How new automation technologies shape industrial networking trends

 

Cybersecurity Insights

• Advanced networking protocols like TSN and EtherCAT enable faster, more reliable data transfer in industrial environments.
• Cybersecurity-certified switches and IDS and IPS capabilities are essential to protect industrial networks from evolving cyber threats.

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As industries embrace digital transformation, the role of networking infrastructure has become more critical than ever. Traditionally, industrial networks served as isolated environments, primarily responsible for enabling basic communication between devices and systems. Today, they must support a vast array of connected devices, handle real-time communication and defend against ever-evolving cyber threats. With automation, remote monitoring and data-driven decision-making as the pillars of modern industrial operations, networking solutions must be designed to accommodate these demands securely and efficiently.

Key trends such as the IIoT, AI, Industry 4.0, and 5G are pushing industrial networks toward a new era, one in which networks are not only responsible for transmitting data but also for processing, analyzing and protecting it. This transition highlights the need for resilient networks capable of handling high-speed, low-latency data transmission and advanced cybersecurity requirements. As a result, emerging networking protocols and enhanced cybersecurity measures have become central components of modern industrial network infrastructure.

AI and IIoT: Driving demand for real-time, data-intense networks

The integration of AI and IIoT has transformed the industrial sector, enabling real-time insights, predictive maintenance and autonomous operations. IIoT connects devices and sensors, producing a continuous stream of data that helps organizations monitor equipment health, optimize performance and minimize downtime. AI then processes this data, for example, applying machine learning algorithms to identify patterns and detect anomalies before issues arise.

The combination of AI and IIoT increases the data volume, velocity and variety within industrial networks. To accommodate these demands, networks must have sufficient bandwidth and low-latency capabilities to support real-time data processing. Furthermore, as IIoT devices proliferate, security risks increase. Each connected device becomes a potential entry point for cyber threats. In this environment, network resilience and cybersecurity become mandatory, and solutions must be designed with both performance and security in mind.

Industry 4.0 and 5G: Enabling the smart factory

Industry 4.0 represents a major shift toward smart, interconnected systems within manufacturing and other industrial sectors. It encompasses the use of automation, data exchange and IIoT to create a more agile, efficient and responsive industrial environment. 5G networks, with their high-speed, low-latency capabilities, are integral to the Industry 4.0 landscape, enabling seamless connectivity between a wide range of devices and applications.

Given 5G’s potential to support ultra-reliable low-latency communication (URLLC) and massive machine-type communication (mMTC), it is well-suited for industrial applications where split-second decision-making and device density are essential. With 5G, industrial networks can achieve real-time automation, which is critical for processes such as autonomous robotics, real-time quality inspection, and augmented reality for maintenance.

As Industry 4.0 and 5G converge, the infrastructure supporting industrial networks must be able to scale rapidly and manage the significant data traffic generated by these technologies. Additionally, 5G introduces new security challenges, as its extensive reach and connectivity capabilities create additional attack vectors. Consequently, integrating advanced cybersecurity protocols within 5G-enabled industrial networks is essential to mitigate these risks.

Advanced networking protocols: The backbone of future industrial networks

With the increase in connected devices and real-time data demands, industrial networks require protocols capable of ensuring timely, reliable communication. Traditional Ethernet, though widely used, often falls short in addressing the specific requirements of industrial environments, particularly in terms of latency and determinism. Newer protocols like Time-Sensitive Networking (TSN), EtherCAT and Ethernet-APL are emerging as critical enablers of industrial automation, offering the features and flexibility necessary for modern applications.

Time-Sensitive Networking (TSN)

TSN is a set of IEEE standards that enhances Ethernet to support real-time communication. By ensuring deterministic data delivery, TSN guarantees that critical data packets arrive on time, making it ideal for applications where latency and jitter must be minimized, such as robotic control and process automation — though, realistically, any application can benefit from this level of determinism. TSN also supports traffic shaping and prioritization, allowing various types of data to coexist on a single network without compromising performance

EtherCAT

EtherCAT, a high-performance Ethernet protocol, is widely used in applications requiring ultra-fast communication, such as motion control and precision manufacturing. Unlike traditional Ethernet, EtherCAT processes data on-the-fly, which reduces latency and increases network efficiency. This capability is especially valuable in applications where rapid data exchange between devices is critical to maintaining operational speed and accuracy.

