Our Client develops safety solutions for extreme industrial environments. Their portfolio includes emergency equipment, monitoring devices, and infrastructure for tracking people and machinery underground. Their customers operate in environments where system failures can have critical consequences.

Modernizing the existing application

The existing application was built on Ext.js 3, a framework long past its end of life. We migrated it to Ext.js 4 while preserving all existing functionality, including:

• data import from field devices,

• manual report impo

• machine and personnel management.

It's the kind of work users rarely notice, but without it, the entire platform would eventually become difficult to maintain and extend.

New real-time monitoring module 

We designed and implemented a completely new monitoring module. At its core is an interactive map where every monitored machine is represented by a marker that changes color automatically as new telemetry arrives.

The key design challenge was determining the overall status of a machine when multiple sensors could report different conditions simultaneously.

The solution was straightforward and reliable: the machine's overall status always reflects the most critical active sensor alert. If a single sensor reports a critical condition, the entire machine is immediately marked as critical.

Operators can select any machine to view:

• the current status of individual sensors,

• the history of status changes,

• location details and navigation information.

Email notifications are triggered automatically whenever a machine's status changes, ensuring operators are informed immediately.

Telemeter Server — a custom UDP server

Behind the user interface runs a custom server developed by our team. It continuously listens for incoming UDP packets containing device locations, sensor readings, and configuration updates.

Why UDP instead of HTTP? In remote industrial environments, minimizing communication overhead is often more important than delivery acknowledgments. Telemetry is transmitted via satellite from GPS tracking devices and industrial controllers, allowing the system to process updates with minimal latency.

The Client gained a centralized monitoring platform that transforms a continuous stream of telemetry from dozens of field devices into a clear operational overview.

Operators can monitor the status of every machine in real time without relying on field communication.

The most critical alerts are always highlighted immediately, preventing important events from being lost among less significant notifications.

Automatic email alerts reduce response time, while historical event data supports incident analysis and operational improvements.

The solution is designed to scale across large mining operations with multiple sites and extensive equipment fleets.