What Is Industrial Communication? How Does It Work?
In an industrial setting, it’s important that every system fits together perfectly. This is perhaps the only way to ensure smooth operations — especially with higher sector-wide demands. Industrial communication is the bedrock of this, promoting unity between a facility’s many devices.
Understanding more about industrial communication will help your facility improve its standards, making it more efficient in the process. In this article, we explain what industrial communication is and how audiovisual technology can boost it even further.
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What Is Industrial Communication?
Industrial communication is the exchange of data between machines and devices, specifically in an industrial environment. As plants and factories now automate many of their processes, this is the only way to guarantee safety.
This communication can only happen with a strong network, which could be wired or wireless. In most industrial facilities, wireless is more reliable. The communication itself covers quite a broad range of processes. For example, the use of sensors to monitor temperature and pressure.
Each specific industry will implement this process in its own way. For example, oil and gas firms will place more of a focus on monitoring their use of chemicals. Automotive plants will use it for discrete manufacturing, and building systems will use it to regulate HVAC systems.
What Are Industrial Communication Networks?
The systems that facilitate this communication have been in use for over four decades. Shifts in output over time, however, have raised these networks’ standards. With this in mind, here are the main tenets of reliable industrial communication:
- Real-time exchange: Your network must be able to handle high volumes of data. Delays here can lead to inefficiencies, or even outright safety hazards.
- Durability: Industrial settings often traffic in extreme environments. Make sure that your physical infrastructure is able to easily stand up to wear and tear.
- Standardized: This process relies on clear standardized protocols. This helps ensure a network sends and receives the right amount of data every time.
- Interoperability: Your comms strategy will only work if it fits every device you’ll be using. Open architecture guarantees this even between different manufacturers.
- Flexibility: Similarly, good networks always have space for more devices. Growing firms in particular will need a scalable solution that fits their long-term plans.
- Hierarchical: “InCom” has three distinct levels: device, control, and information. Without this robust hierarchy in place, the entire process would simply fail.
These seamless networks are a key part of the Fourth Industrial Revolution. This means they’re arguably the backbone of 21st century industry as a whole.
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How Many Levels Do Industrial Communication Networks Have?
These hierarchical networks have three levels. Each one fulfills a different purpose and has their own protocols. This is necessary to handle the sheer volume of complex information and the full range of interactions. Here is a guide to all three of these levels:
1. Device Level
This level is where the network communicates directly with sensors and other devices. Industrial sensors read pressure, flow, temperature, and other sensitive metrics. The network will then use this data to flag any outliers, such as high-pressure pumps.
This level includes three “subnetworks”. This includes the sensor bus, device bus, and Fieldbus protocols. On top of this, a network’s device level controls the actuators. This means it can carry out minor tasks, such as starting electric motors and opening valves.
2. Control Level
At this level, Programmable Logic Controllers, Human-Machine Interfaces, and other controllers can talk to one another. The control level is where the network must be at its fastest. The device level simply isn’t complex enough to handle this data.
This level also controls the actuators, but usually in ways that execute more complex processes. For example, Computer Numerical Control (CNC) machines form part of the control level. You’ll need a strong network to execute these decisions in real time.
3. Information Level
The information or enterprise level is what manages the network’s automation systems. This will integrate the broader business processes with the network’s industrial operations. In effect, this is where the network puts the data it has collected into practice.
As the top layer, this level connects to the supply chain and customer relationship management system. Through this, it enables better decision-making, demand forecasting, and various other strategic advantages. Your facility might monitor this through its command center.
How Does Industrial Communication Operate?
Industrial communication networks rely on protocols. These dictate how a system transmits and receives data. For example, PROFIBUS is a Fieldbus protocol that links field devices to control systems. These protocols are effectively the language that links an industrial facility’s machines and devices.
The industrial world is full of electrical noise. This can pose a problem for sub-par protocols. For this reason, these protocols must fit strict standards. Originally, these protocols were specific to each manufacturer. Today’s networks embrace interoperability as standard.
Going beyond protocols, here is a simple step-by-step guide outlining how these systems work:
- At the device level, the facility’s sensors collect any relevant information.
- The network selects the right protocol and converts the data into packets.
- The network then transmits the data, which the control level processes.
- When the system receives the data, it analyzes it and makes decisions.
- The network then uses the connected actuators to adjust its parameters.
- Some networks will automatically generate the relevant documentation.
This whole process happens near-instantly. Even small amounts of latency can have a knock-on effect that leads to much slower response times. If the actuators are too slow, they might be too late to prevent a serious issue.
How Can AV Technology Improve Industrial Communication?
Audiovisual tools offer a serious boost to nearly any field. This is because, no matter which form they take, they prioritize situational awareness. For example, a facility can use digital signage to highlight alerts.
Here are the main benefits of adding AV tech to an industrial communication strategy:
- Real-time monitoring: Monitors that show video feeds, possibly with a multi-viewer, will highlight visible defects. This lets employees see the network’s findings for themselves.
- Virtual inspections: Even if the system doesn’t flag any issues, team members can still carry out their own checks. This tech also lets them instantly get an expert to help.
- Safety alerts:Integrating AV tools with a distributed control system will even flag up live alerts. This gives the team instant awareness and helps them fix the problem right away.
- Better training: AV tools deliver more engaging training that fits visual learners. This lets employees learn at an even deeper level, possibly with the help of virtual reality tasks.
- Data dashboards: Teams can also see the network’s data through a special dashboard. This will translate it to a more intuitive format to help people grasp the data right away.
- Remote troubleshooting: Video calls give teams a way of instantly assembling when a concern arises. This lets them start troubleshooting it, even if only one person is on-site.
What Are the Most Expansively Used Industrial Communication Networks?
There are a number of networks that industrial facilities can make use of. Each one has its own benefits and specific use cases. Your facility may even set up a network operations center to guarantee consistent and high-quality service. Here are the biggest five networks.
1. Ethernet/IP
Ethernet Industrial Protocol is very popular for both real-time control and data exchange. This is, in part, because it builds upon Common Industrial Protocol. It also evolves on the foundations of DeviceNet and ControlNet. Ethernet/IP offers high-speed transmission and scalability, but might falter in time-sensitive situations.
2. Profibus (Process Field Bus)
Process Field Bus is a key standard for fieldbus communication, itself one of the main industrial network families. It has been in use since 1989 and allows cyclic data exchange at lower device and higher control levels. However, it has higher initial and long-term costs.
3. Modbus
Modbus has been in use since 1979, but it’s still popular today. This is because it’s open source and royalty-free. Through a serial bus, it creates a master-slave hierarchy which can have up to 247 “slaved” devices. While its age makes it simple to use, it’s also relatively slow.
4. Industrial Wi-Fi
Standard (though high-quality) wireless internet can also link your facility’s devices together. It’s important you shield this from standard industrial interference, however. It should work on nearly any networkable device. In practice, these devices only need to send small data packets.
5. OPC UA
OPC UA, or Open Platform Communications Unified Architecture, entered use in 2006. This is a highly secure network, able to resist threats such as spoofing and message flooding. However, quite a high number of OPC UA users believe it to be overly complex.
Final Thoughts
Industrial communication is, simply put, a modern necessity in so many sectors. But it needs the right protocol and accompanying tools to reach its full potential. With the right AV tech, a facility can bring its human element to the same standard as its industrial systems.
Choosing the best network is also a key consideration. Each of these has their benefits and may suit different processes (such as automation) better. Carefully consider how to bring your InCom network to life, and it’ll revolutionize your whole facility.
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