Industrial Networking
Reliable Industrial Networks for Connected Automation Systems
Modern industrial automation depends on reliable communication. PLCs, remote I/O, HMIs, SCADA systems, Variable Speed Drives and production equipment increasingly need to exchange information across industrial networks for machinery and processes to operate effectively.
When industrial communication becomes unreliable, the effects can range from intermittent device faults and lost production data to complete machine or process stoppages.
Stratos provides industrial networking services for manufacturing and automation environments, helping businesses design, integrate, troubleshoot and modernise the communication infrastructure connecting their control systems.
Whether you're introducing new automation equipment, integrating existing systems or investigating recurring communication faults, our engineers consider the network as part of the wider industrial control environment.
What Is Industrial Networking?
Industrial networking is the communication infrastructure that allows automation devices and control systems to exchange information.
An industrial network may connect:
PLCs.
Remote I/O.
HMIs.
SCADA systems.
Variable Speed Drives.
Motor control equipment.
Instrumentation.
Industrial computers.
Production machinery.
Other control systems.
Unlike conventional office networks, industrial networks often support time-sensitive communication that directly affects the operation of physical equipment and production processes.
Reliability, availability and appropriate network architecture are therefore particularly important.
PROFINET Industrial Networks
PROFINET is widely used within industrial automation, particularly across Siemens-based control environments.
A PROFINET network may connect equipment such as:
Siemens PLCs.
Distributed I/O.
HMIs.
Variable Speed Drives.
Industrial switches.
Instrumentation.
Machine control systems.
Other compatible automation devices.
Stratos can support the design, integration and fault finding of PROFINET networks as part of wider PLC and automation projects.
Network configuration should consider device addressing, topology, communications and how the system will be maintained as equipment is added or changed.
PROFIBUS Networks and Legacy Systems
EtherNet/IP is commonly used within industrial automation environments and is particularly associated with Rockwell Automation and Allen-Bradley control systems.
EtherNet/IP networks can connect:
PLCs.
Remote I/O.
HMIs.
Drives.
Industrial devices.
Machine systems.
Network infrastructure.
Reliable configuration is important because industrial Ethernet networks can carry significant amounts of automation data between equipment.
Stratos can consider EtherNet/IP communication alongside the PLC software, devices and machinery relying on the network.
Modbus TCP and Modbus RTU Integration
Modbus remains widely used for communication between industrial automation equipment.
Depending on the application, systems may use:
Modbus TCP over Ethernet.
Modbus RTU over serial communication.
Modbus may be used to connect:
PLCs.
Variable Speed Drives.
Energy meters.
Instrumentation.
HMIs.
Third-party machinery.
Building or process equipment.
Integration requires correct configuration of device addresses, data registers, communication settings and how information is interpreted by the PLC or supervisory system.
PLC and Industrial Network Integration
PLCs frequently sit at the centre of industrial communication architectures.
A PLC may exchange information with numerous devices across several communication technologies.
This can include:
Remote I/O.
Drives.
HMIs.
SCADA systems.
Other PLCs.
Instrumentation.
Safety systems.
Production equipment.
Network architecture and PLC programming therefore need to be considered together.
A communication problem may appear to be a PLC fault when the underlying cause is actually network configuration, cabling, device communication or another connected component.
SCADA and HMI Network Integration
SCADA and HMI systems depend on reliable communication with PLCs and industrial equipment.
Communication problems can result in:
Missing process values.
Lost equipment status.
Delayed information.
Communication alarms.
Inaccurate dashboards.
Missing historical data.
Loss of supervisory visibility.
Industrial networking therefore forms an important part of successful SCADA integration.
Stratos can assess the communication path between field equipment, PLCs and supervisory systems to identify where reliability or architecture can be improved.
Industrial Network Fault Finding
Intermittent industrial network problems can be particularly disruptive because equipment may operate correctly for long periods before communication fails again.
Symptoms may include:
Devices intermittently disappearing.
PLC communication faults.
