How Industrial Ethernet Powers Industrial IoT in Factory Environments

What happens when regular Ethernet equipment is used in factories? It fails fast in factory environments. Factories operate in extreme temperatures, ranging from -40°C to +75°C, experience constant vibrations, and are exposed to harsh chemicals. When industrial networks fail, production comes to a halt, resulting in financial losses.

This article demonstrates the differences between industrial Ethernet and traditional office networks. It explains how special components let machines communicate with each other reliably. The discussion covers three main parts: ruggedized network switches, industrial-grade cables, and protected patch panels that create networks capable of withstanding harsh factory conditions.

Performance limitations in industrial environments

The Industrial Internet of Things (IIoT) operates in conditions that quickly disable standard IT equipment. Manufacturing floors generate dust that clogs cooling systems, while moisture in food processing causes shorts and corrosion. Temperature extremes, constant vibration, and electromagnetic interference from motors all compromise regular networking components, leading to failures and costly downtime.

Unlike office networks, where occasional delays are acceptable, industrial networks must be deterministic, ensuring that events occur within a predictable timeframe. Standard Ethernet is a probabilistic (best-effort) protocol with no guaranteed delivery times. Industrial applications require compatibility and determinism, particularly for operations such as motion control, where millisecond delays can damage equipment.

Maintaining compatibility and determinism

Industrial protocols operate at Layer 7 of the Open Systems Interconnection (OSI) model using PROFINET-based networks, as shown in Figure 1. PROFINET can be divided into PROFINET RT and PROFINET IRT ("Isochronous Real-Time"). RT bypasses normal TCP/IP processing to reduce latency, while IRT modifies Ethernet traffic-switching rules to prioritize time-critical data exchanges.

Figure 1: The OSI model illustrates how industrial protocols function at various network layers. (Image source: Eaton)

As PROFINET operates on standard Ethernet at the physical layers (1-2), industrial networks can connect with regular Ethernet equipment while providing exact timing for machine control, protocol flexibility, and network expandability.

IIoT automation system components and operational challenges

The industrial Ethernet switch, cable, and patch panels are essential components of the Industrial Internet of Things (IIoT) in factory automation. There is a list of common and unique challenges for each of the three components.

Common challenges: All components must protect against electromagnetic interference from factory machinery. For this purpose, switches and patch panels require shielded housings, while cables employ Shielded Twisted-Pair (STP) or Foiled Twisted-Pair (F/UTP) construction. Switches feature ruggedized cases for shock resistance, cables resist vibration and mechanical stress, and patch panels utilize heavy-duty materials, such as 14-gauge cold-rolled steel.

Unique challenges:

Industrial Ethernet switches

• Must operate reliably across extreme temperatures (-40°C to +75°C)
• Require redundant DC power inputs and alarm relays for unstable industrial power
• Need Quality of Service (QoS) protocols to prioritize critical industrial data streams

Industrial Ethernet cables

• Face direct environmental exposure, requiring IP68-rated connectors for dust and liquid protection
• Use specialized M12 connectors with locking threads to prevent vibration-induced disconnection
• Feature right-angle plugs for installation in confined spaces around machinery

Industrial patch panels

• Must organize many cable runs in a limited space with high-density designs
• Incorporate strain relief bars to maintain long-term connection integrity
• Use 90-degree down-angle ports for easier access in crowded racks

Eaton offers a wide range of industrial Ethernet solutions, including industrial Ethernet switches, cables, and patch panels, which address the aforementioned challenges in factory environments.

Industrial Ethernet switches

Eaton’s NGI series switches connect devices on industrial networks. They have different sizes: small ones with five ports and large ones with 16 ports. The small switches handle up to 14 Gbps of data. The large switches handle up to 32 Gbps. All the RJ45 ports can work at three speeds: 10 Mbps, 100 Mbps, or 1000 Mbps. Figure 2 illustrates the product images of the key components for the NGI-U08A and NGI-U05C2POE4 models.

Figure 2: Key components of Eaton’s NGI series industrial Ethernet switches. (Image source: device.report)

The NGI-U05POE4 network switch features a ruggedized metal housing that withstands vibration and shock and can operate in temperatures ranging from -10°C to +60°C. Its key feature is its four PoE+ ports that can deliver up to 30 W of power each (with a total budget of 120 W). This addresses the challenge of powering devices such as cameras and sensors in areas where AC outlets are not readily available.

