Industry 4.0 and wireless communication
It has been over ten years since the term “Industry 4.0” was first introduced at the Hannover Fair in 2011. Since then, the concept has established itself as the guiding paradigm in the digital transformation of the manufacturing sector, bringing with it new communication protocols — including EtherNet/IP, RFID and Bluetooth — and a growing integration of smart technologies in production facilities.
In this context, wireless serial communication is becoming an essential element. Modern industrial networks share a common goal: reducing physical connections, simplifying maintenance and improving device monitoring on the factory floor.
The most affected sectors include automotive assembly lines, electronic component manufacturing and any industrial process involving rotary tables or robotic systems — contexts in which cable routing has historically been one of the main operational bottlenecks.
The benefits of wireless systems are invaluable in industries that regularly use cable-connected control applications for communication systems.
Automation and productivity: a modern necessity
Since the second half of the 20th century, automated systems have become the backbone of manufacturing industries. Pneumatic rotary tables, Cartesian manipulators, industrial robots for welding and assembly: these technologies are today fundamental in automotive, electronics and many other sectors.
Control systems and automated systems share two key requirements:
Increasing productivity
Every minute of unplanned downtime has a direct impact on revenue. Operational continuity is a non-negotiable requirement.
Communicating data effectively
Without a reliable data flow between field devices and control systems, no automation can perform to its full potential.
Market data: According to the International Federation of Robotics (IFR), in 2018 422,000 industrial robots were sold worldwide, exceeding McKinsey’s forecasts. Estimates pointed to a further increase of up to 630,000 units by 2021. Every new robot brings with it new cabling and interference management challenges.
Cables: types and challenges
In modern industrial environments, two main categories of cables are used for data transmission. Both offer significant advantages, but also have intrinsic limitations that become critical in high-dynamic applications.
Copper Cables
Up to 100 m · Max ~1 Gbps
+ Low cost and easy installation
+ Reliable with adequate shielding
− Low transmission capacity (problematic for Industry 4.0)
− Spark risk: not suitable for oil & gas environments
− Susceptible to electromagnetic interference (EMI) if unshielded
Fibre Optic (FO)
Up to 2 km · Max 10 Gbps
+ Speed up to 10 Gbps (500 m), 100 Mbps (2 km)
+ Immune to electromagnetic interference
+ No spark risk, safe in hazardous environments
− Higher costs and specialist installation required
− Extremely sensitive to torsion (rotary applications)
The critical issue common to both cable types is the limitation in dynamic movement contexts: in applications with rotary tables and industrial robots, cables undergo continuous torsion that causes signal attenuation, disconnections and breakages. This results in frequent maintenance interventions, unplanned downtime and high operating costs.
Operational issues: cable-related problems
The use of communication cables in industrial environments generates three recurring categories of problems, with direct impacts on costs, safety and plant flexibility:
Constant maintenance
Cables in rotary or control applications are prone to disconnections, mechanical damage and breakage. This generates high replacement costs, lost working hours and both planned and unplanned machine downtime.
Electromagnetic interference
Unshielded copper cables are vulnerable to EMI generated by electric motors and high-frequency power supplies, causing data loss, unreliable transmissions and component damage.
Poor flexibility
Cable routing requires careful planning and limits the ability to reconfigure plant layouts. Changes to the line involve long installation times and further machine downtime.
In environments such as industrial robotics, cabling is necessarily confined to predefined spaces. The inevitable proximity to high-voltage cables increases the risk of interference on communication signals, with consequences for data quality and equipment reliability.
To address these limitations, companies face a costly choice: invest in expensive rotary connectors or additional flexible cables that, over time, replicate the same problems. The only structurally effective solution is the adoption of certified industrial wireless systems.
SMC technology: the solution — Wireless System EX600-W / EXW1
To meet the growing demands of modern industries, SMC Corporation has developed the EX600-W / EXW1 system: a decentralised wireless fieldbus designed to eliminate communication cables in the most critical applications, without compromising reliability or performance.
SMC EX600-W / EXW1
Decentralised wireless serial interface system for cable-free industrial communication.
Frequency Band
2.4 GHz
Industrial ISM band
Operating Range
10 m
Max base-to-remote distance
FHSS Technology
79 channels
Frequency hop every 5 ms
Latency
250 ms
Communication cycle time
Remote Units
up to 127
Per base unit
Protocols
EtherNet/IP
Also Profinet
Key technical features
EMI interference resistance:
The 2.4 GHz ISM band, combined with FHSS across 79 channels, operates outside the standard noise range of industrial installations (5 MHz – 1 GHz), ensuring stable communication even in environments with welding and motor drives.
Decentralised point-to-multipoint communication:
The base unit controls up to 127 remote units, each assignable to analogue, digital and pneumatic modules for I/O and valve control.
Data encryption:
Transmission is encrypted and protected against external interception and interference, ensuring signal integrity and security.
Fast integration:
The system integrates with existing configurations via standard Ethernet connection. Each base unit has its own IP address.
Modularity and scalability:
Compact and modular design — remote units mount directly onto robots, rotary tables and mechanical arms with no additional cabling required.
Outlook: future-proof
As Industry 4.0 enters its maturity phase, the demand for reliable wireless technologies will continue to grow. Experience gained in the European industrial sector clearly indicates that flexibility, availability and durability are now essential requirements in modern communication systems.
Wireless systems like the EX600-W have overcome the issues traditionally associated with industrial wireless — interference, latency, security — and today represent a structurally superior solution compared to traditional cabling, which has historically limited plant performance and scalability.
Companies adopting the EX600-W wireless system do not only solve immediate operational problems: they equip themselves with a communication infrastructure ready to embrace the future evolution of industrial automation.
The challenges faced by SMC customers in the automotive, sub-assembly and food & beverage sectors are the same ones encountered daily by companies across every production segment. What makes the difference is the technological quality of the system and the specialist technical support — elements that BSA Italia makes available to guide every customer towards the optimal solution.
Want to eliminate cables from your plant?
Discover how the SMC EX600-W wireless system can reduce maintenance costs, increase plant availability and improve your OEE value.
Contact our experts for a personalised technical assessment.
