Why RFID tags are increasingly becoming a key component of digital maintenance and asset management concepts

Whether it’s a production machine, a transformer station, a wind turbine or a rail vehicle – technical assets are now managed digitally throughout their entire life cycle. Maintenance intervals, spare parts histories, test records and operational data are no longer available exclusively in paper documentation, but are increasingly being recorded in digital asset management systems. This also places greater demands on the labelling of the equipment itself. It must remain permanently legible, withstand environmental influences and, at the same time, establish a reliable link between the physical object and its digital information.

Traditional nameplates are increasingly reaching their limits in this regard. Whilst they provide basic information such as serial numbers or technical data, they do not allow for direct interaction with digital applications. This is precisely where the next stage of development in industrial labelling systems comes in: RFID-enabled nameplates combine robust material properties with digital identification, thereby laying the foundation for more efficient maintenance and documentation processes.

More than just permanent marking

The requirements for industrial identification systems have changed significantly in recent years. Operators of critical infrastructure, industrial companies and energy suppliers now expect not only durable nameplates, but also solutions that can be seamlessly integrated into digital workflows.

A service technician maintaining a machine or inspecting a component often needs to access extensive documentation. Maintenance logs, circuit diagrams or spare parts lists are usually stored in central databases or maintenance systems. RFID technologies make it possible to link this information directly to the relevant object. A single scan is all it takes to access the digital asset history or to document maintenance tasks directly.

As a result, the nameplate is evolving from a static information surface into a digital interface between the asset and the information system.

Digitalisation is transforming asset management

This development is becoming increasingly significant, particularly in the context of Industry 4.0, smart maintenance and the digital twin. Today, equipment is continuously monitored, condition data is automatically recorded and maintenance processes are increasingly organised digitally. However, this requires the unambiguous identification of every single component – even under demanding operating conditions.

Outdoor environments, in particular, place high demands on the labelling systems used. UV radiation, moisture, corrosive substances or extreme temperature fluctuations can render conventional labels illegible within a few years. Added to this are mechanical stresses caused by cleaning, maintenance or day-to-day plant operations.

Operators of critical infrastructure, in particular, therefore require solutions that function reliably over many years whilst also enabling secure identification. This is because damaged labelling can not only delay maintenance processes but, in an emergency, may also have safety-related consequences.

RFID on metal – a long-standing technical challenge

The use of RFID technology on metallic surfaces presents a particular challenge. Metal affects electromagnetic fields and can significantly impair the range and reliability of conventional RFID transponders. For this reason, special so-called on-metal tags have been developed in recent years, with an antenna design specifically tailored to metallic surfaces.

As a result, even machine housings, control cabinets, pipework or industrial plant can now be reliably equipped with RFID technology. At the same time, different frequency ranges are available depending on the application.

HF and NFC technologies are particularly suitable for applications in which staff identify individual objects using smartphones or mobile readers. UHF RFID, on the other hand, enables longer read ranges and offers advantages in automated stock-taking or logistics processes. Hybrid solutions are also increasingly being used, combining both technologies in a single identification system and thereby supporting a variety of use cases.

A real-world example

herpa print GmbH is pursuing such an approach with its RFID type plate, titanID Steel. The solution was developed specifically for use in demanding outdoor environments and combines robust material properties with integrated RFID technology.

Depending on the application, titanID Steel can be equipped with HF/NFC, UHF or, as a hybrid solution, with both frequency ranges. Thanks to its on-metal properties, the self-adhesive nameplate can be applied directly to metallic surfaces – such as on machinery, industrial plant or technical infrastructure.

According to the company, the nameplate’s durability was tested under real-world conditions, including on an offshore installation, over a period of more than a year. There, the system had to withstand constant exposure to UV radiation, moisture, dirt and mechanical stress – conditions that are also encountered in numerous industrial applications.

Furthermore, the nameplates can be custom-printed and adapted in terms of shape and size to suit different application scenarios. In this way, they combine traditional labelling functions with digital identification in a single component.

Sustainability and efficiency throughout the life cycle

The significance of smart labelling systems now extends far beyond maintenance processes. An increasing number of companies are aiming to digitally map the entire life cycle of technical installations – from installation through maintenance and modernisation to decommissioning or recycling.

Permanently available and digitally linked object identification not only facilitates documentation and traceability, but also supports regulatory requirements and sustainability strategies. In the context of the Digital Product Passport and growing documentation requirements, the ability to uniquely link physical products to digital information is likely to become even more important in the future.

Overview starts with identification

Digital maintenance does not begin in the control room or in the asset management system – it begins directly at the plant. The easier it is to uniquely identify an object and link it to its digital information, the more efficient maintenance, documentation and operation become.

RFID-based type plates are therefore increasingly evolving from simple labelling elements into intelligent interfaces within digital plant concepts. Solutions such as titanID Steel exemplify how robust material technology and digital identification can merge. What is crucial here is not merely the RFID technology itself, but its contribution to more reliable, efficient and, in the long term, digitised plant management.

At a glance | titanID Steel by herpa print

Typical areas of application

• Plant and machinery labelling
• Energy and utility infrastructure
• Industrial and production facilities
• Offshore and outdoor applications
• Asset management and maintenance

Concept

Robust, self-adhesive RFID nameplate with on-metal capabilities for long-lasting labelling and digital object identification.

Features

• On-metal compatible
• Choice of HF/NFC, UHF or hybrid (HF + UHF)
• Customisable multi-colour printing
• Various sizes and shapes
• High resistance to UV radiation, moisture and mechanical stress
• Suitable for demanding outdoor environments and industrial applications