The client works with long-range sprinkler irrigation systems used over large areas, where equipment may operate far from the main infrastructure.

In this type of application, simply switching irrigation on is not enough. You need to monitor line pressure, identify mechanical failures, know where the equipment is operating and send this information to a supervision center.

ECK’s work was to support the evolution of the system’s electronics, communication and power strategy, while preserving the knowledge the team already had about the agricultural application.

Pressure as a control variable

One of the system’s central points is measuring pressure in the irrigation line.

The sensor installed on the pipe provides the information used to control the pump, allowing operation to be adjusted when pressure moves outside the desired range.

This information is also important for diagnosis. A change in pressure can indicate an abnormal condition in the system, a loss of performance or a situation that requires intervention.

Beyond local control, pressure data is sent to the telemetry system, so the central office can monitor the equipment’s behavior remotely.

GPS to track equipment on the move

The irrigation unit does not necessarily stay in a fixed position.

So the system uses GPS to periodically transmit its location.

This makes it possible to follow the equipment’s movement and identify situations where irrigation stopped before covering a given area, stayed concentrated in one zone or ran into a mechanical problem.

Position data also helps identify events such as the unit tipping over or stopping unexpectedly, so the operation knows where the problem occurred without having to inspect the whole area in person.

Long-range LoRa telemetry

Communication between field devices and the concentrator uses LoRa in a point-to-point topology.

This choice makes it possible to send small amounts of data over long distances with low power consumption, an important feature in large farm areas.

Each device sends information such as pressure, position and operating status to a concentrator located at a point with better communication infrastructure.

The concentrator receives data from the LoRa nodes and bridges the local field network to external systems.

From LoRa to the cloud over 4G

After receiving data over LoRa, the concentrator uses 4G to send it to a cloud server.

The server processes this information and makes the data available through an API.

As a result, the solution can be integrated with the system the end customer already uses, such as farm management platforms or sugar mill systems.

ECK also supported the cellular communication architecture, since the team had more experience with ESP32 and LoRa than with 4G modems and their integration specifics.

Migrating from ESP32 to STM32 to reduce power consumption

Most of the system’s early versions were developed with the ESP32.

The platform met development and communication needs well, but power consumption became a significant limitation for equipment installed in the field.

At many points there is no electrical supply available. Using a solar panel can also be problematic on mobile equipment that is subject to impacts, falls or mechanical damage.

So the consulting work evaluated migrating part of the electronics to low-power STM32 microcontrollers.

The change allowed an architecture better suited to battery power, reducing system consumption without losing the acquisition, control and communication functions required.

Designing for battery power changes the architecture

When equipment has to run for long periods on battery, power consumption stops being just a component characteristic and becomes an architecture decision.

You need to evaluate processor active time, low-power modes, acquisition rate, transmission frequency, sensor power and the behavior of the communication modules.

Choosing the microcontroller becomes part of a larger set of decisions that determines the product’s real autonomy.

Satellite communication where 4G does not reach

Another important requirement was maintaining telemetry even in areas without cellular coverage.

For these scenarios, ECK worked on integrating Globalstar satellite communication.

This way, the system can send critical information even in regions without 4G coverage or any other terrestrial communication infrastructure.

Combining LoRa in the field, 4G where coverage exists and satellite as a fallback allows the architecture to be adapted to the conditions of each installation.

Consulting to integrate different technologies

The challenge of this system did not lie in a single technology.

It required integrating sensors, pressure control, GPS, LoRa, 4G, satellite communication, low-power microcontrollers, battery, cloud server and API.

The client’s team already knew the application well and had development capability, but needed support in specific areas of electronic engineering and communication.

The consulting work made it possible to review architecture decisions, reduce power consumption, broaden connectivity options and create a solution better suited to remote field operation.

This kind of irrigation system consulting shows how electronics can be decisive in turning agricultural equipment into a connected, monitored platform integrated with existing management systems.

Learn more about ECK’s electronic engineering consulting.