I always thought that industrial networks were simply the “tube” through which data passes, but I was very wrong. In modern factories, the network has become the true beating heart of production, the factor that determines efficiency, quality and competitiveness. Think of an orchestra conductor (I don't know, let's say Riccardo Muti) who has to coordinate hundreds of musicians in real time: this is the challenge that industrial networks face today.
Every device, sensor, actuator, or controller must receive and execute instructions with millimeter precision. And why? Well, because a single millisecond delay can result in defective products, wasted materials, or in the most serious cases, dangerous situations. Technologies such as Time-Sensitive Networking (TSN) and Deterministic Networking (DetNet) are revolutionizing this landscape, bringing an unprecedented level of determinism.
The technological landscape of industrial networks has changed dramatically in recent years. Traditional communication protocols are gradually giving way to Ethernet-based solutions, but with characteristics that are very different from the conventional Ethernet we use in offices. Modern smart factories require networks that can handle huge volumes of data in real time, with predictable and guaranteed latencies. This is not just a technological upgrade, but a real revolution that will completely transform the way machines communicate with each other.
On the other hand, the communication needs in the industrial environment are fundamentally different from those of regular IT environments. Incidentally, Few verbose. A typical computer network is primarily designed to allow maximum bandwidth and can tolerate occasional inconveniences, such as adjusting for delays or packet losses. In industrial automation, however, these situations can have truly devastating consequences. If, for example, a robot needs to synchronize with the moving conveyor belt, a delay of a few milliseconds can cause the part to be defective or damage the equipment.
The perfect ingredient for industrial networks
I mentioned it before: the fundamental characteristic that distinguishes modern industrial networks is the determinism. But what does this mean exactly? A deterministic network guarantees that messages are delivered within a predefined and constant time, with little or no variation (jitter). This is in stark contrast to the operation of traditional Ethernet networks, where packets can experience variable delays depending on network traffic.
The solution to this is Time-Sensitive Networking. This is a set of IEEE 802.1 standards that extends and in some cases improves on the Ethernet deathtrap by using mechanisms including ensuring deterministic data transmission. This provides precise time synchronization, traffic scheduling, and queue management to reserve specific time “slots” for critical data. This can then be prioritized over other traffic, using QoS priority encoding at the base of Ethernet frames.
What is interesting to note is that this technology, born to transmit audio signals in synchrony in concert hall environments, is spreading in industrial applications mainly because of the possibility of ensuring predictable communication times and synchronization between network nodes. It is also important to remember that in this way, the problem of determinism, which in the past severely limited the implementation of traditional Ethernet protocols, is solved and opens new perspectives in the development and implementation of industrial networks.
Complementary to the TSN is the Deterministic Networking (DetNet), developed by the Internet Engineering Task Force (IETF). While TSN operates primarily at the data link layer, DetNet extends these concepts to layer 3 (the network layer), enabling deterministic communications across larger and more complex IP networks. This approach allows determinism to be maintained even in the more extensive and complex network configurations typical of modern industrial environments.
Private 5G: The Wireless Revolution
While TSN and DetNet are transforming wired networks, another technology is revolutionizing the world of industrial wireless networks: “private 5G”. Private 5G networks represent an innovative solution that brings the advantages of the fifth generation of mobile technology directly to industrial environments, without depending on external operators.
A private 5G network offers very high speeds, ultra-low latency (down to 1-2 milliseconds) and the ability to connect a huge number of devices simultaneously. These features make it ideal for advanced industrial applications such as autonomous vehicles, collaborative robotics, and IoT sensor-based predictive maintenance systems.
Private 5G technology represents a breakthrough in industrial wireless communications. Unlike public networks, private 5G provides complete control over the infrastructure, ensuring security, low latency and high capacity.
The main advantage of private 5G over previous wireless technologies is the ability to configure the network based on the specific needs of the industrial environment. For example, you can allocate more network resources to critical applications, ensuring optimal performance even in intensive usage scenarios. In addition, by keeping the data within your own infrastructure, you get a higher level of security and privacy.
Companies like Bosch Rexroth are already integrating 5G into their production lines to improve coordination between mobile robots and automated systems, enabling more flexible and precise operations. In Sweden, Sandvik is using private 5G networks within its mines to manage excavations and machinery, demonstrating the incredible versatility of this technology even in extreme environments.