Ethernet-APL

Ethernet Advanced Physical Layer (Ethernet-APL) is designed to enable Ethernet connectivity in hazardous and explosive environments, such as oil and gas or chemical processing. By providing two-wire Ethernet connectivity with power and data transmission capabilities, Ethernet-APL enables seamless integration of field devices into industrial networks. This protocol is transforming industrial networking by allowing real-time communication at the device level, even in challenging environments.

The growing importance of cybersecurity in industrial networks

As industrial networks expand and become more interconnected, they also become more vulnerable to cyber threats. Traditional IT security measures, such as firewalls and antivirus software, are often insufficient to protect industrial networks, which have unique security and reliability requirements. The shift toward IIoT and Industry 4.0 has highlighted the need for comprehensive cybersecurity strategies that address both IT and operational technology (OT) environments.

Intrusion Detection Systems (IDS) and Intrusion Prevention Systems (IPS)

Intrusion Detection Systems (IDS) and Intrusion Prevention Systems (IPS) are becoming more popular in industrial networks, providing real-time monitoring and threat response capabilities. IDS continuously monitors network traffic, identifying and alerting administrators to potential security threats, while IPS takes proactive measures to block malicious activity.

In the context of industrial applications, IDS and IPS must be designed to handle the unique traffic patterns and protocols used in these environments. For instance, IDS must be capable of monitoring protocols specific to industrial control systems (ICS) without generating excessive false positives. This requires cybersecurity solutions that are specifically tailored for industrial networks and comply with standards like IEC-62443, which provides guidelines for securing OT environments. It is important to note that historically, IPS (Intrusion Prevention Systems) did not perform well in industrial environments, partly due to limited expertise in industrial protocols and inadequate training of AI engines with the specific traffic required — resulting in a classic case of “garbage in, garbage out.” This problematic combination led to incidents in the past, creating higher resistance to IPS usage in the market. While technology has evolved in recent years, it has not entirely eliminated the need for proper training and industrial-specific solutions.

Companies like Moxa can now confidently offer solutions that help customers deploy IPS effectively. However, IPS is not universally recommended; it should be applied selectively to use cases where it truly adds value. When carefully implemented, it can be a powerful ally in industrial cybersecurity

Multi-site management and centralized security

As industrial networks grow in scale and complexity, multi-site management tools are becoming essential for overseeing cybersecurity across multiple locations. Centralized security management allows organizations to monitor, configure and enforce security policies consistently across all sites, ensuring that even remote facilities maintain high standards of protection.

These tools provide real-time visibility into network performance and security status, enabling faster incident response and simplifying compliance with regulatory requirements. In addition, centralized management helps streamline the deployment of patches and updates, which are critical for defending against emerging threats. By investing in multi-site management solutions, organizations can reduce the complexity of managing security across diverse industrial networks, improving both efficiency and security.

Preparing for the future: Building resilient, scalable industrial networks

Looking forward, industrial networks must evolve to support the increasing demands of IIoT, AI, Industry 4.0 and 5G. This evolution will require networks to be more robust, secure and capable of handling real-time data transmission. Implementing advanced networking protocols like TSN, EtherCAT and Ethernet-APL, along with comprehensive cybersecurity measures, will be essential for achieving these objectives.

To build resilient networks, organizations must adopt a holistic approach to industrial networking, considering not only performance but also scalability, reliability and security. As the number of connected devices continues to rise, network architectures must be designed with flexibility in mind, enabling future expansion without compromising current operations.

The integration of AI and machine learning into industrial networks will further enhance network resilience by enabling predictive maintenance, anomaly detection, and automated threat response. As these technologies mature, they will allow networks to adapt in real-time, responding to changes in traffic patterns and detecting potential security risks before they escalate.

Shaping the future of industrial networking

The future of industrial networking will be shaped by technologies such as AI, IIoT, Industry 4.0 and 5G, along with the continued development of advanced networking protocols and cybersecurity solutions. By adopting these technologies, industrial networks can become more efficient, resilient and secure, capable of meeting the demands of increasingly complex and interconnected environments.

To remain competitive in the digital age, organizations must invest in networking infrastructure that not only meets today’s requirements but also prepares for the future. Advanced protocols like TSN, EtherCAT and Ethernet-APL, coupled with robust cybersecurity measures such as IDS, IPS and multi-site management, will be key to building networks that support the next generation of industrial applications.

 

Felipe Sabino Costa is a cybersecurity director and an official ISA/IEC 62443 industrial cybersecurity instructor at both ISA and EC-Council. He is the senior product marketing manager at Moxa Americas.