Inside the lab: how Escort R&D works

Escort is best known for its fuel level sensors – flagship products that set the company’s reputation worldwide. Yet the scope of expertise goes much further. Under the Sokol Meteo brand, Escort creates telematics equipment for eco- and weather monitoring. Under the SKAT brand, it develops systems that safeguard electrical grids. Escort’s R&D is not limited to internal projects.

Q: How is Escort’s R&D different from others on the market?

A: Not many companies in the telematics and sensor industry can afford to maintain such a broad R&D structure and make it work effectively. Escort can – because it invested in building a complete in-house ecosystem of specialists.

Escort’s strength lies in having a fully self-sufficient R&D department. The team covers every critical area: circuit board design, embedded software, high-level software, data analytics, testing, mechanical design, documentation, and certification. This in-house expertise allows Escort to evaluate and bring a customer’s idea to life without depending on outside contractors.

Beyond internal projects, Escort offers contract development services (ODM, OEM, and EMS), enabling partners to turn their own concepts into market-ready products. Sensors can also be customised and adapted for specific client requirements, ensuring that solutions are not only technologically advanced but also practical and tailored to real business needs.

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Q: What does the development process consist of?

A: The department follows a structured but agile workflow:

Idea gathering – input comes from clients, integrators, sales teams, and engineers.
Analysis & design – each idea is checked for technical and economic feasibility.
Prototyping – rapid models are built to test concepts in practice.
Field testing – devices pass not only lab trials but also real-world testing on trucks, buses, construction machinery, and mining equipment.
Refinement & production launch – feedback is applied, and products are prepared for reliable large-scale manufacturing.

This process ensures that every Escort solution is practical, durable, and ready for integration into real operations.

Q: What was the most technically challenging development recently?

A: The automatic fault location system for power grids, due to its complexity in electronics and embedded software. Another was Printed Circuit Board + Assembly auto-programmer, which challenged our Python development and data analytics teams.

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Q: How does the R&D department test devices before launch?

A: Each product passes internal test check lists, including climate chamber tests, vibration stand testing, salt spray testing, and specialised benches for each type of device. After that, devices go through long-term durability tests. As a result of the tests, a final test checklist is formed. This checklist is used by the testing team during the production of the product.

Q: What are the current projects in development?

A: Escort’s R&D pipeline is diverse, covering several industries and directions:

Power grid monitoring (SKAT Energy line):

Automatic fault location system for power grids – designed to locate faults in power transmission lines. The team is now working on a version optimised for mass production with enhanced characteristics.

Meteorological devices (Sokol line):

Autonomous vane and anemometer with BLE interface – a portable yet stationary-capable solution for measuring wind speed and direction. It transmits data wirelessly to a mobile app and will later integrate with the Sokol-M weather station.
Ultrasonic anemometer – a precise wind speed and direction meter without moving parts.

Transport telematics:

Ecargosens v2 – a new generation axle load monitoring sensor, capable of fast switching between semi-trailers and compensating for atmospheric pressure changes.
Automatic calibration station – an automated system that calibrates fuel level sensors in a single click, without manual action.

Other developments (Escort Engineering):

A vending machine for windshield washer fluid.
An upgraded inspection robot.
A sterilisation device.
A digital spreading sensor for winter road maintenance.

Some projects are still in early stages, but what unites them all is Escort’s commitment to pushing technical boundaries while keeping solutions practical, reliable, and ready for the real world.

Q: What values guide your work?

A: Flexibility and customer satisfaction are more important to us than bureaucracy. We design products and use development methodologies that minimise technical debt, while also leaving room for expansion and modification without needing a full redevelopment cycle.

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Escort’s R&D is not just about creating new devices – it’s about anticipating what industries will need tomorrow. Whether it’s smarter fuel monitoring, more robust environmental sensors, or advanced telematics solutions, the team is focused on shaping technologies that are both innovative and field-ready.