components more efficiently.
The PM Sys device uses GSM connectivity to transfer monitoring data to the cloud. However, the client experienced connectivity issues between the device and the GSM network outside Germany. Establishing a stable network connection was not always possible, which limited the solution’s reliability in certain environments. To identify the root cause of the problem and restore reliable connectivity beyond Germany, Balluff required a detailed technical investigation.
Our responsibilities
We began the engagement by conducting a technical audit of the existing solution. To better understand the source of the connectivity issues, the team developed dedicated monitoring and diagnostic tools that enabled detailed analysis of the device’s behaviour during network communication.
The analysis revealed that the observed connectivity issues were influenced by factors beyond the GSM communication layer, including software limitations affecting connection establishment and communication reliability.
Based on the findings, we designed and implemented a new firmware architecture that addressed the identified issues while preserving the intended functionality of the original solution. The scope of work included the development of key firmware components covering low-level setup, driver layers, application skeletons, connectivity, firmware-over-the-air (FOTA) functionality, IO-Link integration, and fuel gauge support.
Results
The project successfully resolved the GSM connectivity issues affecting the PM Sys device and improved communication reliability beyond the German market. In addition to eliminating the immediate problem, the solution established a more maintainable software foundation capable of supporting broader deployment scenarios in the future.
Key outcomes included:
- Removed connectivity barriers that limited the solution’s use outside Germany.
- Improved device stability and communication reliability.
- Supported reliable data transmission for machine condition monitoring.
- Created a robust firmware foundation supporting future product development.
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Lukasz Wojcik
Director of Industry 4.0 – Automation & Connectivity