How to Design Private Networks for Manufacturing

Private networks are part of critical infrastructure improvements in manufacturing. Private 4G/5G networks provide reliable connectivity to overcome coverage challenges in manufacturing facilities, like construction that often includes metal, concrete, screening, and pipework. Private networks for manufacturing provide secure and reliable communication between machines, allowing for automation and efficient data transfer.

By using private networks in manufacturing operations, industrial organizations can also benefit from improved performance and reduced costs. Security features, such as authentication and encryption, are key components of private networks, enabling secure communication and limiting the risk of cyber-attacks.

Additionally, with private networks, organizations can optimize their network infrastructure and customize it to their specific needs. Private networks also provide better control over network performance, allowing for higher data speeds and better coverage.

Manufacturing requires a sophisticated network infrastructure. This infrastructure often includes integration with operational technology like IoT and automation systems, as well as more conventional IT and telecommunication needs.

Manufacturing assets are also becoming more connected, data-driven and interconnected across broad supply chains. As the industry transforms there is an increased need for high-capacity and low-latency reliable connectivity. Accurate private networks in manufacturing can help enterprises avoid the extremely high costs of downtime and provide complete control of data assets.

Radio Frequency (RF) engineers and operations must work together to create the optimal private wireless network to guarantee the highest level of performance possible.

Designing a private wireless network in manufacturing environments requires careful consideration of the environment, power requirements, signal propagation characteristics, antenna placement, security measures, and other factors. It is essential to have a comprehensive understanding of all the components that make up a wireless system.

Often multiple technologies will be used in combination, with a variety of integration or gateway approaches needed to combine technologies like Citizens Broadband Radio Service (CBRS), 4G, 5G, or Wi-F-6/6E. iBwave offers certification programs for designing in-building wireless network projects, site surveys, and the fundamentals of testing. This article will provide an overview of the process needed to design private networks for use in manufacturing environments.

Determining Requirements

The first step in designing a private wireless network for manufacturing is to determine what type of system is required. Depending on the size and complexity of the project, different types of systems may be necessary.

It is essential to understand what types of devices will be connected to ensure that there are no compatibility issues when choosing hardware or software solutions.

You also must make sure that the designed network provides the required KPI’s (Key Performance Indicators) regarding signal strength, throughput and latency for all of those devices.

Devices and applications may include:

Proximity & Stop functions for worker safety.

Automation systems to control industrial production machinery.

Process monitoring

Automatic Guided Vehicles

Robotics for assembly and welding

Asset tracking and positioning

Human/Machine Interfaces

Video Surveillance

Site-wide communications networks

Additionally, it is important to understand current regulations regarding frequency, usage, and licensing (signal leakage, EMF) before beginning any network design or installation process.

Site layout

Once these initial steps have been completed, it is time to begin designing the physical layout of the network itself. iBwave’s Network design solutions allow you to upload floor plans or photos of site locations to design your network and automatically calculate coverage.

iBwave’s software allows you to model antenna placement to optimize coverage and performance while minimizing interference from other radio signals or environmental elements such as infrastructure in the building itself.

Power

Power requirements must also be considered when deciding on an antenna placement strategy. Some installations may require additional power sources due to their distance from existing outlets or wiring limitations.

Security

Security is also an important consideration. Comprehensive security protocols must be implemented to protect sensitive proprietary information within the network as well as prevent malicious actors from gaining unauthorized access.

Robust security requires careful selection and configuration of encryption protocols as well as authentication mechanisms based on user roles within each organization’s internal IT structure.

By combining these elements into one cohesive plan, engineers can create robust and secure private cellular networks that meet industry standards while providing maximum performance.

Design Considerations for Private Networks for Manufacturing

When designing a private cellular network for manufacturing, there are several key considerations to consider.

Spectrum

First, engineers and IT professionals must consider the available spectrum, the frequency band that the network will be operating on. A wide range of frequencies are available for use with private networks, for example for 5G in the sub 6GHz (FR1) and mmWave (FR2) band. It’s important to select the ones which are suitable for the particular application.

