Network Infrastructure Blog

While the concept of the Internet of Things (IoT) has been around for a while, Industrial IoT (IIoT) has been getting a lot of attention lately due to its rapid growth and the promise of optimized operations, productivity and efficiency in industrial environments. And now with more ways to connect IIoT devices, the global IIoT market is expected to reach nearly USD $1 trillion by 2025.

IoT vs. IIoT

While IIoT is technically a subcategory of the broader IoT concept, it relates primarily to digital devices such as meters, sensors, actuators and controllers used in industrial environments, creating the foundation for automation via smart technology that is often referred to as Industry 4.0.

From a networking standpoint, IIoT devices are typically associated with Operational Technology (OT) networks that handle machine-oriented monitoring, control and supervisory data via Industrial Ethernet. In contrast, IoT has become synonymous with commercial and consumer devices associated with information technology (IT) networks that primarily handle business- and consumer-oriented data via commercial Ethernet. While IT and OT networks are converging in terms of sharing data to optimize industrial processes, there remains some fundamental differences between how IoT and IIoT devices communicate, how much bandwidth they need and the components they use.

While both IoT and IIoT devices utilize Ethernet frames to send data packets to and from networked devices, IIoT devices require time-sensitive networking (TSN). Unlike commercial Ethernet that cannot determine the time it takes for a given packet to arrive at its destination due to collision detection (i.e., waiting to transmit data when another device is also attempting to transmit), communication between industrial devices cannot have even the slightest delay and requires prioritization and time synchronization mechanisms via specific industrial Ethernet protocols.

Unlike many IoT devices that require high-speed data rates of 1 Gb/s or higher to transmit greater amounts of data like high-definition video, the majority of IIoT devices are low-speed and only require data rates less than 100 Mb/s. Many industrial Ethernet applications also use bus topologies where multiple devices share a common link, versus commercial Ethernet that is almost always configured in a star topology where each device has its own link. Industrial devices also often require longer link lengths to effectively traverse expansive manufacturing spaces to remote locations.

It’s also important to note that the components used to connect IIoT devices often need to be protected from harsh environmental factors such as mechanical forces (e.g., crushing and vibration), ingress of liquids and dust, chemical or climatic issues (e.g., temperature and corrosive solvents), and electromagnetic interference (EMI). That’s why many IIoT device connections require Ruggedized cables and connectivity.

New Ways to Connect

IIoT technology is being driven in part by emerging applications that will offer significant benefits over traditional fieldbus communication protocols historically used for industrial devices found in control and automation systems. Many traditional fieldbus systems operate over a wide range of media with varying lengths and connector interfaces, which are often proprietary and not interoperable. Not only has this made for more costly, complex deployments, but it has significantly limited the ability for industrial devices at the I/O level to effectively transmit and share information across OT and IT networks.

Traditional 4-pair Ethernet applications used in the commercial enterprise are cost-prohibitive for IIoT device connections. That’s why the IEEE developed the 802.3cg 10BASE-T1L standards for single-pair Ethernet (SPE) that supports 10 Mb/s Ethernet transmission over balanced single-pair cabling up to at least 1000 meters, as well as the delivery of DC power using IEEE 802.3 power over data lines (PoDL).

The emergence of SPE essentially provides a convergence communication application that solves the need to support IIoT connections up to 10 Mb/s with non-proprietary category-style cabling, while also providing a common networking platform for IT/OT convergence.

Another emerging application for connecting IIoT devices is newer next-generation Wi-Fi 6/6E, which offers real-world data transmission rates of greater than 5 Gb/s, longer device battery life, the ability to connect more devices and improved security that may make it feasible for connecting wireless IIoT devices. This could be extremely beneficial for connecting to wireless sensors and devices located in remote and hard-to-reach areas of the industrial environment, as well as mobile IIoT devices such as those used for inventory management and asset tracking and monitoring. In fact, a new report from Guidehouse Insights, entitled Wi-Fi 6 and the IIoT, examines how IIoT and Wi-Fi infrastructure can be used for industrial sites and estimates that industrial Wi-Fi infrastructure will grow from $1.7 billion in 2021 to $6.9 billion in 2030 at a compound annual growth rate of 16.8%. An executive summary of the report is available here for free download on the Guidehouse Insights website.

