Industrial communication

Industrial communication is the exchange of information and data within and between different systems, machines and devices in industrial environments via fieldbus or industrial ethernet technologies. It plays a crucial role in ensuring smooth processes, increasing efficiency and improving the reliability of manufacturing processes. Devices that are networked through industrial communication include field devices such as sensors and actuators as well as controllers such as PLCs and distributed control systems.

Industrial communication systems enable real-time monitoring and control. In a factory, for example, sensors can monitor machine performance and send data to the HMIs so that operators can make quick adjustments. This ensures minimal downtime and optimized production.

With the advent of the Internet of Things (IoT), industrial communication has evolved to include advanced data analytics and cloud-based services that are driving the progress of Industry 4.0. This modernization supports predictive maintenance, reduces costs and increases overall productivity.

In essence, industrial communication is the backbone of modern manufacturing, paving the way for the smart factories of the future.

Industrial communication has undergone a transformative evolution, emerging as a pivotal cornerstone within the ecosystem of modern industrial automation and control systems. The roots of this evolution delve into the latter half of the 1960s, marked by the inception of ARPANET, heralding the dawn of the first public computer network. With further developments as the introduction of standards such as RS 232 in 1960 and subsequent innovations like Modbus in 1979, Ethernet in 1983, and PROFIBUS in 1989. This historical juncture not only laid the foundation for subsequent advancements but also crystallized the significance of industrial communication in shaping the intricate tapestry of contemporary industrial automation technology.

Industrial communication has become a critical component of modern automation and production processes pertaining to the systematic transition towards industry 4.0 by serving as the backbone for the successful operation and control of machinery and plants. It encompasses the reliable transmission of data from the field level to the control level, ensuring that systems are interconnected seamlessly for optimal performance. For instance, Connected PLCs, machine controls, HMIs, sensors, and systems help manufacturers overcome data silos and drive industrial automation The importance of industrial communication can be seen in its ability to facilitate the transfer and exchange of information necessary for process and production automation.

In the era of Industry 4.0, industrial communication has become a cornerstone for the seamless operation and integration of various systems within the manufacturing environment. The role of industrial communication is pivotal, as it enables the interconnectivity of cyber-physical systems, such as sensors, actuators, embedded PC, and machines. These systems are interconnected to exchange data both internally and externally, facilitating real-time control and monitoring that revolutionize the manufacturing floor. Such advancements have led to the creation of intelligent factories, characterized by their flexibility, efficient use of resources, improved ergonomics, and the integration of customers and business partners into business and value creation processes.

Industrial communication occurs across various levels, including informational, control, device, and safety, each with unique network requirements. The communication networks used in industrial settings are designed to handle massive amounts of real-time data, even in challenging environments. 

Data transmission in industrial communication can be simplex, half-duplex, or full-duplex, with full-duplex being the most common in computer networks as it allows simultaneous two-way data transfer. The transmission medium can range from copper wires, such as coaxial or twisted-pair cables, to fibre optics and wireless technologies. For a basic technical understanding of industrial communication, there are two important aspects: the OSI model as a multi-layered framework for data exchange and the existence of a variety of industrial network protocols and technologies.

The Open Systems Interconnection (OSI) model is a fundamental element in the field of industrial communications, providing a standardized framework used to understand and implement network protocols in seven distinct layers. 

The structure begins at the Physical Layer (Layer 1), dealing with hardware and transmission media. Next is the Data Link Layer (Layer 2), which handles error detection and correction from the physical layer. The Network Layer (Layer 3) is responsible for data routing and forwarding, making connections between different networks. The Transport Layer (Layer 4) ensures complete data transfer with error recovery and flow control. The Session Layer (Layer 5) manages sessions and controls connections between applications. Moving up, the Presentation Layer (Layer 6) translates data formats, encrypting and compressing as needed. At the top is the Application Layer (Layer 7), providing end-user services such as email, file transfer, and web browsing. Each layer serves a distinct role and communicates with the layers directly above and below it, ensuring a robust and modular approach to networking.