Remote I/O failures.
Drive communication errors.
SCADA communication alarms.
Slow network response.
Repeated device reconnections.
Unexplained production interruptions.
Effective fault finding involves considering the network alongside the devices and control software using it.
Rather than simply resetting equipment, the objective is to identify the underlying reason communication is becoming unreliable.
Industrial Networking and Control Panels
Network infrastructure is often physically distributed through industrial control panels.
As a control panel manufacturer, Stratos can incorporate industrial communication requirements into the wider electrical and automation design.
This may include:
Industrial Ethernet switches.
PLC network interfaces.
Remote I/O.
Communication gateways.
Network power supplies.
Device connections.
Cable management.
Network segregation.
Equipment labelling.
Considering networking during control panel design helps ensure communication hardware is appropriately integrated, accessible and documented rather than added as an afterthought.
Network Segmentation and Industrial Cyber Security
Increasing connectivity between industrial systems makes network architecture an important part of OT cyber security.
Not every device or system needs unrestricted communication with every other part of the organisation.
Industrial network design may therefore consider separation between:
PLC networks.
SCADA systems.
Production areas.
Engineering workstations.
Remote access systems.
Corporate IT infrastructure.
Third-party equipment.
Appropriate segmentation can reduce unnecessary communication paths while still allowing required production information to move between systems.
This becomes particularly important where industrial networks support remote monitoring, reporting or connections between IT and OT environments.
Industrial Network Maintenance and Modernisation
Industrial networks change as production equipment is replaced, new machines are introduced and automation systems are upgraded.
Over time, this can create inconsistent configurations, undocumented connections and ageing network equipment.
Network maintenance may consider:
Communication health.
Network equipment condition.
Device configuration.
Obsolete hardware.
Cabling and connections.
Network documentation.
PLC communications.
SCADA connectivity.
Future expansion requirements.
Where ongoing support is required, maintenance and service contracts can incorporate industrial network checks alongside PLC, SCADA and control system maintenance.
Older communication infrastructure can also be incorporated into a phased modernisation strategy, allowing higher-risk areas to be addressed first.
Why Choose Stratos for Industrial Networking?
Industrial networking cannot be treated independently from the automation systems using it.
A communication problem may involve the PLC program, network hardware, remote I/O, a drive, SCADA configuration or the physical infrastructure connecting the devices.
Stratos combines PLC programming, SCADA engineering, control panel design and industrial automation expertise to investigate and develop networks within the context of the complete control system.
Whether you're designing a new automation network, integrating additional equipment, modernising legacy communications or investigating recurring network faults, our engineers can develop a practical solution around your existing production environment.
Build a More Reliable Industrial Network
Your automation system is only as connected as the network supporting it. Stratos provides industrial networking services covering PLCs, SCADA, remote I/O, drives and production equipment, helping manufacturers improve communication reliability, integrate new systems and diagnose recurring network faults.
Speak to our engineers about industrial network design, integration, fault finding or modernisation.
Frequently Asked Questions
What is an industrial network?
An industrial network allows PLCs, HMIs, SCADA systems, drives, remote I/O and other automation equipment to exchange operational information across a manufacturing or production environment.
Which industrial communication protocols do you support?
Industrial automation systems may use technologies including PROFINET, PROFIBUS, EtherNet/IP, Modbus TCP and Modbus RTU. The appropriate approach depends on the existing equipment and automation architecture.
What causes industrial network faults?
Network faults can be caused by configuration problems, cabling, connectors, ageing hardware, failed devices, communication settings, network architecture or problems with connected automation equipment.
Can older industrial networks be upgraded?
Yes. Legacy communication systems can often be modernised as part of PLC, SCADA or wider control system upgrades. A phased approach may be appropriate where immediate replacement of the complete network is impractical.
Why is network segmentation important for industrial automation?
Segmentation can help control communication between different automation systems, production areas and IT infrastructure. This can improve network structure and form part of a wider industrial cyber security strategy.