Enabling smart manufacturing with private 5G

The tremendous amount of data that can be transmitted and processed today has paved the way for smart manufacturing. Using Industrial Internet of Things (IIoT) technology, the factory floor can now achieve real-time monitoring and control, resulting in improved efficiency, a larger return on investment (ROI), and the ability to offer cost-effective customization for a competitive advantage.

To build truly automated, intelligent and robust industrial applications, communication capabilities must meet a set of stringent requirements. Boasting unprecedented speeds, 5G networks check all the boxes. Moreover, private 5G offers extensive capabilities, making it ideal for building reliable connectivity in manufacturing applications.

A private 5G network architecture not only grants smart manufacturing the benefits of a 5G cellular network—like high bandwidth, low latency and extensive IIoT capabilities—but also ensures interference-free operation with allocated network frequencies. As a result, private 5G networks improve stability and security by allowing the storage of data privately, rather than on a shared public network.

Going forward, going wireless

Each year, the manufacturing industry experiences a rise in wireless data transmissions as it embraces Industry 4.0 and lighthouse factories.

In key regions promoting smart manufacturing, local governments have already allocated specific frequencies for 5G private networks. The frequencies are reserved for specific regions to avoid wireless instability caused by interference from public networks. Additionally, the frequencies of telecom providers are leveraged for private 5G networks in certain regions, like China.

According to the Private 5G Network Market Size, Share & Trends Analysis Report (2023), the private 5G network market will grow from US$2 billion in 2023 to US$36 billion by 2030, achieving a compound annual growth rate of 51 per cent. These projections show a positive outlook and substantial market potential for private networks, justifying increased investment.

Leading global electronic device brands and manufacturers worldwide are already developing their own 5G-specific equipment, such as central units (CUs), distributed units (DUs) and radio units (RUs), as part of the Open Radio Access Network (ORAN) framework. The market’s recognition of the extensive applications of 5G and the development of its architecture are driving this trend. And one of the primary applications is private 5G.

Transformative benefits for industries

Private 5G networks greatly enhance the security and stability requirements of smart manufacturing. They offer exclusive frequencies for stable signal performance, free from public frequency interference. Additionally, they create a customized network environment that ensures optimal connectivity and security in specific areas. The major benefit lies in storing all data on-site, rather than on a potentially compromised public network. For example, hackers could intercept data transmitted over a public network or infiltrate a vulnerable network and gain unauthorized access to sensitive data.

Some current private 5G applications in smart manufacturing include fixed-point programmable logic controllers (PLC) and mobile transportation carriers, such as automated guided vehicles (AGVs), automated mobile robots (AMRs) and rail-guided vehicles (RGVs).

Many industrial 5G gateways available in the market tend to highlight their compatibility with various interfaces, most often resulting in more intricate equipment designs and larger dimensions. However, this focus fails to consider the demand from manufacturing customers for energy-efficient compact 5G devices.

Private 5G networks in smart manufacturing applications. (Credit: Moxa)

Navigating the pain points

Reconciling IT and OT priorities is the primary challenge in deploying a private 5G network for smart manufacturing. IT and OT often clash as they prioritize top security and high availability, respectively. In OT systems, for example, they prioritize production capacity and occupational safety over cybersecurity. The impact of strict cybersecurity measures on production line operations can cause a decline in production capacity, something manufacturers cannot afford. Therefore, conducting an on-site analysis is crucial for obtaining detailed insights into manufacturing processes, OT network architecture, and production line assets. It involves recognizing customers’ genuine needs regarding OT and converting them into a language IT can comprehend, aiming for an intelligent system that blends efficiency and security.

But understanding the differences between OT and IT is only the first step. Industrial private 5G implementation also requires overcoming challenges such as infrastructure deployment, device and endpoint management, and system integration.

1. Infrastructure deployment: To use private 5G, integrators must construct the infrastructure, including 5G gateways, base stations, 5G core networks, and multi-access edge computing (MEC). These devices are expensive and demand skilled professionals for deployment because of their technical complexity. Because of the unique nature of each 5G deployment, custom configurations are necessary for every site and cannot be replicated effortlessly.
2. Device and endpoint management: It’s challenging to handle multiple devices and endpoints in a private 5G network. Managing all 5G devices often requires customized software for tasks such as authentication, firmware updates, status monitoring, and viewing past messages.
3. Integration with existing systems: The communication protocols of industrial equipment typically function at Layer 2, while 5G architecture operates at Layer 3 and higher with IP capabilities. As a result, IT professionals face the challenge of enabling 5G communication to support Layer 2 packet pass-through.

As smart manufacturing advances toward Industry 4.0, private 5G networks play an increasingly pivotal role. Private 5G not only enables wireless connectivity but also paves the way for a smarter, more agile, and secure industrial ecosystem. Private 5G aligns seamlessly with the specific requirements of smart manufacturing applications, thanks to its dedicated network frequencies, improved stability and secure local data storage.

Moxa’s CCG-1500 Series private 5G cellular gateways deliver powerful performance in a compact design. (Credit: Moxa)

With its comprehensive suite of products and decades of expertise, Moxa addresses the 5G migration challenges by offering compact and energy-efficient solutions like the CCG-1500 Series of private 5G gateways. Furthermore, Moxa shows its dedication to the industrial sector by incorporating features like Ethernet frame tunneling, low-noise amplifier accessories, and network oversight and management software into their reliable and customized 5G solutions.

Jun Wang is a product manager with Moxa.