FOR OUR UPDATE ON INDUSTRIAL WIRELESS SOLUTIONS, the Industrial Ethernet Book reached out to industry experts to get their perspective on the trends driving new technology. Not surprisingly, adoption of 5G is leading the way along with the emergence of Wi-Fi 6/6E and new developments with Wi-Fi 7. Add in AI, advancements in Time-Sensitive Networking (TSN) over wireless media and new 6GHz spectrum — and the scope and evolution of the technology is apparent.

As Alice Masini of Cisco concluded, “the outlook for industrial wireless is marked by rapid growth, deeper integration, and expanding capabilities. As organizations increasingly value flexible, scalable, and reliable wireless connectivity, adoption of advanced solutions will continue to rise—extending well beyond traditional Wi-Fi or 5G alone.”

“5G, especially in the form of campus networks, opens up a largely wireless factory infrastructure. It combines high reliability, low latency and real-time capability for industrial processes,” Jörg Brasas, Strategic Product Marketing, Business Unit – Automation Infrastructure for PHOENIX CONTACT.

Wi-Fi 6/6E and 5G solutions

NearFi technology offers very low latency, contactless energy and data transmission.

Phoenix Contact sees several key technologies enabling new Industrial Wireless solutions. Wi-Fi 6/6E brings higher capacity, deterministic communication and improved security with OFDMA, MU-MIMO and WPA3. The use of the 6 GHz band reduces interference and supports applications such as driverless transportation systems and moving machines.

“5G, especially in the form of campus networks, opens up a largely wireless factory infrastructure. It combines high reliability, low latency and real-time capability for industrial processes,” Jörg Brasas, Strategic Product Marketing, Business Unit Automation Infrastructure for PHOENIX CONTACT GmbH told IEB. “NearFi technology also offers very low latency, contactless energy and data transmission via air gaps or non-conductive materials, ideal for wear-critical or moving components.”

Another trend is consistent security by design in accordance with IEC 62443: wireless solutions are embedded in holistic security concepts to ensure data integrity and network protection. With these technologies, Phoenix Contact creates scalable, robust and real-time capable wireless solutions “from the sensor to the network” and lays a foundation for flexible, secure and future-proof industrial applications.

Industrial 5G in smart factory operations

“Industrial 5G acts as a lever for more flexibility, real-time capability and efficiency in the smart factory,” Brasas said. “From Phoenix Contact’s point of view, 5G, together with Wi-Fi 6/6E, will make standardized real-time communication and high reliability widely available on an industrial scale for the first time. As a result, production systems can be networked largely wirelessly, which reduces wiring, speeds up conversions and seamlessly integrates mobile assets such as AGV/AMR.”

At the same time, the network capacity for sensor technology, condition monitoring and data-driven services increases. In practice, 5G enables deterministic communication in control processes, extends coverage over large plant areas and supports scalable fleets of autonomous systems.

Where rotating or moving applications have additional requirements, Phoenix Contact technologies such as NearFi (contactless energy and real-time Ethernet transmission) and Industrial WLAN/Wi-Fi 6 complement the 5G infrastructure – always thinking “from the sensor to the network”. Security by design is also an integral component: Industrial Wireless solutions are embedded in IEC 62443-compliant concepts to ensure that the connectivity provided by 5G remains secure.

New industrial wireless technologies

New Industrial Wireless products from Phoenix Contact combine state-of-the-art wireless technologies with consistent cybersecurity. Wi-Fi 6/6E offers OFDMA, MU-MIMO and WPA3 for high data rates, low latency and reliable communication, while the 6 GHz band reduces interference. Series such as WLAN 1020/1120 combine client and soft access point functionality for mobile applications such as AGVs. In addition, NearFi enables contactless energy and real-time Ethernet transmission via air gaps – a unique selling point compared to previous solutions.

“In the 4G/5G sector, we are focusing on the simplest connection of devices and networks with END-to-END encryption with the new Celllulink devices,” Brasas said.

He added that “a key differentiating feature is the security-by-design strategy; all products meet the requirements of IEC 62443-4-1 (secure development process) and IEC 62443-4-2 (secure components). This includes features such as secure boot processes, cryptographic key management, role-based access control and encrypted communication.”

This ensures the integrity of the data and the resilience of the network – even in highly networked smart factory environments. This creates scalable, robust and future-proof wireless networks “from the sensor to the network”.

