Summary: A logistics HVAC team replaced consumer Android phones (breaking under warehouse drops) with rugged Android PDA devices while keeping the Barcode to PC workflow. By switching input to Intent Broadcast, they gained faster laser scans, longer battery life, and lower total device replacement cost—without rewriting their barcode-to-desktop process.

The challenge

Standard retail smartphones were failing after accidental drops and exposure to dust. Camera-based scanning slowed operators on dense label racks. Replacing phones frequently inflated costs and created downtime. The team needed a durable, high‑speed scanning setup that still sent barcodes instantly to desktop applications and CSV/Output Templates already in use.

Why rugged PDA devices

• Integrated laser/imager: Faster, more forgiving aim vs camera auto‑focus.
• Ergonomics: Physical trigger reduces repetitive strain.
• Durability: Drop resistance (1.5–2.0 m) and sealed housings.
• Battery hot‑swap: Multi‑shift availability.
• Extended RF range: Maintains live link to the Barcode to PC server further across the warehouse.

Connection architecture

The mobile device acquires the barcode with the hardware scanner and delivers it to the Barcode to PC app via Intent Broadcast. The app instantly streams the value to the desktop client where existing Output Templates format it (e.g., model, serial, quantity) and optionally simulate keystrokes or build CSV logs.

Implementing Intent Broadcast input

1. Install Barcode to PC mobile app on the rugged PDA.
2. Open device scanner middleware (e.g., DataWedge) and set an Intent output with action: com.scanner.broadcast.
3. Leave category and extra name blank; ensure the barcode value is placed in the standard data field.
4. Test: Scan; the code should appear in the Barcode to PC app instantly without manual tapping.
5. Adjust scanner profile to append ENTER or rely on Intent trigger (no keystroke emulation needed).

Operational tips

• Set scan mode in the app to Manual Input (keyboard) if keystroke fallback is needed.
• Label each PDA with a device name matching the DEVICE_NAME output for audit trails.
• Enable duplicate handling rules if serial uniqueness matters (see duplicate detection docs).
• Run a 1‑day pilot capturing failure events (misreads, drops, battery swaps) to compare against phones.

Results observed

• Scan time per label reduced (laser trigger vs camera focus waiting).
• Device breakage incidents sharply decreased.
• Operators required minimal retraining—workflow inside Barcode to PC unchanged.
• Consistent data quality feeding existing CSV and desktop automations.

FAQ

Do I need keystroke mode? Not when Intent Broadcast is configured; use keystroke only for legacy apps.
What if scans don’t appear? Recheck Intent action spelling and ensure the output mode is set to Broadcast from the device settings

Getting started

1. Select a rugged PDA model (pilot two units).
2. Configure Intent Broadcast (action com.scanner.broadcast).
3. Associate device names and verify Output Template columns populate.
4. Benchmark scans vs smartphone baseline.
5. Roll out fleet-wide and monitor duplicate/error rates weekly.

Next: Transition a pilot line this week and measure scan speed + device downtime improvements before full adoption.