Frequency

The second consideration when designing a private cellular network is the frequency of operation.

Depending on the application, different frequencies may be more suitable than others. Frequency selection should consider factors such as signal strength and interference characteristics to provide optimal performance.

Location

Finally, another important design consideration is location.

Radio transmitters must be positioned appropriately to guarantee maximum coverage area while minimizing interference from other networks or signals in the area. Proper placement of antennas can also help reduce noise levels and improve overall signal quality.

iBwave software uses advanced 3D modeling to predict coverage and advanced capacity simulations for radio transmitters to determine the ideal locations in your designs.

Challenges in Designing Private Networks for Manufacturing

When designing a private cellular network for manufacturing, there are challenges that come with creating a reliable connection.

Connectivity, coverage, and security are all key aspects of any wireless network and need to be considered when planning out the system design.

Connectivity

Connectivity is the most important aspect of any wireless network. In industrial settings, poor connectivity leads to data loss, disruption of services, and lost productivity.

Engineers must make sure that networks can provide the required bandwidth and latency to support the desired applications. They should also consider factors such as interference from other networks. Physical obstacles such as buildings, machinery, and the terrain between the small cells or antennas and the end-devices should be modeled in the software for accurate network design and reliable connectivity.

Coverage

Coverage is another critical factor in providing network reliability. To provide adequate coverage, engineers must consider factors such as transmitter power levels, antenna placement, and frequency selection.

Additionally, they should consider what type of radio waves will be used for transmission. Line-of-sight or non-line-of-sight propagation methods can have a significant impact on overall coverage area.

Security

Finally, security is essential for any private wireless network for manufacturing purposes.

Access control measures (such as authentication protocols) should be in place to protect against unauthorized access to confidential data or resources. Encryption technologies (such as TLS/SSL) should also be employed to prevent eavesdropping on communication links; and firewalls should be implemented at each access point.

Additionally, physical security measures (such as camera surveillance) may be necessary depending on the environment in which the system will operate.

The Design Process

The design process for a private cellular network for manufacturing can be divided into three distinct phases: spectrum selection, frequency planning, and infrastructure deployment.

Spectrum Selection

The first step in designing a private cellular network is to select the right spectrum. The application requirements, signal strength, and interference characteristics of available frequencies should be considered when selecting the spectrum.

The selected spectrum must provide enough bandwidth for the desired application and should also anticipate future expansion plans. Regulatory requirements also need to be adhered to for the chosen frequency range.

The next step is to consider the antenna type and size required for the chosen spectrum. The antenna size and shape should be in line with the range, performance, and power requirements of the system. Antennas should be optimized to meet the needs of the application and reduce interference.

iBwave software can be used to design and plan the number of antennas and the location of each antenna to ensure proper coverage and signal strength in all areas.

Frequency Planning

Once the spectrum has been selected, engineers must then plan the frequency of operation to maximize signal quality and minimize interference from other networks.

Frequency planning involves selecting an appropriate combination of transmitter power levels, antenna placement, and channel spacing that will provide adequate coverage while minimizing noise levels.

Additionally, measures such as directional antennas or additional repeaters may be necessary to provide reliable coverage over larger areas or through obstructions such as walls or hillsides.

Engineers must also analyze the environment to assess potential sources of interference and develop strategies to reduce or mitigate them. Mitigation might involve limiting the transmission power of nearby base stations, using directional antennas, or adding filters or shielding to reduce interference.

By making sure that the system is properly configured and optimized, engineers can ensure that the network will be reliable and provide quality service to its users.

Infrastructure Deployment

The final phase of designing a private cellular network involves deploying the necessary infrastructure components such as base stations, small cells, access points (AP’s), and transceivers. It is important that these components are properly installed according to the manufacturer’s specifications to provide optimal performance and reliability.

Additionally, proper maintenance should also be carried out regularly to maintain optimal performance over time.

Finally, measures such as access control systems, encryption technologies, firewalls, and physical security devices may also need to be implemented depending on the environment and application requirements.

