Eight Pointers for Enhancing Your Industrial Wireless Network

Operational wireless technology offers a competitive advantage to supervisors and plant executives globally in their quest for innovative communication enhancements in their manufacturing and dispersal units. An efficient communication framework can empower industrial machinery to deliver heightened levels of dependability, accessibility, and serviceability, thus curbing operational and maintenance costs while reducing capital investments.

Despite its widespread use in everyday scenarios, numerous plant supervisors and executives are still hesitant about integrating wireless technology into their facilities. Conversely, those entities that have adopted wireless technology may not have fully exploited its potential or reaped its benefits. In this piece, we offer eight valuable suggestions to aid industrial wireless users in identifying and rectifying issues within their network infrastructure.

1. Surmount Channel Saturation by Employing 5-GHz Channels

Within standard Wi-Fi communication, all Wi-Fi radios configured with alike channel settings and operating within the same Wi-Fi zone share a common transmission medium. Hence, it’s crucial to consider all radio devices in that zone when assessing channel usage. For instance, while inspecting the saturation levels of the 2.4-GHz channel 6, one must factor in all access points in the vicinity deployed on this channel, along with other non-802.11 communication devices like microwaves, ZigBee, and Bluetooth operating on the same channel. If the channel is congested, a switch to a less crowded channel is advisable. The 2.4-GHz frequency isn’t recommended for industrial applications due to its limited bandwidth and frequent channel usage. Conversely, the 5-GHz frequency offers a broader spectrum of channels, often featuring more non-interacting channels. However, radar systems also utilize 5-GHz channels. Compliance with most countries’ regulations mandates that wireless devices support dynamic frequency selection (DFS) to legally operate within the 5-GHz spectrum. Hence, in an industrial setting, deploying devices with a 5-GHz radio equipped with the DFS function gives you the liberty to opt for the clearest communication medium, ultimately enhancing your network’s communication quality.

2. Attain Maximum Signal Reaching Capability in Long-Distance Connectivity through Scientific Distance Estimation

An elevated 802.11 wireless transmission rate necessitates a robust radio signal. Inadequate radio signal strength results in diminished throughput or disconnections. Various methods exist to enhance signal reach; for instance, installing high-gain antennas or transitioning to a lower frequency, like 900 MHz, to mitigate free space path loss impacts. Utilize a wireless distance estimation tool to precisely gauge communication range and bandwidth needs for the area in question. Such a tool furnishes you with a theoretical panorama of the site, later verified through physical site surveys. Hence, craft your network’s long-distance communication specifications using a distance estimator, corroborate these estimates through on-site inspections, and gain enhanced control over your network’s wireless bandwidth and capacity.

3. Enhance Link Uptime by Employing Wireless Redundancy Mechanisms

Even amidst a clear communication setting and adequate signal reach, other factors could induce network instability. Issues related to configuration, such as Hidden Nodes, might cause connectivity glitches within a well-crafted network. Furthermore, if the deployment site isn’t under your jurisdiction, unforeseen wireless interferences from unknown sources could disrupt an otherwise well-functioning setup. Leveraging wireless redundancy technologies, such as dual RF redundancy, can aid in recuperating from unforeseen breakdowns, especially critical for crucial applications, ensuring optimal connection uptime.

4. Secure Adequate AP Coverage for Mobile Devices Across Your Network

Wireless Access Points possess limited outreach. Commercial APs, equipped with default antennas, typically cover a radius of approximately 50 meters. To facilitate seamless client mobility between APs, overlapping coverage is indispensable. Employ site planning software like Ekahau or AirMagnet to create a wireless coverage heat map, illustrating the AP distribution within your network for optimized AP number and placement. Antennas influence coverage extension, albeit users often disregard an antenna’s vertical outreach. Most 802.11 antennas are passive components without signal amplification capabilities. Expanding signal reach is achieved by altering the radiation pattern produced by the antenna signal. For example, an omni-directional antenna features a 360-degree horizontal radiation angle. Enhancing its horizontal coverage necessitates a compromise on the vertical angle. Post high-gain antenna installation or transition, refrain from excessively elevating the antenna; excessive elevation weakens signal strength, hindering ground-level device connectivity.

