Ursa-Chemie: Innovative sample transport by drone and IoT

Ursa-Chemie, a specialist in the contract manufacturing of chemical products, operates two production sites in Montabaur that are around 700 metres apart as the crow flies. For quality assurance purposes, it is essential to regularly transport samples between the production site and the laboratory. Previously, a laboratory technician carried out this task several times a day by car. "This process naturally takes time," says Andreas Möller, Managing Director at Ursa-Chemie. "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."

Möller turned to Deutsche Telekom, the medium-sized company's long-standing service provider: "It was a shot in the dark, but the contacts at Deutsche Telekom were immediately very motivated to realise this project." In collaboration with Droniq, a joint venture between Deutsche Telekom and Deutsche Flugsicherung (DFS), Ursa-Chemie implemented a drone system for transporting samples. Droniq assisted with the complex approval of the project and with the training of the employees, who now have a drone licence.

The drone used, manufactured by DJI, can carry a payload of up to 3 kg and flies in an approved corridor of around 850 metres between the two factory sites. Overflight of inhabited areas was 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 programmed route that the drone flies automatically at the touch of a button. As the flight route leads over a hill and visual contact is temporarily lost, two employees at the start and finish are currently still monitoring the flight by remote control.

"At the moment, manual control still serves as a backup," says Möller. "Our aim is to carry out fully autonomous flights in the future." For the next stage of development, Ursa-Chemie is therefore planning to equip the drone with a 5G mobile radio module from Deutsche Telekom. This will enable drone flights without sight (Beyond Visual Line of Sight / BVLOS). To this end, Deutsche Telekom and DFS have jointly developed a technology that enables the localisation of unmanned aircraft systems (UAS) via the mobile network. The drone's position data can be used to create a complete aerial image for the drone's safe flight in German airspace.

The hardware for this future solution consists of a special transponder modem with an integrated Telekom SIM card. This device uses fast 5G mobile communications to transmit not only the position and identification of the drone, but also enables the transmission of additional information such as image and measurement data in real time.

"This further development 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 to its destination independently and lands there. This means that personnel are no longer required for control."

In addition to autonomous sample transport, Ursa-Chemie is considering another innovative use of drone technology: premises surveillance. Möller: "When we built our second factory site, we installed an outdoor video surveillance system on one building. However, monitoring both factory premises completely by video would be very cost-intensive and technically complex. As we already have authorisation for drone flights, it makes sense to use this technology for security as well."

The concept envisages equipping the factory premises with sensors. If a sensor sounds an alarm, a drone will automatically fly up and check the area in question. Ursa-Chemie is planning to use a "drone-in-a-box" solution that can autonomously ascend 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 looking into whether our own control centre service, which is currently responsible for the Telekom shops, could also take on this task." The drone would also carry out irregular control flights on its own as a deterrent.

The use of drone technology brings Ursa-Chemie several advantages: Drone transport saves around one hour per day compared to transport by car. The automation of sample transport allows laboratory technicians to concentrate on their core tasks. Last but not least, the system forms the basis for further innovations. "Our aim is to use technology where it relieves the burden on people," says Ursa Managing Director Möller. "This drone case fits in perfectly with our pioneering spirit at Ursa-Chemie. It also attracts attention - in the industry, but also among new applicants."

Ursa-Chemie's project shows how IoT technologies and drone systems are also opening up new opportunities in traditional industries. By collaborating with Deutsche Telekom and Droniq, the medium-sized company has not only optimised its internal processes, but also positioned itself as an innovation leader in the chemical industry.