By: Dave Cavalcanti

Automation, software-defined systems, connectivity and AI are now commonplace in many sectors, enhancing operational efficiency and safety. This is especially true in the industrial sector, as businesses embrace software-defined controls to drive automation systems, such as assembly line robots, automated data analytics and AI-driven optimizations for processes and business.

Companies sticking with their legacy methods risk being left behind as their more agile competitors modernise workflows. From predictive maintenance in manufacturing to real-time monitoring and control in logistics and industrial processes, automation is transforming how businesses operate, ensuring greater reliability and efficiency across the board.

The benefits of automation

It’s clear to see why; the benefits are clear-cut. 32% of businesses have now fully automated at least one element of their operations. In comparison, 88% of small business owners believe that automation enables them to compete with larger companies within their sector, partly due to automation freeing up employees for higher-value tasks. Manual labour, and accompanying monotonous tasks like data entry and scheduling, can lead to faster turnaround times and improved resource allocation.

This can be achieved without proportionally increasing overhead costs, meaning businesses can scale their operations and expand into new markets, meeting growing demands while maintaining efficiency and cost-effectiveness. And with the emerging news that only one-third of all work expected to be carried out by humans by 2030, reliable data delivery is paramount. 

Issues to overcome

However, when it comes to automated processes, operations quickly live or die based on the availability of computing and connectivity resources. Take an industrial distributed control system involving sensors, actuators, and robotic arms carrying out fine manipulation tasks on a production line; for example, it can’t function without reliable computing and near-instantaneous data transmission between the system’s distributed elements. The same applies to operations with a safety element in an industrial machine or process. Specifically in high-risk environments where lives could be endangered, health and safety are beyond imperative. In any scenario where an emergency stop is ordered, the signal must be delivered instantly to avoid severe, life-threatening consequences.

Legacy and proprietary networks struggle to support new automation and AI applications that demand distributed computing with low latency and high reliability. As more applications requiring reliable communication are deployed, networks must advance to ensure Quality of Service (QoS) guarantees. Legacy networks also face challenges with interoperability due to diverse components from different manufacturers, leading to higher costs and limited capabilities. Successful deployment of automation and AI hinges on achieving seamless interoperability and converging mixed-criticality applications on the same network and computing infrastructure.

Creating a suitable foundation for modern networks

Historically, traditional industrial communication networks have been built to serve specific operational applications, like real-time control systems. In contrast, IT and other types of traffic (voice, video, data) were enabled through different networks. This networking model still exists in many factories today but is clearly ineffective as networking infrastructure for deploying next-generation automation and AI.

Instead, businesses are turning towards converged networking for their operational and IT requirements. In contrast to the traditional networking models, the different data elements are unified within a single integrated infrastructure designed to transmit all types of traffic. The combination of mixed-criticality applications brings greater efficiency and simplicity to operations while helping to reduce overheads.

That’s not to say that all traffic is treated the same within this unified infrastructure; converged networking provides the means to prioritise different types of traffic depending on the application requirements. And with the industry developing enhancements to converged networks based on standard connectivity like Ethernet, Wi-Fi, and 5G cellular networks, this makes them a suitable option for industrial applications and key sectors like data centres, aerospace, healthcare, and the performing arts. Embracing these technologies means network design can be streamlined, reducing cabling infrastructure and maintenance costs across these unique sectors.

The role of converged networks and TSN