Application areas

The latest industrial wireless solutions from Phoenix Contact are addressing central application areas of the smart factory. The focus is on mobile transportation systems such as AGVs and AMRs, which require reliable wireless communication for navigation and fleet management. Wi-Fi 6/6E enables stable, low-latency networking in environments with a high density of devices – ideal for flexible material flows and intralogistics.

Another area is flexible machine integration: wireless solutions enable location-independent operation, set-up and maintenance of production systems via tablets or smartphones. For moving or rotating machine parts, Phoenix Contact offers NearFi, a contactless energy and real-time Ethernet transmission system that replaces wear-prone plug connections and reduces downtime costs.

It also addresses applications in the automotive industry, machine building and logistics, where robust communication under harsh conditions and high safety requirements are crucial. All solutions are developed according to IEC 62443 standards and offer security-by-design for the protection of critical data and processes. Phoenix Contact thus creates wireless networks that combine mobility, flexibility and security – from the sensor to the network.

Engineering challenges

Automation engineers face challenges such as high cabling costs, limited flexibility during conversions and the integration of mobile systems into existing networks. Phoenix Contact addresses these problems with advanced Industrial Wireless technologies.

“Wi-Fi 6/6E and 5G make wireless communication available for the first time with high reliability and low latency, so that mobile robots, AGVs and sensors can be integrated without complex cable infrastructure. This reduces installation costs and speeds up production adaptations,” Brasas said.

He added that another obstacle is communication in moving or rotating applications, where cable wear leads to failures. With NearFi, Phoenix Contact offers contactless energy and real-time data transmission via air gaps – a solution that drastically reduces maintenance costs and downtimes.

“There is also growing pressure to ensure IT security in networked factories. Phoenix Contact integrates security-by-design in accordance with IEC 62443-4-1 and -4-2, minimizing risks such as tampering or data loss.” Brasas said. “The result: Advanced wireless solutions eliminate cabling constraints, increase flexibility and secure the smart factory against cyber threats.”

Looking to the future

From Phoenix Contact’s perspective, Industrial Wireless will become a standard component of the Smart Factory in the coming years. Wi-Fi 6/6E and 5G will become widely available and carry real-time radio into control processes; additional 6 GHz channels and higher packet rates will allow larger, more densely occupied networks for mobile robotics, intralogistics and flexible machine islands.

NearFi expands the spectrum to include contactless energy and real-time Ethernet transmission for moving/wear-critical areas. At the same time, security-by-design in accordance with IEC 62443-4-1/-4-2 is becoming a basic requirement: future wireless products and solutions will have integrated, certifiable safety functions and thus accelerate the scaling of wireless networks.

Brasas said that two drivers in particular are shaping the outlook: AI and virtual solutions. AI-supported analytics optimizes radio planning, roaming parameters and anomaly detection (e.g. for condition-based maintenance), while virtual radio evaluation/simulation and remote services accelerate commissioning and check changes in advance with low risk.

“Key technological trends driving new industrial wireless solutions include the introduction of Industrial 5G, advancements in Time-Sensitive Networking (TSN) over wireless media, and the adoption of the latest Wi-Fi standards with new 6GHz spectrum in several countries.” — Daniel Mai, Director Industrial Wireless Connectivity Siemens AG.

Industrial 5G and Wireless TSN

Along with the adoption of the latest Wi-Fi standards with new 6GHz spectrum.

According to Daniel Mai, Director Industrial Wireless Connectivity at Siemens AG, “key technological trends driving new industrial wireless solutions include the introduction of Industrial 5G, advancements in Time-Sensitive Networking (TSN) over wireless media, and the adoption of the latest Wi-Fi standards with new 6GHz spectrum in several countries.”

Mai said that these technologies offer higher data rates, lower latency, and improved reliability, which are essential for modern industrial applications that need more and more connectivity. As a result, there is a growing acceptance and adoption of these wireless solutions across various industries, enabling more efficient and flexible operations.

“With growth of an ecosystem of end devices supporting these new technologies the adoption will be accelerated,” Mai said.

Industrial 5G impact

“Industrial 5G is significantly impacting smart factory operations by providing deterministic and highest reliability in wireless communications. This enables reliable real-time control of machines and processes, which was sometimes challenging with other wireless technologies. The enhanced connectivity supports the deployment of autonomous vehicles and collaborative robots, improving the flexibility and efficiency of production lines,” Mai said.