Safety: the essential pillar
As connectivity increases, so does the attack surface for potential cyber threats. Industrial network security is no longer an option, but an absolute necessity, especially considering that a cyber attack in this context can have not only economic, but also physical and environmental consequences.
Network segmentation is one of the most effective strategies for protecting industrial environments. By dividing the network into isolated segments, it is possible to limit the spread of potential threats and implement specific security policies for each area. This approach is especially important when integrating IT (Information Technology) networks with traditionally separate OT (Operational Technology) networks.
Industrial firewalls play a crucial role in this scenario, acting as a barrier between different network segments. Unlike conventional firewalls, those designed specifically for the industrial environment are able to understand and filter even industry-specific communication protocols, providing more targeted and effective protection.
Le virtual private networks (VPN) are another key element for security, especially for remote access to industrial systems. Through data encryption and user authentication, VPNs allow secure connections to be established even through public networks, allowing remote maintenance and monitoring without compromising the security of the infrastructure.
Multi-factor authentication adds an additional layer of protection by requiring multiple forms of verification before granting access to critical systems. This dramatically reduces the risk of compromised credentials being used for unauthorized access.
Implementation and management: choosing partners
Implementing and managing advanced industrial networks requires specific skills and a deep understanding of both network technologies and industrial processes. In this context, the choice of technology partners becomes a critical success factor.
Specialized companies such as moxa.distry.shop offer hardware and software solutions specifically designed for industrial environments, with a focus on reliability and performance. The range of available products ranges from TSN-compatible industrial switches to routers for private 5G networks, to security management and monitoring systems.
And what about technical support? Industrial networks are critical infrastructures that cannot afford extended downtime, so having access to fast and competent technical support can make all the difference in emergency situations. The best suppliers They offer 24/7 support and preventative maintenance programs to identify and resolve potential problems before they cause disruption.
Another key element? Training your internal staff. Industrial network technologies are evolving rapidly, and keeping your technical team up to date is essential to fully exploit the potential of new solutions and effectively manage your existing infrastructure.
Future challenges and prospects
Despite significant progress, it must be said that the implementation of advanced industrial networks still presents several challenges. The integration of systems with new technologies such as TSN and private 5G requires careful planning and, in many cases, phased approaches that allow for a smooth transition without disruption to production.
Standardization is also a critical area. Although TSN and DetNet are based on open standards, there are still different interpretations and proprietary implementations that can complicate interoperability between devices from different manufacturers. Organizations such as IEEE and IETF are actively working to improve and clarify the standards, but it will take time to achieve full compatibility.
Initial costs can be a barrier to adoption, especially for small and medium-sized businesses. However, it is important to consider not only the initial investment, but also the long-term return in terms of increased efficiency, reduced downtime, and new business opportunities enabled by these technologies.
Looking ahead, we can expect further convergence between different industrial network technologies. The integration of TSN with private 5G, for example, will open up new possibilities for hybrid systems that combine the determinism of wired networks with the flexibility of wireless connections. In addition, artificial intelligence will play an increasingly important role in the management and optimization of industrial networks, allowing them to predict and prevent potential problems through advanced data analysis.
Industrial Networks: What Happens Now
Industrial networks are no longer simple support infrastructures, but strategic elements that can determine the success or failure of a company in the era of Industry 4.0. TSN, DetNet and private 5G represent the key technologies that are redefining the landscape of industrial connectivity, offering unprecedented levels of determinism, speed and reliability.
Security is of course still a fundamental aspect, which must be integrated from the early stages of network design and not added as an afterthought. Tools such as segmentation, industrial firewalls and VPNs are essential to protect critical infrastructures from increasingly sophisticated threats.
The choice of technology partners and the continuous training of personnel are key factors in the success of the implementation and long-term management. Specialized suppliers offer not only advanced products, but also the support and expertise needed to meet the complex challenges of modern industrial networks.
What happens now? Simple. Companies that embrace these new technologies and integrate them effectively into their production processes will be best positioned to address future challenges and seize the opportunities offered by the fourth industrial revolution. The others? My best wishes.
