Every product we build at Extronics starts with a challenge worth solving. For the iTAG X40, that obstacle was clear from the outset:

How do you design for long-range connectivity and accurate worker tracking in hazardous areas, and make it work reliably?

The Philosophy Behind the iTAG X40

The iTAG X40 was developed to give connected workers freedom to move across large, hazardous sites while staying visible and safe. We recognized the need to expand our range of connectivity options to support a wider range of infrastructure demands and match the expectations of the market. As part of our Real Time Location Systems (RTLS) offering, the iTAG X40 supplies real-time insights on personnel movements; improving site awareness, safety, and efficiency. LoRaWAN (Long Range Wide Area Network) was the natural choice for our iTAG X40, its ability to transmit positioning data over long distances with low power makes it ideal for wide-area sites where using Wi-Fi or Bluetooth is too cost prohibitive. But integrating LoRaWAN connectivity into a compact, intrinsically safe wearable device came with its own design challenges such as antenna placement.

Working closely with our antenna partner, Radientum, we focused on achieving performance that would exceed expectations, not just meet them. Careful mechanical and RF design meant that even within the strict boundaries of Ex certification, the iTAG X40 could deliver a communication range of up to 15 kilometers line of sight. The result: fewer gateways needed across a site, resulting in lower infrastructure costs and more consistent connectivity for workers.  

If you’d like to learn more about the collaboration, click here.

Designing for GPS, LoRaWAN, and BLE Efficiency 

Inside the X40, every component plays a role in keeping the tags connectivity consistent. The X40’s GPS (Global Positioning System) chip links directly to its antenna, which sends through satellite data for processing such as latitude, longitude, and time. To aid signal processing, the GPS chip is strategically positioned closer to the processor to optimize data flow: 

1. A LoRaWAN antenna is placed around the edge of the PCBA (Printed Circuit Board Assembly) to facilitate long-range communication.
2. We then selected matching components to achieve most global LoRaWAN frequencies.
3. Finally, the LoRaWAN chip is positioned as close to the antenna as possible to maximize power, while still maintaining enough clearance from the GPS and BLE (Bluetooth Low Energy) antennas. The BLE antenna is placed on the free side of the X40 to avoid interference between the other 2 antennas.  

The iTAG X40 is one of the latest additions to our iTAG X Range, strengthening our commitment to advanced tracking technology that supports worker safety in hazardous areas.

Purpose-Driven Engineering 

Long distance connectivity was just the starting point of the iTAG X40’s development. The same thinking that shaped the antenna design also influenced every part of the iTAG X40, from its mechanical design and materials to wearability, power use, and certification. Each decision was made as part of a bigger picture: creating a device that’s reliable, safe, and built to last in tough industrial environments. We’ll share an example of how these design principles came together in the iTAG X40. 

Man Down Functionality, Safety for Your Workers:  

Positioned at the top of the unit, the emergency call button provides easy user access in case of emergency, ensuring worker safety is always within reach. The emergency call button is protected from ‘false presses’ by a flip-up cover. 

The tag responds in three distinct ways to confirm activation: 

1. Speaker: Provides audible confirmation when the button is pressed, letting the worker know that the call for help has been successfully initiated.
2. Vibration Motor: The user can feel the alert activate, an important feature in noisy or visually limited environments. 
3. LED Indicators: High-visibility LEDs provide clear visual confirmation. Workers can see that the emergency signal has been triggered, even in low-light or outdoor conditions. 

Together, these responses ensure that the tag communicates across multiple senses, enhancing reliability and user confidence.  

Working in conjunction with the LoRaWAN network server and the Extronics Location Engine, the press of the emergency-all button can be acknowledged back to the personnel’s tag in a bi-directional manner. This ensures the tag user receives confirmation that their emergency alert has been seen by the control centre and supports accurate data collection for incident tracking. 

The iTAG X40 design demonstrates how thoughtful integration of sensory feedback can make critical safety features more intuitive and effective in real-world industrial environments. 

In Conclusion: 

When designing a connected Worker Location Tag, it’s about finding the right balance between; radio performance with battery life, safety with usability, and selecting the appropriate method of connectivity. The iTAG X40 embodies that approach; a wearable tag designed not only to improve worker safety, but to deliver reliable performance in the field. 

Our iTAG X range is designed to keep personnel connected and safe across every part of your site. The range combines Wi-Fi, Bluetooth, and GPS for accurate indoor/outdoor tracking with LoRaWAN for wide-area connectivity, ensuring dependable performance in most environments. This flexible mix of technologies helps businesses improve worker protection, increase efficiency, and maintain clear visibility of their team members.  

Ready to see how the iTAG X40 could streamline operations and track employees on your site? Contact us today to discover how our RTLS technology can elevate operational efficiency and deliver precise location information. 

About the Author

Julian Poyner

Head of Engineering

From a highly technical background, Julian delivers strategic leadership to our Engineering and R&D departments. With a significant patent portfolio, Julian brings a pedigree of innovation to the development of our market leading products.

Published on December 4, 2025

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