Coal Truck Tracking System — Real-Time GPS + Activity Sensing

A coal truck tracking system is not just a GPS dot on a map. For Indian coal plants receiving hundreds of trucks per day, the system needs to answer one question basic GPS cannot: did the truck unload coal somewhere it wasn't supposed to?

That requires GPS plus activity sensing using sensors — IoT devices that capture physical activity data from the truck body to detect the signature of an unloading event.

What the System Must Cover

Mine Gate: GPS + activity sensing IoT device fitted. Trip auto-created. Tarpaulin sealed, photos captured.

In Transit: Real-time GPS at 1-minute intervals. Automated alerts for route deviation, overspeeding, halts. Activity sensing monitors continuously.

Halt Detection: Every halt triggers analysis — location cross-referenced with risk zone database, sensor data reviewed for unloading activity.

Gate-In: Geofence trigger on arrival. Risk score pushed to security dashboard before weighbridge.

Unloading at Plant: Activity sensing confirms physical offloading. Farthest unloading point logged.

GPS Hardware Options

Wired GPS for dedicated fleet: Permanently installed, continuous high-fidelity data.

Portable trackers for market trucks: Fitted at mine gate, collected at plant. Intugine manages reverse logistics across 12,000+ pin codes.

The IAS Module

The IAS (Intugine Activity Sensing) module is a specialised IoT device that captures physical activity patterns using sensors and classifies each halt as transit, loading, unloading, or idle. A coal tipper performing an unloading action has a distinct physical sensor signature. At an authorised delivery point this is expected. At a roadside halt 60 km from the plant, it triggers an immediate alert.

Integration

SAP/ERP: Trip completion syncs, updating inbound inventory and triggering Goods Receipt. LIMS: High-risk trips flagged to quality lab for special sampling. Weighbridge: Risk score visible at operator terminal before truck drives in.