Process industries and other manufacturing industries are introducing digital technologies to further improve production efficiency. As a core technology, wireless communication that provides connectivity wherever it is deployed is becoming increasingly important. At the same time, wireless communication needs to meet the needs of a variety of applications, which is becoming increasingly challenging.
01 Overview of 5G communication features
After 3G and 4G/LTE, "5G" is the fifth generation of mobile communication systems. While these generations of systems have been developed more for personal communication services, 5G can also be used for Internet of Things (IoT) network infrastructure, which will connect all devices and objects in everyday life, manufacturing and other industries.
Three features of 5G communication and their practical applications.
● Enhanced mobile broadband
5G is focused on increasing the data throughput of broadband wireless communications, which has been enhanced in previous generations. Broadband services for smartphones and other mobile devices are a prime example of taking advantage of this feature.
● Ultra-reliable low-delay communication
5G is designed to enable highly reliable, low-latency and real-time wireless communication.
● Large-scale machine communication
This feature means that many low-traffic terminals are connected simultaneously.
02 Dedicated spectrum in 5G
With most existing wireless communication technologies, this unlicensed spectrum can be used for a variety of scenarios with an unlimited number of users. However, there is a risk of interference between different wireless systems on the same frequency band.
03 Operating Private Network (Local 5G)
Existing mobile communication systems are usually designed to provide a wide range of communication services in a nationwide network established by a mobile network operator.
04 International standardization of 5G
In some countries, companies and local governments are expected to build and operate their own dedicated 5G networks. After obtaining a license, local operators can exclusively use these bands within their region.
5G is expected to be used in the traditional mobile communications industry and many other industries. The inclusion of new requirements for industrial applications is an important factor in the successful development of standards. Major companies from the manufacturing and telecommunications industries are actively participating and exploring the application of 5G technology in the manufacturing industry.
05 Five potential applications in the process industry
In the manufacturing sector, the communication requirements for different field applications vary, and as mentioned earlier, 5G is expected to be used as a wireless infrastructure capable of introducing a variety of wireless factory applications. In addition, those applications that best leverage 5G's communication features are being developed to facilitate digital remote operations in manufacturing.
1. On-site operation support for mobile devices
Mobile devices are being deployed to the field to increase productivity, and current network coverage and field bandwidth limitations limit application support via wireless communication. 5G will enable broadband wireless communication at higher speeds and lower latency in any area of the factory.
Augmented reality (AR) is one of the application scenarios of 5G enhanced mobile broadband. Although AR requires a lot of data, it can superimpose high-definition images on the target device and display them in real time on the worker's tablet or wearable terminal device, providing an intuitive solution. Field workers can operate the target equipment while referencing the superimposed work procedures, or share images in real time with technicians in remote locations and get specific recommendations. It not only helps to improve the efficiency, reliability and safety of field work, but also can pass on skills more effectively through practice.
2. Remote monitoring with high-definition images
5G has more capacity than the previous generation of 4G/LTE, especially in terms of uplink communications. This makes it possible to stream video in 4K or higher resolution in real time. In factories, one potential use is the use of wireless cameras for remote monitoring. When the clarity of the image is high enough to distinguish subtle changes in the color of the liquid surface or corrosion of the pipe, visual inspection can be carried out remotely. High-resolution images can also be used as input for AI analytics, which can automatically detect anomalies such as unauthorized human intrusion or situations such as fires.
3. Cloud robots
As the working population shrinks, mobile robots are expected to ensure that factories operate safely and reliably. Robots move autonomously throughout the factory, taking the place of workers to patrol dangerous areas. Drones can perform high-altitude work, which can be dangerous for workers. "Cloud robotics" is emerging as a promising technology. Because control functions in the cloud are not limited by the computational performance of the robot, advanced control functions can be deployed.
Utilizing its high-speed and high-capacity properties, 5G enables mobile robots to wirelessly connect to control functions in the cloud in real time. Use massive computing resources in the cloud and process large amounts of sensor data in real time. The ultra-reliable and low-latency features offered by 5G allow it to be used for emergency, time-sensitive communications, which can avoid events such as collisions between robots and mobile process equipment.
4. Wireless/cloud control system
Existing wireless technology cannot achieve high reliability and low latency at the same time, but it can be achieved with 5G. This makes 5G available for mission-critical applications. One possible application is to wireless part of a distributed control system (DCS) to reduce the cost of installing and maintaining communication cables across a wide plant area. Monitoring points can also be added and modified without any manipulation of the communication cables.
In addition, if 5G ensures highly reliable, low-latency communication between field devices and the cloud, controllers and other DCS functions can be configured in the cloud while maintaining mission-critical performance. In addition to external cloud systems, 5G can also be used with multi-access edge computing (MEC), which will build a low-latency computing platform in the network. When control applications are implemented on the MEC platform, cloud control services can be enabled to take full advantage of the high reliability and low latency of 5G without the need for the Internet or other networks.
5. Connected sensors for digital twins
The digital twin is the digital realization of the actual factory in cyberspace and is the foundation for the digital transformation of factory operations. Applications are not limited to static digital plant design information. Digital twins reflect real plant conditions in real time, enabling predictive maintenance and optimized operations through simulation and AI analytics.
To more precisely synchronize the state of physical and digital twins, companies must accurately understand the state of equipment, pipelines, and other assets, as well as weather and other conditions. To do this, the factory had to install many sensors. To meet this demand, each sensor must be wireless, inexpensive, and able to operate for years without having to replace the battery. 5G's ability to connect multiple devices at the same time is key to this application.
Potential 5G application cases in factories include support for mobile devices, remote monitoring, cloud robotics, wireless/cloud control systems, and enhanced sensor connectivity for digital twin optimization.
06 Status and challenges of industrial 5G applications
Despite the many potential application cases in the factory, 5G has yet to be widely implemented in the process industry. Industrial 5G applications still face many challenges.
In order to meet the needs of consumer and industrial applications, 5G must support multiple functions. The 5G standard is being developed in a phased manner with different priorities. R16 and later versions of the 5G standard include features that can be used for industrial applications. They enhance high-reliability, low-latency communications and private networks, and also support interoperation with time-sensitive networks (TSN), an essential networking technology in automation.
The capabilities of the industrial sector will be further enhanced in R18 and later (5G-Advanced) standards. While 5G offers advanced industrial capabilities such as high reliability, low latency, and multipoint simultaneous connectivity, further development of 5G standards, compliance products, and infrastructure are needed to support these capabilities.
Proof-of-concept test configurations use new algorithms and 5G to solve tough advanced process control challenges.
07 Proof of concept of remote control technology using 5G
While PoC is a promising step, further testing is needed to develop a clear commercial value for industrial 5G solutions. One possible solution is to deploy high-speed wireless communication edge devices in factories and use cloud-based autonomous AI technology to control the devices in real time.
08 5G and cloud-based autonomous control AI
The combination of FKDPP and cloud with 5G, which offers low latency and the ability to connect many devices, is expected to become the core technology to achieve industrial autonomous control.
Many industries are beginning to consider the use of 5G wireless communication technology to accelerate digital transformation. High reliability, low latency and the ability to connect multiple devices simultaneously are critical for industrial applications. In order to achieve a wider range of applications, it is necessary to continuously improve the 5G standard, provide more mature compliance products and infrastructure, and show users the unique advantages and value brought by 5G.
