WiFi vs Industrial Wireless - What is the Difference?

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▶ Check out the full blog post over at
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⌚Timestamps:
00:00 - Intro
01:07 - Data volume
01:43 - Industrial Wireless data
02:28 - Battery life
03:01 - Industrial Wireless battery consumption
04:08 - Reliability
04:30 - Industrial Wireless Reliability
07:29 - ISA100 Wireless
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After watching this video you will be able to easily explain the difference between a typical wireless network that we use at home or the office, like WiFi, and an industrial wireless network.
The two major types of wireless networks are different in terms of the amount of data that they typically send and receive, the battery life of the devices used in these networks, and how important the reliability of the data is to the user.
1) Data volume
The main difference between a typical wireless network compared to an industrial network is the amount of data that is usually sent and received between devices.
A WiFi network is designed for devices that send and receive large amounts of data.
Examples of these large amounts of data packages are videos on the internet, images, web pages, etc. these are what we consider large data packages.
In contrast, an industrial wireless system is designed for devices that only need to send and receive a small amount of data.
An example is the small amount of data that a gas pressure sensor in an industrial process needs to send to the controller. The data exchanged may be as simple as a tag name and process variable.
This represents only a few words of data that are sent from a device in the field to a controller in the control room, wirelessly every few seconds.
So in an industrial wireless network, we send tiny packages of data in a relatively short period of time about the status of an industrial process.
2) Battery life
Since a typical wireless network such as WiFi or Bluetooth is designed to send and receive large amounts of data, the devices that are used in these networks such as laptops or smartphones consume a lot of battery in a relatively short period of time.
Because of this, you need to charge these devices every few hours or days depending on how much you’re using the device.
But this is totally different with the devices that are used in an industrial wireless network. An Industrial wireless network is designed to send and receive small amounts of data.
Because of this, the devices that are used in these networks such as wireless sensors and actuators consume very little battery in a relatively large period of time.
As a result, these industrial wireless devices can often operate for years without any need for a battery charge.
This is a fundamental difference, in terms of battery life, between a device that is used in a typical wireless network such as WiFi and a device that is used in an industrial wireless network such as IIoT.
3) Reliability
When you are using your smartphone in a typical wireless network such as WiFi, it is ok to lose the connection from time to time.
But when it comes to an industrial wireless network such as IIoT, this is not acceptable.
In an industrial wireless network, the reliability and the accuracy of the data that is sent and received are very critical.
If the data that is sent from the wireless sensor gets interrupted, the controller which works as the brain of the system will not be provided with the required input data to be able to send a correct output command to an output device such as a valve.
One of the most reliable and accurate industrial wireless protocols that you can use to build your industrial wireless network is ISA100 Wireless.
This industrial wireless protocol is developed and maintained by ISA, which is the organization responsible for the development of the standards and the certifications for the industrial automation industry worldwide.
To learn more about ISA100 (‪@isa_interchange‬ ) head on over to isa100wci.org
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Пікірлер: 98

@MrWaalkman 3 жыл бұрын

There's a bit more to it than that. The first thing is that you want to avoid the 2.4 Ghz and 5 Ghz bands at all costs, especially 2.4 Ghz. Both of these are used in virtually every phone and the bands get very congested in a large plant. Bluetooth operates on the 2.4 Ghz band so it should be avoided. Zigbee can operate on 2.4 Ghz, so be sure to avoid 2.4 Ghz Zigbee. Along with the congestion of 2.4 Ghz in general, a microwave oven with a bad door seal tends to wipe out the 2.4 Ghz band in its area as well. Many plants now have a WiFi use policy and visitors are expected to shut their WiFi off upon entering the plant. Some locations take a more proactive approach and shut it off for you (Boeing, for example). So a better choice is the 900Mhz band (or 433Mhz in Europe). The lower frequencies penetrate the machinery in a plant far better, and its ranges are vastly superior. And since these bands are not incorporated in consumer electronics, it is far easier to manage its use within the walls of your plant. As the owner of the plant, you can dictate which channel a vendor uses, as well as its power level. The better radios (I'm fond of the Esteem radios) allow you to set up your networks in a number of different modes that you wouldn't necessarily get with WiFi. And with ranges that by all appearances drill through any obstacles in its way. The lower frequencies limit the bandwidth on the channel, so streaming video isn't a real option with these.

@realpars 3 жыл бұрын

Thanks for sharing that additional information with us! We appreciate that.