5. Augment Mobile Operations with MIMO Client Antennas

Both 2.4 GHz and 5 GHz wireless communications necessitate a direct Line of Sight (LoS) between the AP and its client(s). While signal-penetration and obstacle-reflection techniques maintain wireless connectivity, signal attenuation can impede network stability and overall throughput. Expanding AP distribution to evade obstruction-induced connection loss can be costly. Extending client radio antenna installations to establish optimal AP-client line-of-sight can render tangible advantages. Leveraging 802.11n’s 2×2 MIMO technology allows the installation of dual antennas, front and back, on a mobile unit to broaden wireless coverage.

6. Fine-tune Roaming Efficiency for Mobile Operations

Implement advanced wireless roaming technology to achieve millisecond-level roaming transition periods. Despite existing standards such as802.11r, which enhances the efficiency of roaming, is still predominantly favored by most wireless M2M suppliers when it comes to their roaming technologies. Enhanced roaming technologies empower a wireless client to automatically seek out a new AP in cases of weak current AP connectivity. The crucial aspect in this setup is configuring the appropriate roaming threshold parameter to prevent any interruptions. Opting for a roaming technology that permits operators to adjust roaming parameters based on diverse environments and application scenarios will aid in boosting network performance and eradicating downtime. For instance, Moxa’s Turbo Roaming offers customizable roaming parameters to cater to the varying needs of industrial applications.

7. Addressing Protocol Compatibility Challenges

There are certain characteristics inherent in the standard 802.11 protocol that impede seamless communication between a wired Ethernet and a wireless link. Although most TCP/IP-based automation protocols can transmit data without issues, there are situations where adjustments need to be made to the 802.11 functionality to ensure compatibility with industrial automation protocols. The design of the 802.11 AP/Client communication protocol assumes that wireless clients, like smartphones, serve as the network endpoints. However, in scenarios where the wireless client is connecting to additional Ethernet-based endpoints such as a PLC and its associated field devices, the standard 802.11 protocol may struggle to accurately forward data packets using only the MAC address of the endpoint device. Moxa addresses this limitation in layer 2 Ethernet communication with their MAC Clone technology. This technology facilitates the transparent transmission of MAC addresses for additional endpoint devices across wireless links, enabling wireless communication for layer-2 based automation protocols like PROFINET.

8. Ensuring Handheld Device Interoperability through the Wi-Fi Alliance Logo

The usage of smart handheld devices such as smartphones and tablet PCs is widespread in industrial settings. Various vendors like Apple, HTC, Samsung, and Sony offer smart devices with different operating systems (e.g., iOS, Android, and Windows). Despite these differences, all these handheld devices can effectively communicate with factory APs through the 802.11 standard. Only devices that adhere to specific interoperability standards are granted the Wi-Fi logo. The Wi-Fi logo is granted by the Wi-Fi Alliance, a nonprofit organization dedicated to promoting Wi-Fi technology and certifying Wi-Fi products. Not all IEEE 802.11-compliant devices undergo certification by the Wi-Fi Alliance due to associated costs. However, the absence of the Wi-Fi logo doesn’t necessarily mean a device is incompatible with Wi-Fi devices. Nonetheless, the presence of the Wi-Fi logo instills confidence in the device’s Wi-Fi interoperability.

Moxa’s Tailored Solutions for Industrial Environments

Moxa, a renowned provider of industrial wireless solutions, possesses the expertise to enhance your industrial wireless networks based on their extensive experience and knowledge in this field. To explore how Moxa has successfully optimized wireless networks in various industrial applications at customer sites, download our success-stories brochure here.