With its higher-frequency radio waves that offer speeds up to 10 Gb/s and reduced latency, there’s also much potential for 5G cellular to connect to IIoT devices, particularly those used in distributed telemetry applications and remote mining, excavation, smart grid/substation, and rail and transit applications. While Wi-Fi is ideal for wireless IIoT devices permanently located within a structure, distributed antenna systems (DAS) can extend 5G signals over the building campus to effectively support seamless wireless communications for mobile IIoT devices that need to operate both inside and outside of a facility. For example, consider the sensors being used to monitor and track shipments and temperature of new COVID-19 vaccines that must remain at minus 70°C to maintain effectiveness.

We’ve Got You Covered!

As buildings and factories becomes smarter and more efficient via IoT and IIoT technology, and IT and OT networks continue to converge, you need the right infrastructure in place to support it all. Whether you’re connecting devices to the IT network or the OT network, in commercial environments or industrial, Siemon has you covered with the right low-voltage system to support direct SPE and 4-pair wired Ethernet connections to devices, as well as connections to Wi-Fi access points and DAS nodes.

To learn more, check out these resources:

• Wi-Fi 5 and Wi-Fi 6
• Preparing for Wi-Fi 6E: Cabling considerations for high efficiency wireless access point connections
• Distributed Antenna Systems (DAS)
• Ruggedized/Industrial Cabling & Connectivity
• Tech Brief: Solutions for Retrofit, Future-Proof New and Day 1 SPE Installations

Over the past decade, we’ve heard a lot about the Internet of Things (IoT) and how it will transform our daily lives. While IoT has become a bit of an overused and often misused term, no one can deny the growing number of connected “things” collecting and transmitting data via Internet protocol (IP) over Ethernet-based networks. This is also happening in the industrial environment with the proliferation of industrial Ethernet and more connected industrial devices and machines to support supervisory, control, monitoring and collection of real-time production data. As a result, we now also hear quite a bit about Industrial IoT (IIoT) and how it will transform the manufacturing industry.

While IoT and IIoT both relate to the concept of devices communicating via IP, and they share some common connector interfaces and intelligence, they are in fact quite different in terms of their primary use and goal. IoT refers primarily to commercial applications used by consumers and end users with a focus on everyday systems that support business needs, communication, safety, security, health and wellbeing with the primary goal of improving business outcome and daily life. In contrast, IIoT refers primarily to industrial applications used by machines and production equipment with a focus on automated control and monitoring to improve efficiency, maximize productivity and optimize operations.

There are other key differences between IoT and IIoT networks including Ethernet application requirements (i.e., collision detection vs. deterministic real-time Ethernet) and topology variations, but often one of the most talked about differences are the environmental factors to which these networks are exposed. These include potential mechanical forces (e.g., crushing and vibration), ingress of liquids and dust, chemical or climatic issues (e.g., temperature and corrosive solvents), and electromagnetic interference (EMI). While industrial environments and IIoT devices are most often associated with these factors, the proliferation of IoT means that devices communicating via standard commercial Ethernet may also be located in more unforgiving environments than ever before. Whether it’s point-of-sale machines in outdoor eateries, Wi-Fi access points in a science laboratory, security cameras at a marina or medical equipment in an operating room, cables and connectors use to establish connections can also be at risk. That means many of the cable and connectivity characteristics required for IIoT may also be required for IoT.

Thankfully there are industry standards that look at these environmental factors using the MICE (Mechanical, Ingress, Climatic and Electromagnetic) method of classification and consider each of them at various levels of harshness, including Level 1 for everyday commercial office environments, Level 2 for light industrial and Level 3 for industrial. MICE parameters can be instrumental in selecting cables and connectors for both IoT and IIoT connections. Let’s take a look at a few characteristics to meet various MICE parameters.