@amiral3187 3 жыл бұрын

Thank you for those information. Using frequency different than 2.4Ghz as you said, does this mean the transmission range of this technology goes more beyond the standard WiFi ?

@MrWaalkman 3 жыл бұрын

@@amiral3187 Depends, but 10 - 20 miles is no big deal. Penetration of walls and trees is much better. However bandwidth is lower, limiting the data rate. Here's one that advertises 13 to 60 miles: www.campbellsci.com/rf450 I've only used them in an enclosed building, so any distance beyond a 1/2 mile was of no concern to me. One annoying thing is some radios use reverse polarity connectors, and some don't. And you might have to use the 433 Mhz band depending on your location. Antennas have a lot to do with it, and that's an entire subject in itself. :)

@jimmymifsud1 3 жыл бұрын

You have a lot of issues with 900MHz in the fresnel zone, it’s a bad design for wireless networks. Smart mesh technologies can overcome 2.4ghz 5.8ghz congestion

@MrWaalkman 3 жыл бұрын

@@jimmymifsud1 Well no, not really. There is so much metal in these plants that the transmission path already gets broken up anyway. Nonetheless, it works. Throughput is quite a bit lower, but packet size for us is nearly negligible. Check out Freewave if you want smart mesh in a 900 Mhz radio. IIRC, Freewave radios will "upvote" the best packet portion that they get and the master will reassemble it. The bottom line is that for large companies 2.4 Ghz is simply not allowed. Period. The Boeing warehouse in Georgia would shut our 2.4 Ghz off for us at the door.

@mayurimahadik3781 3 жыл бұрын

Thanks a lot for keep posting informative and useful videos, whenever a new video is posted I make sure I watch it.

@realpars 3 жыл бұрын

That's great to hear! Thanks for your support.

@Francirius 3 жыл бұрын

We used to have a lot of wireless transmitters in a plant, but just to monitoring the process, not for control. The I&C team told us that wireless transmitters arent used to control. Thanks for the video.

@realpars 3 жыл бұрын

Thanks for sharing that! You're more than welcome.

@DrivewayWorkshop 3 жыл бұрын

Nice video. The place I work makes a lot of this equipment, it’s always changing.

@realpars 3 жыл бұрын

Thank you!

@PhG1961 3 жыл бұрын

Nice video ! I really love your work, entertaining and very well explained !

@realpars 3 жыл бұрын

Thanks a million, Philip!

@paolomrfly9676 3 жыл бұрын

Real Pars videos quality over the top always!

@realpars 3 жыл бұрын

Thanks a lot for your kind compliment! We are always extremely happy to hear such positive feedback! If you ever have any questions, feel free to reach out to us. Happy learning!

@lodiebooyse 3 жыл бұрын

Good day, I enjoyed your video on the subject. I'm a Industrial WiFi technician in the mining industry. We install Wi-Fi Mesh networks with the capability of a high level of through put like a home base network but in a industrial environment. We use this network for mobile and static installations.

@samuelokwara6276 3 жыл бұрын

Once again, thank you for your timely videos. U are bringing industrial revolution right to our doorstep.

@realpars 3 жыл бұрын

You're very welcome, Samuel! Happy learning.

@MohammedHussain-cc5hl 3 жыл бұрын

Absolutely Samuel Okwara . Thanks to RealPars.

@realpars 3 жыл бұрын

Thank you, Mohammed! We're really happy that you like our videos! :)

@orhan4633 3 жыл бұрын

Accurate explanations on topic. Thank you

@realpars 3 жыл бұрын

Glad to hear that, thanks for sharing!

@javierferrer4634 3 жыл бұрын

Thank you! For this video.

@fatonaoladimeji9697 3 жыл бұрын

Thanks for the video. I came across some transmitters like this on the field and was trying to understand the rationale behind them

@realpars 3 жыл бұрын

You're more than welcome, Fatona!

@bhargav3699 3 жыл бұрын

Such an hardwork realpars team is doing to make understand latest technology in easier and simple.kudos to efforts your making .keep going good luck👍🎉🙏

@realpars 3 жыл бұрын

Thank you, Bhargav!

@cyberlads28 3 жыл бұрын

We appreciate the knowledge you are giving us keep it up

@realpars 3 жыл бұрын

Thanks a lot for sharing, we're glad to hear that!

@NipkowDisk 3 жыл бұрын

I have to agree with the other commenters here, your videos are most informative. THANK YOU for uploading these, RealPars!!!