Industrial 5G also facilitates seamless communication between a vast number of devices, contributing to more integrated and intelligent manufacturing environments. Additionally, the possibility to set up tailored private 5G networks utilizing private spectrum will enable secure and interference-free wireless connectivity on industrial campuses.

Unique capabilities

Mai added that the new products offer improved performance, higher data throughput, and support for deterministic wireless communication, enabling the wireless control of mission-critical applications. They meet the need for increasing connectivity, edge computing and higher data traffic in smart factories to collect and transfer data and thus enable data driven decisions and e.g. AI applications.

Compared to previous solutions, they also provide advanced cybersecurity measures and seamless integration with existing industrial protocols, enhancing both security and ease of deployment and creating a reliable OT-backbone.

The latest industrial wireless solutions are targeting business-critical applications that require high bandwidth, deterministic, and reliable connectivity. This includes mobile robotics, remote monitoring and maintenance, augmented reality for training and complex assembly tasks, autonomous inspections, and process automation.

“The use of wireless for industrial control is becoming more prevalent, as modern wireless technologies have addressed many of the reliability and latency concerns that previously hindered their adoption. Industries are increasingly confident in deploying wireless solutions for a broader range of control applications,” Mai said. “A big game changer will be the introduction of AI to the industrial space. AI applications need data. Implementing a reliable wireless communication infrastructure will facilitate the easy deployment of additional sensors and edge devices in existing factories to feed AI and enable data driven decision making.”

Addressing challenges

Mai said that automation engineers often face challenges such as the inflexibility of wired networks and high installation costs, especially in existing installations. Advances in industrial wireless technology are helping to overcome these issues by providing increased mobility, flexibility, and real-time communication capabilities. This allows for easier reconfiguration of production layouts and more scalable operations, also in brownfield environments.

“Looking to the future, the outlook for industrial wireless is promising, with expected continued innovations in areas like Industrial 5G, Wi-Fi technologies, and edge computing,” Mai concluded. “These advancements are likely to lead to fully connected and highly adaptable industrial environments, driving efficiency and productivity to new levels addressing the emerging economic challenges driven by global competition and upcoming retirement waves with the associated workforce shortage.”

“The industrial wireless landscape is rapidly evolving, fueled by the rise of automation and the rapid adoption of AI. A new generation of wirelessly connected assets, including AI-driven robots, autonomous and automated vehicles, and data-rich endpoints such as cameras, demands networks that deliver ultra-low latency, high reliability, and seamless handoffs,” — Alice Masini, Product Manager, Industrial Wireless, Cisco.

Industrial Wireless Evolution

Driven by the rise of automation and rapid adoption of AI.

“The industrial wireless landscape is rapidly evolving, fueled by the rise of automation and the rapid adoption of AI. A new generation of wirelessly connected assets, including AI-driven robots, autonomous and automated vehicles, and data-rich endpoints such as cameras, demands networks that deliver ultra-low latency, high reliability, and seamless handoffs,” Alice Masini, Product Manager, Industrial Wireless at Cisco told the Industrial Ethernet Book recently.

Masini said that Wi-Fi 6E and Wi-Fi 7 have significantly increased bandwidth and device capacity, enabling high-performance connectivity in demanding industrial environments. While 5G continues to attract attention, it remains complex and costly for many organizations. Cisco Ultra-

Reliable Wireless Backhaul (URWB), an extension of Wi-Fi, is specifically designed for critical applications that require more reliability than Wi-Fi alone can provide—applications that cannot tolerate communication loss and must remain connected even while roaming amid obstacles and RF interference.

Now, Wi-Fi and URWB are integrated within the same access points, greatly simplifying network operations, reducing costs, and giving industrial organizations the flexibility to choose the optimal wireless technology for each use case.

Impact of Industrial 5G

“Industrial 5G introduces valuable capabilities such as high capacity, low latency, and reliable connectivity for a wide range of smart factory applications. However, real-world experience shows that 5G is just one component in a broader connectivity strategy,” said Masini.