Sealed for Ingress Protection

Connectors are of important consideration in unforgiving environments because they can be a source of ingress. When dust and liquids infiltrate network connections, contacts within jacks and plugs can become corroded and no longer maintain connectivity. For example, consider an operating room in a hospital where mobile heart monitors, respirators and other machinery are wheeled in. Solvents used to disinfect the environment can infiltrate unprotected equipment connections and over time potentially cause those connections to malfunction, which could be catastrophic in that environment.

Ingress doesn’t just apply to liquids. The “I” in standards-based MICE parameters also looks at particulate matter (i.e., dust and debris) and classifies the level of protection based on the maximum diameter of a particulate. For example, a Level 1 commercial environment allows for a maximum particulate diameter of 12.5 millimeters while Level 2 and Level 3 environments allow a maximum of 50 micrometers. One standards-based rating to consider for unforgiving environments is ingress protection (IP) ratings developed by the European Committee for Electro Technical Standardization (CENELEC). Sometimes referred to as an IP code, the IP rating consists of the letters “IP” followed by two digits-the first digit classifying protection against solids (e.g., dust) and the second classifying protection against liquids (e.g., water). A common IP rating for ruggedized network connectivity is IP67, which offers total protection against dust ingress and water ingress.

It’s not always just the outlet and plug interface to consider when it comes to ingress protection. IP44-rated stainless steel faceplates with rear sealing gaskets provide a protective seal that prevents moisture and debris from infiltrating the space behind the wall where outlets are terminated to the cable. Note that connections that reside within enclosures may not require additional projection and an IP67 rating, but the enclosure itself may need to offer protection. The National Electrical Manufacturers Association (NEMA) uses a standard rating system for enclosures that includes IP code equivalents. For example, a NEMA 4X enclosure offers the equivalent of an IP66 rating.

The Vibration Factor

IoT/IIoT connections that are subjected to consistent vibration and movement such as those on machinery or in proximity to drive belts, motors, pumps, fans and other equipment, can experience problems due to misalignment, disconnects and long-term wear caused by loosening. One way to help prevent the impact of vibration is to use bayonet-style mating connectors like Siemon’s Ruggedized copper and fiber connectors. Ruggedized cables that feature an over-molded 90-degree angle can also help maintain vibration for connections versus manual bending of straight connectors that can increase the potential for connectors to come loose.

For even more protection against vibration, some devices will also often make use of M series connectors such as D-coded M12 connectors us in 100 Mbps Ethernet applications. These connectors feature a highly durable impact-resistant circular design that utilizes a locking thread to prevents them from loosening and becoming disconnected or misaligned. They are also IP67 rated for protection against ingress and shielded for protection against EMI. The overall smaller size of the M12 is also ideal for supporting the trend toward smaller IIoT devices and sensors in more places. Siemon offers M12 cable assemblies for these applications.

Cable Construction and Jacket Materials Matter

When it comes to protecting cables in unforgiving environments, the overall construction of the cable and its jacketing materials may need to be considered. For example, environments subjected to EMI from other equipment (e.g., fluorescent lights, air conditioners, X-ray machines, motors, actuators, etc.) should use shielded cabling. EMI can produce disturbing signals that can degrade transmission performance, and the cable shield protects data from those signals. This can be especially critical in an environment like a hospital where proper transmission of data could impact the reliability of life-saving applications. Note that optical fiber cable used to support above 10 gigabit per second transmission speeds, extended distance requirements and backbone cabling is inherently immune to EMI.

Other characteristics to look for in cables might be increased operating temperature durable jacketing and the use of more jacket materials that are resistant to the various environmental elements present in production and other harsh environments. While polyvinyl chloride (PVC) jacketing used for commercial-grade cables can support some light industrial environments, other environments might need a little something more. For example, thermoplastic elastomer (TPE) jacket materials support wider operating temperature ranges and are more resistant to sunlight, moisture, abrasion and corrosive chemicals, while polyurethane (PUR) is bit more mechanically tough with a higher tensile strength and tear resistance for use on machinery. That’s why Siemon Ruggedized Category 6A shielded cable assemblies are available with a TPE jacket and our M12 cable assembles feature a PUR jacket.

Learn more about our Ruggedized line of cabling and connectivity. And listen to our recent Network Connections Podcast Episode 7 on How to Protect Critical Connections in Unforgiving Environments.