@realpars 3 жыл бұрын

You're very welcome! Happy learning.

@MichaelBrown-zg9wc 3 жыл бұрын

Thanks for the information

@realpars 3 жыл бұрын

You're very welcome, Michael! Happy learning.

@nightking9615 Жыл бұрын

Thank you for this amazing and informative video! 1- What is the maximum reach of tue signals between Gateways & Field devices? 2- Would the signal be affetced by other WiFi communications in the same plant, using different Gateways and Controllers? 3- Does ISA100 Wireless protocol support Direct Digital Controllers DDCs? or only PLCs?

@realpars Жыл бұрын

The maximum reach for wireless signals depends on a variety of factors: transmitter power, gateway location, the type of network (mesh has the best range) interferences (like tanks, pipe racks, walls, etc.) between sensor and gateway. On average 75 - 200 meters. You would typically do a wireless survey that would identify the specific topology best for your specific application. The only interference you could have is from other wireless networks operating on the same frequency. However, ISA 100 and other wireless systems get around problem by using frequency hopping and other methods to avoid contention for the signals. Normally, you would have your entire plant on the same wireless backbone, so each gateway would act as another access point in a mesh network, which is a desirable thingl ISA 100 wireless is separate from PLC and DCS hardware. You can connect either PLCs or DCS systems to the gateways, depending on what gateway hardware you are using. Remember, a gateway is a device that connects two different networks together by translating communications from one protocol to another. For a DCS system, you have a gateway that can translate the wireless data into a protocol that can be read by your DCS. Many DCS and PLC manufacturers now provide gateways that can be used with their systems and ISA 100 networks.

@andreyace8768 3 жыл бұрын

Thank you!

@doifhg 3 жыл бұрын

I guess saving the cost of running cables and complexity for repair if there is a break makes wireless pretty desirable for control processes. I guess I'm kind of more old school though, it's not as if cabled connections never fail but it feels safer from a security perspective, especially as tech gets more complex. Great video though

@yamensabbagh3897 3 жыл бұрын

This video is very useful thanks a lot

@realpars 3 жыл бұрын

Great to hear that, Yamen!

@pirata31988 3 жыл бұрын

Thanks a lot for your videos! Interesting contents and they are easily understandable even for me with Italian native language. I ask if you can work on more videos where step by step "build" a whole automatic production machine from the beginning (for example starting from the electrical panel, going through the PLC and sensors choice, PLC programming, drive and servo, motor size calculations and so on including all the technical aspects). It would be great because on internet is not possible to find anything like this.

@realpars 3 жыл бұрын

Hi there, Thanks for your kind comment! Great to hear your motivation in regard to learning PLC Programming. Our course library is specifically designed in a way where it provides all the tools needed for beginners to evolve into an advanced level through our hands-on courses. Feel free to browse through our course library to see all the different topics we are covering. bit.ly/30AVJaR Just to let you know, that we also have a free course on PLC Hardware bit.ly/2XnnUrF Additionally, you will have access to our Technical Team - consisting of high ranking engineers with a lifetime of experience - who are here to help you out with any questions you might have along the way! If you are interested, you will obtain full access to our complete course library (400+ video courses) by subscribing to either our monthly package for €22.12 a month or our yearly package for €159.28,-. Hope this helps! If I can be of any further assistance, please let me know - I’m more than happy to help!

@pirata31988 3 жыл бұрын

@@realpars thank you for your reply and I am considering to enroll and obtain the full service. I always followed videos with Siemens and Allen Bradley PLC , may your engineers also help for Omron PLC and devices? Thanks again

@MincilOyabun 3 жыл бұрын

Can you show me how much industrial in oil and gas installed wireless transmitter for control?

@tp6730 3 жыл бұрын

Thank you

@ignaciojavierkairuzeguia599 3 жыл бұрын

Dude, i can't love this videos more

@realpars 3 жыл бұрын

We're glad to hear that!

@messaoudovicbou4455 3 жыл бұрын

Dear RealPars This is another awesome video, I would like to ask if it is possible to make a video on slip ring and how can we change it to a wireless slip ring with keeping the high voltage (400v) with a normal sleep ring and all what concern data and signal with the wireless one if it's possible Thanks in advance!