For enhanced features, the NGI-U08A network switch is a good choice, offering a wider operating temperature range of -40°C to +75°C and a robust case to withstand vibrations. The power redundancy feature of this model is particularly useful during power instability. It features Ethernet/IP QoSe (EIP QoS), which helps prioritize industrial data streams for better performance levels.

Industrial Ethernet cables

Eaton’s industrial Ethernet cables feature shielded construction (STP or F/UTP) to protect signals from interference generated by motors and heavy machinery. The cables are designed to withstand dust, moisture, and corrosive elements through features like IP68-rated connectors and CMX outdoor-rated jackets.

To prevent connections from failing due to constant vibration, the cables utilize robust, circular M12 connectors with a 12 mm locking thread for a secure attachment. Many cables support Power over Ethernet (PoE), allowing them to deliver power and data over a single line to devices such as sensors and cameras where power outlets are not available.

The N206-PC23-IND (Figure 3) has an IP68 rating, indicating that its connectors are protected from dust and can withstand immersion in 1.5 meters of water for up to 60 minutes. Its CMX-rated jacket makes it suitable for outdoor applications. It is built to operate in extreme temperatures from -20°C to +80°C.

Figure 3: Eaton’s Industrial Cat5e/Cat6 STP Ethernet Cable with RJ45 connectors (Model N206-PC23-IND). (Image source: Eaton)

The cable's shielded construction helps protect against EMI/RFI line noise from sources such as heavy machinery, including electric motors and welding equipment. It supports PoE to power compatible devices, such as security cameras and VoIP telephones.

The NM12-6A4-01M-BL (Figure 4) and NM12-602-02M-BL industrial cables have M12 connectors and are IP68-rated for resistance to dust and water. The models support high power 60 W PoE and connect a male M12 X-Code connector to a male RJ45 connector.

Figure 4: Eaton's NM12-6A4-01M-BL, a 10G Cat6a shielded industrial cable with a right-angle M12 connector and 60 W PoE support. (Image source: Eaton)

The NM12-6A4-01M-BL has an edge over the NM12-602-02M-BL, offering a higher 10 Gbps network speed and an overall foil shield (F/UTP) to protect against interference in high-speed applications. It also features a special right-angle M12 connector, as shown in Figure 4, to relieve cable strain and allow for easier connections in tight spaces. However, if only straight M12 connectors are necessary with a longer cable length (6.6 ft.) and lower network speeds (1 Gbps), then NM12-602-02M-BL does the job.

Industrial patch panels

Industrial patch panels feature fully shielded RJ45 ports, providing essential protection against electromagnetic interference common in manufacturing environments. This shielded design prevents EMI and RFI from corrupting data, which reduces packet loss and retransmission requirements. Space-efficient options include standard 1U models and space-saving 0.5U variants, allowing for higher port density in limited rack spaces.

As shown in Figure 5, the N254-024-SH-D model features RJ45 ports pointing downward at a 90-degree angle (C), facilitating better cable management in tight industrial spaces and reducing strain on cables and connectors. The dedicated grounding wire (D) ensures proper electrical grounding of the shield, maximizing EMI/RFI protection in electrically noisy industrial environments.

Figure 5: Eaton’s Industrial patch panel (Model N254-024-SH-D) highlighting key industrial features. (Image source: Eaton)

Integration strategies for industrial network reliability optimization

When integrating industrial Ethernet components, match specifications to environmental challenges. Food processing facilities require higher moisture protection than dusty warehouses, while areas with welding equipment require enhanced electromagnetic interference (EMI) shielding.

Plan for growth by selecting components with expansion capabilities, such as enclosures with additional capacity, higher-bandwidth cabling, and switches with spare ports. Ensure interoperability by maintaining consistent performance specifications across infrastructure. If switches support 10 Gbps, use cabling capable of the same bandwidth.

Consider both latency and jitter when designing time-sensitive applications. Address physical constraints with wall-mount enclosures for limited floor space and extend the length of cables to reach optimal device locations.

Conclusion

Industrial-grade networking works reliably where standard equipment fails. It reduces downtime and cuts maintenance costs. It also provides consistent data for analytics. When manufacturers combine standard Ethernet with industrial protocols, enormous benefits happen. This combination gives universal connectivity and precise timing control. Digital twins and predictive maintenance need this timing control.

As factories adopt IoT, ruggedized infrastructure makes the difference. Companies that invest in proper industrial Ethernet get immediate operational benefits. This investment also prepares companies for the advancements of Industry 4.0. These advancements need reliable networking throughout manufacturing facilities.