Conclusion

Designing a private network for manufacturing is a complex and challenging process, but one that can lead to greater efficiency, reliability, and security. Proper spectrum selection and frequency planning is essential to guarantee the desired performance and coverage levels are met. Additionally, infrastructure deployment needs to be carefully planned to maximize signal quality and reduce noise levels.

Overall, RF engineers and IT professionals need to have a comprehensive understanding of the available technologies and their associated challenges to successfully design a private cellular network for manufacturing.

A successful private cellular network for manufacturing requires a thorough and disciplined approach that combines a deep knowledge of RF engineering, IT expertise, and a clear understanding of the system’s requirements.

iBwave’s solutions help to simplify and improve the private network design process. With the right planning and resources, it is possible to create a secure, reliable efficient network that meets the needs of the manufacturing environment.

To learn more about design considerations in private networks for manufacturing, watch our on-demand webinar: https://bit.ly/3X5zXK2

Key Differences Between Designing Wi-Fi and Private LTE & 5G Networks

As every network designer knows, there are basic similarities across Wi-Fi, 4G/LTE, and 5G private wireless networks. These similarities are often at the root of the assumption that the process of designing each of these networks is the same. But while the network design principles may be similar, there are some key differences for designing each network type. It’s important to understand those differences before tackling a network design and when selecting a network design tool to facilitate the design process.

An understanding of the design considerations and a design tool that can accommodate them results in a more efficient workflow and, ultimately, a more accurate design for each type of network.

Wi-Fi vs. Private LTE & 5G: Signal Interference

Signal interference is one of the key things network designers must consider whether they are designing in-building Wi-Fi networks or private cellular 4G/LTE & 5G networks. While Wi-Fi network designs may have to account for interference from other Wi-Fi signal sources within a building, private 4G/LTE and 5G networks must also consider potential interference from more powerful macro networks. This interference can come from one or more service provider macro networks that are providing service from outside of the private network coverage area. And this interference can affect both private network integrity and user experience.

Network designers must also consider interference from physical barriers. This is especially true in venues like stadiums where the placement of access points near physical barriers such as concrete columns and corners can affect signal strength on a floor, and concrete and steel floors can affect signal strength between higher and lower levels. While cellular networks are designed to penetrate physical barriers more effectively, the very nature of these large venues also requires designers to account for factors such as layout and building materials.

For both types of networks, the interference issue must be addressed during the design process. But mitigating macro network interference for private 4G/LTE and 5G networks is a little more complicated.

Wi-Fi networks simply require the designer to know the transmit power of competing Wi-Fi sources and design the network and the placement of access points around that. With LTE networks, designers must also account for reference signal power from the base station, which is contingent on available bandwidth. Designers also need to know the total power and bandwidth coming from an LTE channel to account for reference signal power.

Calculating Signal Interference is More Complex for 5G

Designing 5G networks is much more complicated. Bands are broken out into different subcarrier frequencies, among other complications. Many more factors come into play when calculating for what is ultimately going to be the signal quality in any given area of a private 5G network.

Signal interference from macro networks further compounds this complexity, making the network design process even more difficult. This is why iBwave imports CSV and other data formats of macro cell signal penetration data to enable dominance over macro plotting of the inbuilding network.

This ensures both faster and more accurate network design while minimizing the risk of under-design and overdesign. Thanks to the seamless integration between iBwave Design and iBwave Reach – our software for designing campus networks, you can design the highest quality indoor and outdoor wireless networks with one solution.

5G Adds Additional Technical Complications

5G further complicates the private wireless network design challenge with additional technical factors that must be considered during the design process.

These include:

Sub-carrier spacing. While 4G/LTE only supports 15 kHz sub-carrier spacing, 5G supports 15, 30, 60, 120, and 240 kHz. This results in much more complex numerology in 5G versus 4G/LTE.

Slot allocation. The major difference here is that 4G/LTE always has a fixed number of slots (two in each 1 ms subframe), but 5G does not.

Bandwidth profiles. These may need to be configured, depending on how many clients are connecting to the network and/or if there are bandwidth limitations on the network.

