The need for IWLAN in today’s automotive industry is already established and the technology used by leading manufacturers in their connected plants.

The digital revolution sweeping across the world is powered by data which is generated by connectivity and facilitated by state-of-the-art communications technology. What started in the pre-internet area with networking of machines or local area network (LAN) became wireless (WLAN), first with radio communication and later Wifi as the internet became widely available leading to a proliferation of digital devices. While Wifi is widely used and hugely popular in general applications, the requirements of industry in terms of capacity and reliability are different, which led to the creation of dedicated Industrial Wireless LAN or IWLAN. Simply put, Wifi neither has the bandwidth, nor reliability for critical requirements of industrial plants or factory environment for manufacturing operations. IWLAN is one of the best options for industrial wireless communication. As for the advantages of IWLAN, there are many, the foremost being elimination of the need for extensive cabling between different devices.

IWLAN in the Automotive Industry

While IWLAN is important for industry, it is even more of a critical requirement for the Automotive Industry, which is one of the most visible and profitable industries, besides being the most automated. Every process in automotive manufacturing, the assembly in particular – the body shop, paint shop and trim and chassis shop – is automated. PLCs play an important role in automation as they communicate, monitor and control automated processes like assembly lines, machine functions, or robotic devices. The movements are either through conveyors of various types and overhead monorails, controlled by PLCs, the programming of PLCs done as per the role and function of the relevant system or cell. Most of these operations are performed with high end robots operating in tandem based on real-time communication between different assembly stages synchronised for continuous operation, with some form of human collaboration. IWLAN plays an important role in this environment in facilitating a safe and reliable operation with low latency, high bandwidth network for modern production concepts. The safety factor, including the plant as well as human safety, is extremely important with the protocols for safe shutdown in place for emergency use, with effective communications. Depending on the requirements and vendor services, various devices and systems of IWLAN are available, adhering to the relevant industry standards and compatible with different automaton protocols.

Changing Requirements

The automotive industry is also in its most disruptive phase of transformation ever. Over the last few years, facing the pressure from various quarters, mainly environmental and safety concerns, cars have become lighter, more fuel efficient and equipped with more and more active and passive safety features, with increased use of electronics and composite materials. Being one of the most R&D invested industry, there are rapid changes in the way which cars are built and assembled, with more models and variants, and ever increasing customisation demands, keeping with the Industry 4.0 promise of batch size 1. Amidst all these changes, automation is making way for digitalisation, which calls for state-of-the-art communications technology. The answer is IWLAN, which conforms to the most recent industry standard relevant to this technology. Manufacturers thus need to upgrade their facilities that do not require expensive infrastructure, just IWLAN compliant components with minimal outlay for the transition to fast and reliable connectivity, even in harsh environments and remote locations.

The Future of Automotive Manufacturing

According to an insight published by McKinsey & Company in late 2020, disruptions will result in billions of dollars lost, and only the manufacturers that reimagine their operations will survive. With labour and skills both in short supply in the developed world, digital factories are the way forward. More automation optimising asset deployment and building a resilient supply chain are among the prescribed changes, reinforced by the learnings from the Covid pandemic. Emerging technologies like 3D printing or additive manufacturing are part of the automobile assembly lines as are software technologies like augmented reality and virtual reality in automotive design and rapid prototyping. With the evolution of the smart factory and the expected future transition to lights-out manufacturing, the role of IWLAN will become critical to the emerging manufacturing ecosystem, also coordinating the logistics and materials movement, in conjunction with the Automatic Guided Vehicles (AGVs), forklifts and crane applications, both spanning the hardware in equipment as well as the software component in networking.

Conclusion

The need for IWLAN in today’s automotive industry is already established and the technology used by leading manufacturers in their connected plants. As the automotive assembly gets digitalised, there will be the cascading effect for technology adoption on the suppliers and vendors, to align them with the new manufacturing ecosystem. The demand for IWLAN compatible products and system integrators would also shoot up. Going forward, it is the autonomous car where IWLAN will be playing a much big role. The autonomous car is a connected car with vehicle-to-vehicle and vehicle-to-supporting infrastructure communication, and these features would be unimaginable without IWLAN. Autonomous cars would also be getting regular software upgrades, reinforcing the importance of IWLAN.
Talk to us today! Reach us on rfq@enwps.com.

There is no silver bullet of a solution in the form of an off-the-shelf industrial wireless communication system for a given requirement.

What is Industrial Wireless Communication?

Industrial wireless communication means machines and devices communicating with each other as well as with human operators without physical connections by cables. Imagine there was no wireless in industry. Consider the typical shop floor with all the machines, control panels and automation paraphernalia like relays, sensors, etc., all needing cables to connect with each other to send the signals for operation and the resultant jumble of wires. The concept of industrial wireless communication is not new. It has been around for over 3 decades now in various forms beginning with radio connection initially, and later the Wi-Fi. However, by wireless what is implied is data communication and cables are still needed for electricity supply and also hydraulic/pneumatic pipelines where the machines and equipment need these. But in general, wireless technology cuts the clutter and problems that occur due to damaged cables and connections.

The Challenges of Industrial Wireless Communication

Data communication is a vital part of the Industry 4.0 ecosystem that aims to create smart factories by networking all the machines with embedded devices. Though the idea of industrial wireless communication sounds simple, especially in view of the proliferation of Wi-Fi devices in day-to-day life, there are many challenges when it comes to implementation in the industrial environment. First and foremost, with all the machines and metallic equipment running on electricity, there is a lot of electromagnetic interference (EMI) or the disturbance caused by an electromagnetic field, which adversely affects the performance of wireless communication with the ‘noise’ it generates. The other major issue is bandwidth and frequency related, which affects the performance by causing system faults due to overcrowding of devices. The third significant factor is the harsh environment of a manufacturing plant with all the heat and dust, and in case of process industries, the corrosive environment due to the presences of vapours and chemicals. Finally, there is the matter of standards and protocols, and the interoperability of products from different suppliers, that need to be matched for compatibility of devices as well as address the cybersecurity concerns. All these challenges call for careful consideration and professional expertise for implementation of industrial wireless communication solutions.

Industrial Wireless Communication Solutions for the Smart Factory

One of the most common mistakes that occurs is when enterprises approach industrial wireless communications networks from the IT perspective. Unlike the IT environment where regular modems and routers can perform satisfactorily, the conditions in OT are different and call for specialised devices to meet all operational requirements in varying conditions. Personnel and equipment safety, reliability of the devices, and productivity are the top priorities here. The concept of smart factory or digital factory essentially evolved thanks to the advances in communications technologies which enabled connected machines and devices for highly flexible and customised manufacturing. This needs precision and accuracy with no room for error. A second of lost communication can cause not just a disruption in the process, but also damage the equipment, and worse, compromise the safety of personnel and equipment. Since technology is in continuous evolution mode, where there are problems, solutions are also available; and so is the expertise in the form of experienced professionals to implement them.

Conclusion

Today there are solution providers galore catering to a burgeoning post-pandemic market where digitalisation has become a priority. But there is no silver bullet of a solution in the form of an off-the-shelf industrial wireless communication system for a given requirement. The ideal solution is a carefully crafted one, devised by taking into consideration actual requirements, existing machinery and equipment with room for expansion, the selection of devices and compatibility, and so on. A solution that seems perfect for a warehouse may not suit discrete manufacturing; a process plant may have its own special requirements. An experienced solution provider like ENPWS, with decades of experience in automation and robotics, can help enterprises implement a robust industrial wireless communication system by studying the operational requirements at length, and coming with the optimum solution that also factors in the total cost of ownership. Talk to us today! Reach us on rfq@enwps.com