Technologies like Wi-Fi and URWB also play vital roles in supporting robotics, automated guided vehicles (AGVs), real-time analytics, and remote operations. The greatest impact comes when organizations evaluate their environments and use cases and deploy the optimal combination of technologies to meet their needs. While 5G can be complex and costly for some organizations, URWB provides private 5G-like performance without the need for licensed spectrum or the associated management overhead.

Wi-Fi and URWB can be operated simultaneously in a single access point, enabling manufacturers to manage both technologies through a single interface, reducing silos between IT and OT teams, and eliminating the need for duplicate infrastructure.

Ultimately, the transformative impact in smart factories lies in adopting a mix of wireless technologies that enable more adaptive, efficient, and secure operations—a holistic approach essential for modern industrial environments.

Technology innovation

Masini said that new industrial wireless solutions deliver greater flexibility, reliability, and operational simplicity. Cisco’s access points support both Wi-Fi and URWB on a unified hardware platform, allowing organizations to use high-bandwidth Wi-Fi for general connectivity and URWB for ultra-reliable, low-latency applications—all with the same device.

“URWB’s “make-before-break” approach ensures uninterrupted connectivity for applications that cannot tolerate loss during roaming. Its Multipath Operations (MPO) technology duplicates critical traffic across multiple, uncorrelated frequencies to several access points, minimizing latency and maximizing reliability,” Masini said.

The capability to enable and configure URWB and Wi-Fi in the field help extend the lifespan of devices and protects investments. Additionally, the refreshed portfolio features compact, industrial-grade form factors for easy deployment in challenging environments. These innovations enable a seamless path to digitalization, supporting advanced automation and mobility while reducing complexity and total cost of ownership compared to previous generations of industrial wireless solutions.

New Industrial Wireless solutions

Masini added that the latest industrial wireless solutions are tailored for a broad spectrum of demanding applications, such as mobile automation, autonomous vehicles, robotics, real-time monitoring, and remote control across manufacturing, logistics, and warehouses. They address the connectivity requirements of AGVs, collaborative robots, and remote machinery, where constant, reliable communication is essential.

URWB provide seamless handoffs and uninterrupted service for fast-moving or mission-critical assets. Beyond mobile applications, URWB’s near-zero latency increasingly supports data-driven use cases, including predictive maintenance, process optimization, and AI-powered analytics, all of which drive productivity and safety improvements.

“The flexibility of Wi-Fi and URWB integration enables precise adaptation to specific needs, from fixed sensors along production lines to mobile assets operating in expansive outdoor environments. As automation and digital transformation continue to accelerate, advanced wireless connectivity is pivotal for unlocking new efficiencies and operational insights,” Masini said.

Challenges

“Automation engineers must ensure reliable, always-on connectivity in dynamic and often harsh industrial settings, support seamless mobility for autonomous assets, and scale or reconfigure networks quickly as needs change. Advances in industrial wireless—especially the convergence of Wi-Fi and URWB—are addressing these challenges with robust, high-reliability connections and simplified management. Wi-Fi supports high-bandwidth needs while URWB supports high-reliability requirements,” Masini added.

Unified hardware platforms reduce network complexity and make it easier to upgrade or transition between wireless technologies as requirements evolve. Enhanced security features guard against growing cyber threats, while improved scalability allows for the rapid addition of new devices without major infrastructure overhauls. These innovations empower automation engineers to deploy and operate advanced automation systems with increased confidence, agility, and efficiency for safer workplaces and more resilient industrial operations.

Industrial wireless outlook

“The outlook for industrial wireless is marked by rapid growth, deeper integration, and expanding capabilities. As organizations increasingly value flexible, scalable, and reliable wireless connectivity, adoption of advanced solutions will continue to rise—extending well beyond traditional Wi-Fi or 5G alone,” Masini said.

She added that integrating technologies such as Wi-Fi 6E, Wi-Fi 7, and URWB on unified platforms will further streamline operations, reduce costs, and support even the most demanding automation, AI-driven analytics, and autonomous system requirements. Ongoing innovations in reliability, security, and ease of deployment will position wireless connectivity as the foundation of industrial digital transformation.

“Looking forward, industrial wireless will enable new applications, drive higher operational efficiency, and support the shift toward more autonomous, data-driven, and adaptive industrial environments—empowering organizations to fully realize the benefits of Industry 4.0 and beyond,” Masini concluded.

Al Presher, Editor, Industrial Ethernet Book