Perform Necessary Calculations Automatically

Normally these factors present network designers with complex calculations to perform. The advantage iBwave offers is that network designers can simply input the information for the network they are designing, and the software will automatically perform the necessary calculations. Private cellular network design, therefore, happens more quickly, with fewer errors.

Report Generation Crucial for Additional Stakeholders

As network design is a process that goes beyond simply mapping coverage, one of the most crucial aspects to consider is report generation. Network designers must have ready access to comprehensive reports before deployment for review and approval by various stakeholders.

Use Cost Summaries, Access Point Placement, Survey Photos and Notes

In the case of enterprise private networks, different types of reports are needed to support, enable, and streamline the approval and deployment process. This can include:

A bill of materials, cost summary, and estimate for the project based on user input

A report to inform deployment technicians (who are generally not engineers) where access points need to go and how much cable needs to be run to connect them

Reports that provide a compilation of photos and notes taken during a survey into one document

Having the ability to generate reports with all the needed information is the key to streamlined network approval and deployment. To ensure the network design process runs smoothly from start to finish, iBwave includes the ability to generate reports such as Cost Detail reports, Access Point reports, and Annotation reports, which contain the key information different stakeholders need as part of the design and review process.

Meeting Regulatory Requirements and Industry Standards for Designing Wi-Fi, LTE & 5G Networks

Finally, cellular network designers must consider the regulatory requirements and industry standards they will be required to meet. For example, there are established signal strength maximums set by the Federal Communications Commission (FCC) that designers must meet. Industry standards provide guidelines to ensure network designs meet carrier requirements and deliver peak performance.

Load Testing and Balancing, Signal Strength, and Quality Evaluation

As a result, in-building cellular network design requires more rigorous testing and validation than Wi-Fi network design.

iBwave includes capabilities for network load projection, testing, and balancing during the design process, ensuring that the network can handle projected traffic while still abiding by FCC guidelines. Designers can also spot-check signal strength and quality throughout the entire network. And iBwave software meets the iBwave Design Standard (iBwave DS), ensuring networks function at a high level with any carrier.

iBwave Addresses Design Considerations for All Networks

While private wireless network designers must consider these and many more challenges before they start a design project, they must also choose tools capable of streamlining the design effort. The chosen design tool should simplify the design process as much as possible by only presenting designers with the decisions they need to make rather than the busywork needed to facilitate those choices, such as calculating the cellular numerology. In other words, one that can be easily adapted to address the complexity of the design challenge for the specific type of network being designed — Wi-Fi, 4G/LTE, or 5G.

iBwave puts this capability and more into designers’ hands. It streamlines and simplifies the network design process regardless of which type of private wireless network a designer is working on. It provides everything network designers need in one comprehensive solution they can rely on.

If you want to learn more about designing Wi-Fi and Private LTE & 5G Networks, check out our new Private Networks Certification and our course on Fundamentals of Private Networks!

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What to Expect With the 5G Shift in Private Networks

While enterprises have predominantly relied on public networks in the past, that situation has changed with the 5G shift in private networks.

Private networks, principally 4G/LTE, have become much more common, offering numerous advantages over public networks, including:

Enhanced cybersecurity

Greater control

More flexibility and customization

However, there is a shift happening in the market and more 5G deployments are taking place, driven by:

Increasing private network allocations in 5G

Greater availability of needed technology and expertise

The device ecosystem embracing 5G

More industry groups certifying 5G solutions

Network design considerations are very important for any enterprise interested in a private 5G network. Justifying the ROI on a private network deployment will depend on accurate network design to deliver that ROI.

Networks must be designed to take advantage of the full potential of 5G’s superior capabilities.

Present and Future Use Cases Should Drive Adoption

For the moment, 4G/LTE remains dominant for a few reasons:

Many deployments required 4G as an anchor

Few standalone 5G products on market

Fragmentation of 5G bands limited market viability

Many products and applications were only available in 4G/LTE

Perception of 5G as a moving target, immature market, has limited demand

Despite featuring in fewer deployments, private 5G networks offer substantial benefits over private 4G/LTE networks. 5G offers greater bandwidth and lower latency, allowing enterprises to introduce bandwidth-intensive and latency-sensitive technologies more easily. It also enables support for more users, devices, and access points simultaneously.