@realpars 3 жыл бұрын

Hi Messaoud! Thanks for your kind comment and your topic suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

@ardentdfender4116 3 жыл бұрын

Great stuff. I also wasn't quite aware of the data load difference between Wifi and Industrial Wireless. I would like to see a video of how Industrial Wireless along with ISA 100 deals with Electrical Noise inherent in most plants with all the operating and electrical equipment around. How is this deal with would be a great video.

@realpars 3 жыл бұрын

Thanks for your support, Ardent! Great suggestion, I will go ahead and pass this on to our course developers. Thanks again for sharing and happy learning!

@ardentdfender4116 3 жыл бұрын

@@realpars Much appreciated, hope we see something as it's a very important inquiry.

@hongsangang1224 3 жыл бұрын

nice video !! can this protocol replace the wire-connection in the near future ?

@realpars 10 ай бұрын

Hi Hong Sang, Thanks for your comment, and our apologies for the delay in our response! As you've mentioned, there are two distinct types: one for personal use and another for industrial applications. In the industrial context, wireless technology is gradually replacing certain wired connections, but its adoption depends on the specific engineering requirements of each design. It's a situation that requires a case-by-case analysis.

@adaptiveagrotech4304 3 жыл бұрын

Thanks for the video. Do plant leaves and green tissue block ISA100? Is it reliable to use LoRa as wireless communication in small scale industrial automation, for example, greenhouse automation?

@realpars 3 жыл бұрын

Leaves and green plant tissue are not very effective at blocking wireless transmissions. My advice has always been the same: test it and test it some more. As much as you plan, something else may cause an issue you did not expect. I believe greenhouse applications would be an ideal place to use wireless since the measured "process" is constantly changing, and wired connections would be susceptible to water and corrosion. Do a web search for "wireless monitoring of greenhouse".

@derina.maleek9408 3 жыл бұрын

Thanks

@paramsingh9338 3 жыл бұрын

then this requires no internet connection and can we use for home automation

@nikolaydubina 3 жыл бұрын

Also, how come industrial automation does not send large volumes of data? Like photos/video/audio or just high frequency signals (like from high frequency trading) from sensors?

@realpars 3 жыл бұрын

In some automation systems, higher rates of data are required. One application I worked on was the recording of deflections in mechanical stressed airfoils. We needed to observe deflections just before the part fractured. Data rates were thousands per second. In these applications, wireless sensors would not be suitable. When we want to capture video or other high-volume data streams we use devices and subsystems that are built for that purpose. This is done for the same reason we don't use PLC's to capture video data -- they were not designed for that purpose. Throughput is also the reason in good automation network design, we segregate HMI and server networks (high data transmission rate) from the device control networks (lower data transmission rates).

@fedorin1234 3 жыл бұрын

Are you sure it's correct to compare wireless connection technologies Wi-fi, BT to IIoT concept? Also, isn't WirelessHART more popular than ISA100?

@realpars 3 жыл бұрын

Great question! The answer is YES! Here's why. IIoT is a framework for device-to-cloud applications that require networking of devices and secure, reliable data transmission. IIoT requires 6LoWPAN connectivity. The 6LoWPAN concept (IPv6 over Low -Power Wireless Personal Area Networks) originated from the idea that "the Internet Protocol could and should be applied even to the smallest devices," and that low-power devices with limited processing capabilities should be able to participate in the Internet of Things. This applies to sensors and devices on the plant floor. ISA 100 is built with full compatibility with 6LoWPAN. Wireless HART is not. While WIreless HART preceded ISA 100 and has a larger installed base, Wireless HART is not able to be part of a true IP-based IIoT solution. Wireless HART is based on node addressing, not IP addresses. Also, the built-in security of ISA 100 is suitable for internet connectivity; Wireless HART does not provide the necessary level of security to be internet-resident. I imagine in future releases, both protocols will improve, but in my opinion, only ISA 100 is IIoT ready today. I like Wireless HART for plant-level sensor networks, but for full IIoT, I will need a 6LoWPAN enabled protocol like ISA 100.

@piusutar1238 3 жыл бұрын

Hi thanks for this video ...one query ...what is the difference between wireless HART and wireless ISA 100 NETWORK ?...

@realpars 3 жыл бұрын

Hi there, Thanks for your comment! That would make for a great topic suggestion for future video courses. I will make sure to pass this on to our course developers. Thanks for sharing and happy learning!

@phuocquangvinhtruong9853 3 жыл бұрын

Easy to understand.

@realpars 3 жыл бұрын

Great to hear that, thanks for sharing!