At the heart of the industrial communication are industrial protocols, which are sets of rules for data exchange among network devices and software systems. These protocols can basically be divided into three categories:

• Fieldbuses

  Fieldbuses are special communication systems developed for distributed real-time control in industrial environments. They essentially act as digital networks that connect different components of an industrial automation system - such as sensors, actuators and control devices - to improve seamless data exchange. Unlike traditional point-to-point cabling, fieldbuses use a single communication cable to connect multiple devices, simplifying the infrastructure and reducing wiring costs. These networks are based on special communication protocols such as PROFIBUS, CANopen and Modbus that enable reliable and deterministic data transmission, which is crucial for maintaining synchronized and efficient operations. Fieldbuses meet the stringent requirements of industrial environments, including harsh environments and the need for high fault tolerance.

• Industrial Ethernet

  Industrial Ethernet protocols are specialized communication standards designed to meet the rigorous demands of industrial environments while leveraging the advantages of Ethernet technology. Unlike traditional Ethernet used in home and office settings, industrial Ethernet protocols must offer high reliability, real-time performance, and robustness to withstand challenging conditions like extreme temperatures, humidity, and electromagnetic interference. Common industrial Ethernet protocols include Ethernet/IP, PROFINET, and EtherCAT. These protocols support deterministic data transfer, ensuring that messages are delivered within a predictable timeframe, which is critical for applications requiring precise control and synchronization. Industrial Ethernet protocols facilitate seamless communication among various devices such as programmable logic controllers (PLCs), sensors, actuators, and human-machine interfaces (HMIs). They enable real-time monitoring, control, and data exchange across complex automation systems.

• Industrial Internet of Things (IIoT) 

  IIoT protocols are special communication standards designed to enable seamless connection and data exchange between different devices and systems in industrial environments. These protocols ensure reliable communication in real time, which is essential for the functioning of smart factories and advanced automation systems. The most important IIoT protocols are MQTT and OPC UA. IIoT protocols facilitate interoperability between different industrial devices and support complex data analytics, cloud integration and edge computing. They play a crucial role in predictive maintenance, real-time monitoring, operational efficiency and the optimization of manufacturing processes. As the backbone of Industry 4.0, these protocols are driving the transition from traditional industrial systems to smart, connected ecosystems, enabling higher levels of automation, efficiency and innovation.

Industrial communication is a cornerstone technology essential for the smooth operation of industrial processes across various industries. It facilitates the seamless exchange of information and data among different systems, machines, and devices, ensuring that all components within an industrial environment can communicate effectively. By leveraging standardized protocols, robust networking infrastructures, and advanced connectivity solutions, industrial communication enables real-time monitoring, control, and optimization of manufacturing processes. This integration is critical for maintaining high efficiency, reliability, and product quality in sectors ranging from automotive and aerospace to food and beverage, pharmaceuticals, and energy.

Industrial communication is the backbone that enables industry to transform traditional manufacturing facilities into smart, connected environments that pave the way for innovative production techniques and a more efficient future.

As a leading company in the field of industrial communication, Hilscher offers a broad portfolio of technologies and solutions for networking industrial environments.

This includes a wide range of interface solutions for connecting sensors, actuators and controllers to industrial communication networks. The communication controllers of the netX family form the basis for this. The multi-protocol-capable SoCs can be integrated into automation components as required and their extensive chip peripherals enable powerful, efficient and flexible solutions. A protocol change is achieved by simply reloading Hilscher's own netX firmware. Building on this, the company also offers embedded modules and PC cards in all form factors in order to realize the flexible communication interfaces with less integration effort.

Hilscher also offers a comprehensive managed industrial IoT range under the netFIELD brand. This ranges from edge gateways as an application-oriented computer platform with integrated container management and the Edge OS Runtime running on it to the central cloud portal, via which the docker containers are deployed to the edge devices, through to turnkey containers for communication applications.

Gateways and switches, devices for network diagnostics as well as controllers and bridges for the wireless connection of IO-Link sensors round off the automation portfolio.