Wireless in industrial systems: Cautious enthusiasm

Editor’s note: Considering wired and wireless networking technologies are featured regularly in Industrial Embedded Systems, we asked IMS Research, a leading market analyst firm, to shed some light on the subject of wireless adoption rates in industrial applications based on their recent research. This commentary presents their viewpoint and key insights.

One to two years ago, Ethernet grabbed most headlines in industrial networking, but that appears to be a done deal. Wireless is now the next big thing – or is it? Although wireless communications has been around for a while, it is still a relatively new concept in most industrial circles. Despite all the buzz about this technology, a recent worldwide IMS Research study titled “The World Market for Wireless Communications in Industrial Automation” has concluded that the number of wireless industrial products in the field that conform to an industrial standard is very modest, even with high-percentage growth rates taken into account.

As with Ethernet, much wireless hardware used in industrial systems was originally designed for use in a nice cozy office or home environment and has succeeded in those settings. However, most commercial- and domestic-grade products installed in industrial settings are being used in trial applications – trial is the byword at this time. Most work being carried out with wireless appears to be on an experimental basis, particularly in the factory environment. This leads to the second byword, caution.

Interference still abounds
It will come as no surprise that users are very cautious about using wireless communications for anything but monitoring, data collection, and maybe a few program tweaks. Users surveyed for the IMS Research study sent these messages loud and clear. Time and again users expressed concerns about reliability and security, with interference being the driving factor (see Figure 1). During discussions on this subject a number of people described how their own home Wi-Fi systems frequently stop working for no apparent reason and often come back to life in the same abrupt manner. In the home environment, this is rarely nothing more than an annoyance. However, in an industrial application this is unacceptable, especially in a mission-critical application or where safety risks exist.

Figure 1. Barriers to Using Industrial Wireless Technology
Responses to a survey conducted by IMS Research when users in Europe and North America were asked what barriers they saw to them using wireless for industrial communications.

This demonstrates the primary reason why many users aren’t convinced wireless communications is a serious technology in the industrial environment. Until this confidence barrier is traversed, the technology will struggle to gain the acceptance it needs to generate significant sales. Real growth in demand will in turn encourage large companies to develop the industrial-grade products required; however, this will take time. During the course of this study, several manufacturers explained they were still digesting the customer requirement for Ethernet products and said they would address wireless development once they saw the demand increase. Users also cited the lack of such industrial-grade products as a barrier to greater wireless communications use.

The safety issue presents a real concern particularly in view of current legislation in Europe, North America, and throughout the industrialized world. Potential litigation costs as well as lost production indicates that wireless communications in industrial systems likely will not enjoy the same rapid growth as industrial Ethernet.

Even with caution, growth is significant
However, it is not all bad news. Several major industrial automation suppliers such as Siemens, Phoenix Contact, Hirschmann, and Moxa supply wireless products. In addition, numerous smaller companies supply wireless products to process industries, many of which have been using wireless communications for years. Some products are wireless enabled by definition (wireless access points), whereas others are offered as wireless-enabled versions (such as wireless-enabled sensors). Considering wireless products overall, IMS Research forecasts the market will grow in unit shipment terms at a nearly 30 percent compound annual growth rate to 2010. Breaches in the confidence barrier are expected to accelerate sales from 2008 onwards.

Confidence likely will increase as wireless technology standards become established and are considered stable platforms on which new automation systems can be based. As with industrial Ethernet, the question of safety will be addressed in time. This will probably progress from a combination of technological developments and increases in user knowledge. Both will take many years to become established, with technological developments likely to be spearheaded by the organizations managing wireless standards. User knowledge probably will grow with the need to know as the pressures of increased efficiency and productivity dictate. Cost savings can be significant in situations when wireless technology can cover long distances where cables would normally be laid. However, cost savings does not always encourage wireless communications use. The flexibility wireless can provide is often a major factor, allowing flexible component positioning and the ability to make changes simply and quickly.

Implementation choices vary
The IMS Research report also examined the component form factor (silicon approach) manufacturers employed or planned to employ in the future when wireless enabling their products. The three options considered were:

Use wireless modules containing all the necessary components or some kind of dongle
ICs straight onto the PCB
Embed the functionality into existing devices

Conclusions varied greatly among product groups. However, in view of high product development costs and relatively low numbers produced specifically for industrial applications, only products employing devices manufactured in commercial quantities take the embedded route. Typical industrial products that fall into this category include industrial PCs, rugged mobile computers, and the more complex human machine interface. For other products, the module or IC approach appeared to be preferred, allowing wireless connectivity to be offered as an option at extra cost, of course.

Most agree that wireless communications in the industrial environment eventually will become commonplace and that the concerns of today will merely mark another milestone in this fast-moving sector of the industrial automation industry.

John Morse is a senior market analyst with IMS Research. To learn more or purchase this or other industrial market studies, contact:

IMS Research
6 Regent Park
Booth Drive
Wellingborough
NN8 6GR
England
Tel: +44 (0)1933 40 22 55
E-mail: enquiries@imsresearch.com
Website: www.imsresearch.com

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