@amitjagtap1716 3 жыл бұрын

How is the reliability ensured in iiot ??

@realpars 3 жыл бұрын

Excellent question! ISA 100 devices use Duocast technology, a wireless redundant communication system standard where each field device simultaneously sends the same data to two designated access points, ensuring uninterrupted communication in the event that one of the points experiences any problem . Other features of ISA 100, like its mesh network design, advanced frequency hopping, and fully redundant architecture, add to its reliability and ensure a deterministic communication path. Every ISA 100 device must pass rigorous testing by the ISA 100 Compiance Institute, ensuring that the device's design will meet the reliability standards.

@sporkybutterz 3 жыл бұрын

Isa100 operates on the 2.4 GHz band...how is interference and noise handled in terms of degradation and error correction? Someone suggested 900MHz bands as a solution but there are issues with using those bands as well including security. Are these tested for exploits?

@realpars 10 ай бұрын

Thank you for your question, and our apologies for the delay in our response! Every wireless system and company-specific model comes equipped with its own security and protection mechanisms, which vary depending on the manufacturer and the specific type of device you choose. I'd advise you to thoroughly review the user manual of the device before making your selection to ensure it aligns with your design specifications.

@cyberlads28 3 жыл бұрын

Can you please explain the breaking resistor operation in a Vsd and DC breaking we need a little clarification

@realpars 3 жыл бұрын

Hey! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

@cyberlads28 3 жыл бұрын

@@realpars I appreciate you guys You are changing people’s lives and we will start subscribing to your site for more information

@alexfed2680 3 жыл бұрын

One jamming device will stop your refinery business until you find it.

@Ryarios 3 жыл бұрын

They have their place, but yeah, I wouldn't put any critical control on wireless if I had another option...

@koeksoda 2 жыл бұрын

any wire cutter or pipe fitter can do equal damage...

@omarelkhamlichi1007 6 ай бұрын

Thinks ❤

@nikolaydubina 3 жыл бұрын

Battery requirement looks odd. How come can not feed industrial network with electricity all the time? For reliability, also TCP guarantees delivery over non-reliable channels. Or is this video about link level network?

@realpars 3 жыл бұрын

Battery replacement is based on the manufacturer's design and typically takes 2 minutes or less. Improvements in battery design make replacement less frequent (~2-5 years). You could wire power to the instrument so that it has a constant source of power, but that would defeat the whole purpose of wireless systems, cost much more to install and maintain, and really not provide any better reliability (no immunity to power outages).

@sandeepkumarmahto2579 3 жыл бұрын

Can you make a video on universal motor controller.

@realpars 3 жыл бұрын

Hi Sandeep! Thanks for your comment and your suggestion. I will pass this on to our course developers! Thanks for sharing and happy learning!

@anplechen 2 ай бұрын

It's a great topic I agree, but I still don't understand how reliability is achieved?

@realpars 2 ай бұрын

Thank you for your question. When it comes to reliability, industrial-built components stand out compared to typical consumer-grade ones found at home. They're designed with a focus on durability, often featuring military-grade housing, electronics, and high IP ratings, among other robust standards. This construction ensures they can withstand the demands of industrial environments, as highlighted in our video segment on reliability (part 3). Additionally, the communication protocols used in industrial wireless networks prioritize the reliability and accuracy of data transmission, crucial for seamless operations.

@shuxratbekrustamov9124 3 жыл бұрын

hello please the black captions at the bottom of the video are spoiling the video

@realpars 3 жыл бұрын

Thanks for the feedback! If you mean the KZfaq caption, you can easily disable that in the video player! ;)

@21LOLxPRO 3 жыл бұрын

Lora comunication is used iot sistem very low power and long sistem but possible integration wifi and or 4g for emergency application

@fengjiang9125 3 жыл бұрын

I really want to know how to make such great video, what software be use , Ppt?

@realpars 3 жыл бұрын

Hi Feng, Thanks for your comment! I am actually not sure about this as this is done by our graphic and animation department.

@philpeko1796 3 жыл бұрын

@@realpars Then, may we know if you could ask you graphic and animation department and come back to us with the answer? This should be quick and simple. TIA.

@didikwahono4728 3 жыл бұрын

Subtitel indonesia please

@realpars 3 жыл бұрын

Hi Didik, Thanks for your comment! We currently only provide our course videos in English, you are always able to turn on the English subtitles as that might make it a bit easier for you. Our apologies for any inconvenience! Happy learning!