Did you know that by 2028, the global industrial communication market is projected to hit $28 billion? Industrial communication protocols play a significant role in enabling real-time communication for Industry 4.0 and IIoT systems, enhancing their capacity, speed, reliability, and compatibility. Continue reading this article to gain insights into these protocols and understand how they can assist in optimizing your operations.

What Are Industrial Communication Protocols?

Imagine a crowded city where everyone speaks a different language. It would be chaotic, wouldn’t it? This is similar to what happens with our digital devices and software systems when they lack communication protocols.

Essentially, an industrial communication protocol is a set of rules that manage the data exchange between network devices and software systems. These protocols detail the syntax, restrictions, procedures, error recovery methods, and synchronization of communication, acting as the guiding principles for data exchange.

These protocols can be thought of as the programming languages for networks. As programming languages use syntax to create a standard for computation processes, communication protocols establish how network devices should interact. Alternatively, you could consider them akin to algorithms.

In industrial automation, these protocols are practical and in use; they are applied in both hardware and software solutions, and often in a combination of both. Comprehending them is important for maintaining efficient operations in an industrial setting that is becoming more interconnected. Let’s delve deeper into understanding the language of industrial communication protocols.

Two Common Types of Messaging Patterns in Industrial Communication Protocols

Network communication protocols, especially in the industrial sector, use structured patterns for data exchange. Two messaging patterns that are most frequently used are the “request-response” and “publish-subscribe” models.

The Request-Response Pattern

Picture a manufacturing shop floor where several machines are operating simultaneously. A specific machine might need data or services from another device. For example, a robot arm on an assembly line may need information from a sensor about whether a part is correctly aligned. The robot arm sends a request to the sensor, which responds with the needed data. This interaction mirrors the request-response pattern.

The Publish-Subscribe Pattern

Consider a scenario where multiple devices need to receive the same updates. For instance, a central control system (publisher) in a factory might monitor temperature conditions and publish this data. Several cooling systems (subscribers) throughout the factory might need this information to adjust their operations accordingly. Instead of sending the data to each cooling system individually, the control system sends it to an intermediary node, which then distributes the data to all subscribed cooling systems. This exemplifies the publish-subscribe pattern.

These two patterns are critical in facilitating efficient data exchange in industrial settings, ensuring all devices and systems can interact seamlessly.

What Are Some of the Different Industrial Communication Protocols?

There are dozens of protocols being used to ensure that machines and systems can talk to each other effectively. Among these, some stand out due to their widespread usage and reliability in various industrial environments. The most common ones include Ethernet/IP, Profibus, Modbus, OPC Unified Architecture, FANUC FOCAS, LSV/2, IO-Link, and UMATI.

• Ethernet/IP: This open standard protocol, often used with Allen-Bradley PLCs, is highly popular among different PLC brands, including Omron. Known for its versatility and robustness, Ethernet/IP allows industrial devices to exchange large volumes of high-speed data.
• Profibus: This is a standard for fieldbus communication in automation technology and was first promoted by Siemens. It plays a pivotal role in applications where data needs to be exchanged rapidly and with a high degree of reliability.
• Modbus: With its roots in the early days of industrial automation, Modbus is admired for its simplicity. It offers several protocol options, but Modbus RTU (Remote Terminal Unit) and Modbus TCP/IP (Transmission Control Protocol) are the most commonly used variants.
• OPC Unified Architecture: This protocol, developed by the Object Management Group, provides a secure and reliable cross-platform framework for access to real-time and historical data and events.
• Wireless Protocols: Among wireless technologies, WLAN holds the most significant market share in industrial communication. It’s followed by Bluetooth and other wireless technologies, which are gaining traction for their convenience and ease of deployment.
• FANUC FOCAS: This protocol is a set of libraries provided by FANUC Corporation, which allows the exchange of information between FANUC CNCs and software applications. It simplifies the connectivity of third-party hardware or software to FANUC CNCs. FOCAS is a standard protocol for collecting data from FANUC CNC machines, making it widely adopted in many machine tool factories.
• LSV/2: This is a common protocol used to communicate with CNC machines. It’s primarily used in Germany and other parts of Europe, and it’s starting to gain wider acceptance in North America as well.
• IO-Link: This is a powerful point-to-point communication protocol for linking sensors and actuators to an automation system. It allows the reading and writing of data from/to sensors and actuators, providing more detailed device diagnostics and simplifying parameterization.
• UMATI: The Universal Machine Tool Interface (UMATI) is an open standard for machine tool communication. This protocol aims to unify communication between machines and software, regardless of the manufacturer.
• Profinet is an industry-standard protocol for data communication over Industrial Ethernet, developed by Profibus International (PI). It’s known for its real-time capabilities and robustness, making it ideal for demanding industrial applications.
• HART (Highway Addressable Remote Transducer Protocol) is a widely used communication protocol in process automation for transmitting additional measurement data and diagnostics along with the main variable, thus providing smart device functionality.

Why Do We Have Different Industrial Communication Protocols?

Consider this: Every industry has unique needs and challenges. A protocol that works well in a power plant might not be the best fit for a car manufacturing assembly line. The various requirements of different industries have led to the development of a range of protocols tailored to meet specific needs.

For instance, some protocols are designed to handle large amounts of data quickly and efficiently (Ethernet/IP or Profinet), making them ideal for industries where speed is crucial. Others prioritize reliability and robustness over speed, which is vital in sectors where precision and safety are paramount (Modbus or HART).

Moreover, the history and evolution of industrial automation have also played a part in shaping the landscape of communication protocols. As technology advanced, new protocols were developed to leverage these innovations. Older protocols were adapted or phased out, but some have managed to stick around due to their simplicity, reliability or wide acceptance in specific industries.

While it might seem complicated, the diversity of industrial communication protocols is actually a strength, giving industries the flexibility to choose the one that best fits their unique needs and challenges.

Most Commonly Used Communication Protocol

Modbus enjoys the status of being the industrial protocol with the most extensive adoption. Originally formulated in 1979 by Modicon for its programmable logic controllers (PLCs), it has since been managed by the Modbus Organization. The key to Modbus’s widespread acceptance lies in its open standard nature, simplicity of implementation, and broad vendor support.

Modbus comes in several variations, with Modbus RTU and Modbus TCP/IP being the most prevalent. Modbus RTU, in particular, is recognized for its frequent use due to its balance of simplicity and efficiency, while Modbus TCP/IP is noted for its seamless integration with modern network technologies.

50+ Different Industrial Communication Protocols

There is a wide variety of industrial protocols used to facilitate communication between devices. This list includes many of them, but please note that it’s not exhaustive:

What You Should Do Next

Explore the Shoplogix Blog

Now that you know more about industrial communication protocols, why not check out our other blog posts? It’s full of useful articles, professional advice, and updates on the latest trends that can help keep your operations up to date. Take a look and find out more about what’s happening in your industry. Read More

Request a Demo

Learn more about how our product, Smart Factory Suite, can drive productivity and overall equipment effectiveness (OEE) across your manufacturing floor. Schedule a meeting with a member of the Shoplogix team to learn more about our solutions and align them with your manufacturing data and technology needs. Request Demo

FAQs