By Eileen Harvey
In the modern era of industrial automation, Industrial Ethernet has become the backbone of communication between programmable logic controllers (PLCs), sensors and human-machine interfaces (HMIs). Unlike office Ethernet, which prioritizes high bandwidth and internet access, industrial Ethernet is designed to handle harsh environments, continuous operation and real-time control.
From automotive production lines to food processing plants, the right Ethernet solution ensures seamless data transfer, machine coordination and process monitoring—all of which are critical for operational efficiency and uptime.
Why Industrial Ethernet for Automation?
Industrial Ethernet offers several advantages over traditional serial communication or proprietary fieldbus systems. They include: high speed and bandwidth, supporting large data volumes in real time; scalability, easily integrating new machines and systems; standardization based on well-established IEEE 802.3 standards; and durability, designed with rugged cables and connectors to withstand temperature extremes, vibration, moisture and EMI.
For example, TKD Industrial-grade cables are engineered with materials like PUR, TPE and PVC jackets for application-specific durability.
Core Components in Industrial Ethernet Automation
1. PLCs (Programmable Logic Controllers)
PLCs act as the central control units in automated systems. They receive input data from sensors, process the information and send output commands to actuators or machines. The Ethernet enables PLCs to communicate with HMIs, supervisory systems and remote control stations. Common protocols are EtherNet/IP, PROFINET and Modbus TCP.
2. Sensors
Sensors gather vital data such as temperature, pressure, speed and position. In an industrial Ethernet setup, sensors transmit data directly to the PLC. Some sensors are Ethernet-enabled, reducing the need for analog-to-digital converters. Industrial Ethernet cables ensure minimal signal interference and data loss.
3. HMIs (Human-Machine Interfaces)
HMIs allow operators to monitor and control processes in real time. A good HMI-PLC connection means: instant display of sensor data; faster troubleshooting and maintenance; and seamless interaction between operator and machine. The industrial Ethernet ensures that these systems stay synchronized with minimal latency.
Choosing the Right Industrial Ethernet Cable
Industrial Ethernet cables differ significantly from commercial ones. The correct choice depends on environmental conditions, application type and required performance.
- Key Cable Jacket Materials: PVC (Polyvinyl Chloride) is cost-effective and suitable for light industrial use. PUR (Polyurethane) has high abrasion resistance and is oil-resistant and flexible. TPE (Thermoplastic Elastomer) has superior temperature resistance and excellent flexibility.
- Shielded vs Unshielded: Shielded cables (STP) protect against EMI/RFI—ideal for heavy industrial areas. Unshielded cables (UTP) are suitable for clean environments with minimal interference.
- Cable Categories: Cat5e supports up to 1 Gbps—cost-effective for short runs and non-critical systems. Cat6 allows up to 10 Gbps for shorter distances and has better crosstalk performance. Cat6a handles 10 Gbps up to 100 meters, which is deal for future-proofing automation systems.
Standards and Protocols for Industrial Ethernet
Automation environments often use specialized Ethernet protocols to meet the demands of deterministic communication. EtherNet/IP is widely used in North American industries. PROFINET is popular in Europe and integrates with PROFIBUS systems. Modbus TCP is a simple and open protocol for device interoperability. EtherCAT is a high-speed protocol for motion control applications.
Applications in Automation
- Manufacturing Assembly Lines – PLCs coordinate robots, conveyors and quality control stations via Ethernet.
- Process Industries – Ethernet ensures real-time monitoring of pressure, flow and chemical composition.
- Material Handling – Automated storage and retrieval systems (AS/RS) rely on Ethernet for precise movement control.
- Energy Management – Ethernet-connected sensors optimize energy usage and reduce downtime.
Installation Best Practices
Here are five ways to get the most from industrial Ethernet in automation. First, use the correct cable length, being careful not to exceed Ethernet’s maximum run limits. Second, route cables away from sharp edges and moving parts to protect them from physical damage. Third, maintain cable bend radius to prevent signal degradation. Fourth, use proper grounding for shielded cables to ensure EMI protection is effective. Finally, label and document connections to speed up troubleshooting and maintenance.
Future of Industrial Ethernet in Automation
With Industry 4.0 and the Industrial Internet of Things (IIoT), industrial Ethernet will continue to evolve. It will have higher data rates, with Cat8 and beyond for advanced automation. PoE will power sensors and HMIs directly through Ethernet cables. Enhanced cybersecurity will protect automation networks from threats. And last, edge computing will bring local processing at the device level to reduce latency.
FAQs: Industrial Ethernet in Automation
Q1: What is the main advantage of Industrial Ethernet over traditional fieldbus systems?
A1: Industrial Ethernet offers higher bandwidth, scalability and compatibility with standard IT infrastructure while being rugged enough for industrial environments.
Q2: Do I need shielded Ethernet cables for automation?
A2: In environments with high electrical noise, shielded cables are recommended to prevent data errors and interference.
Q3: Can industrial Ethernet cables be used outdoors?
A3: Yes, but they must have UV-resistant and weatherproof jackets like PUR or TPE for long-term reliability.
Industrial Ethernet is the foundation of reliable, scalable and high-performance automation systems. By selecting the right cables, connectors and protocols, manufacturers can ensure seamless communication between PLCs, sensors and HMIs, improving productivity and reducing downtime.
For rugged, high-quality solutions, explore L-com’s Industrial Ethernet cable collection built to keep your automation running smoothly.