The use cases an enterprise needs to address should drive the potential adoption of a private 5G network. In general, use cases that need significant bandwidth or have extremely sensitive latency requirements will see benefits from 5G.

It’s important to note that enterprises should consider both present and future use cases in their planning.

Preparing in advance for future technologies and bandwidth that may need 5G capabilities can help enterprises avoid significant added costs down the road.

Ideal Use Cases that Take Advantage of the Benefits of 5G

What are the ideal use cases? While the number and variety of use cases will vary by industry sector, let’s look at three examples.

5G Shift in Private Networks: Enhancing Live Events

Inside of a football stadium, showing the 5G Shift in Private Networks: Enhancing Live EventsA stadium that hosts thousands of fans at a time wants to allow those fans to use their handheld devices to buy merchandise, livestream an event as it happens, or live-tweet or use social media during the event.

Enhancing the event with online services delivers direct value by allowing customers to purchase concessions and merchandise. And it can also generate free organic marketing via social media. But allowing thousands of devices to operate simultaneously requires enormous bandwidth capabilities that only private 5G networks can offer.

5G Shift in Private Networks: Delivering Location-Based Services

Similarly, a shopping mall may want to offer direct marketing to customers inside the mall by advertising stores and products available on premises. Many retail establishments also want to offer services to users, such as directions to shops or amenities like washrooms and parking lots.

These types of location-based services improve the user experience inside the mall and produce direct revenues for retailers. 5G’s substantial bandwidth allows them to support a large number of users at the same time. And its improved latency can be used to provide directions and product offerings in real time as users move through the mall.

5G Shift in Private Networks: Enabling AI and IoT

Factories are also ideal environments for private 5G deployments. With 5G, factory operations can be enhanced with autonomous, connected vehicles that leverage IoT and AI technologies. These vehicles can deliver substantial value by increasing operational efficiency and reducing personnel costs, among other benefits.

Private 5G networks provide the higher bandwidth and low latency needed to support the movement and delivery of the enormous quantities of data that is constantly generated by autonomous vehicles. High-latency networks reduce the value of having autonomous vehicles on the factory floor and can make those vehicles inefficient.

iBwave Delivers Needed Design Capabilities

None of these use cases will exist in sterile, fully controlled environments. Stadiums, malls, and factories are all highly dynamic environments with many ways for a signal to get lost, interrupted, or blocked. And 5G, like 4G/LTE, will have to co-exist with other technologies, such as Wi-Fi. So, integration and interaction with these technologies must be considered when enterprises are designing a 5G network.

5G networks are also more difficult to design than 4G/LTE networks, and more expensive. This means that mistakes are easier to make and more costly. Therefore, accurate network design and coverage prediction are crucial to ensuring that enterprises get the value they need from an investment in a 5G network.

iBwave Private Networks fully addresses all the design complexities and provides clear, easy-to-use software for survey and design. It enables network designers to easily and quickly design accurate networks, avoiding both under design and overdesign. Available as a 5G/LTE and Wi-Fi solution, iBwave Private Networks enables designers to easily:

Model venues in advanced 3D with AutoCAD import

Design from a database of vendor-modeled network components, including Small Cells, Aps, cables, controllers, routers, and more

Calibrate prediction with survey results

Run key project reports

iBwave Private Networks delivers the simplest and most reliable solution for planning, designing, and delivering high-performance private 5G networks. Advanced features such as the Fast Ray Tracing Prediction Engine, Prediction Calibration, Inclined Surface Modeling, and Attenuation by Frequency ensure the network you design and install functions exactly as intended. Plus, cloud connectivity and seamless integration with iBwave Mobile Survey ensures that iBwave can meet all your network needs, present and future.

For more information, take a look at the full product breakdown of iBwave Private Networks.

And for more insights into the growing demand for 5G networks, download our latest e-book: Top Trends in Private Networks for 2023.