5G and the future of connected assembly in smart factories

Smart Integrated Assembly takes both process control and quality assurance to the next level and leads to increased efficiency, reduced downtime, and better overall productivity. It is powered by extensive data collection and connectivity on the factory floor, facilitating seamless real-time re-balancing and adjustments, quality assurance, and continuous improvements. Every tool reading and production log contributes to identifying patterns and bottlenecks, thereby optimizing production processes. As your manufacturing processes evolve, so should the connectivity solutions you choose.

Wi-Fi and Bluetooth have revolutionized factory floors by replacing the chaos of tangled cables with wireless connectivity, and enhanced mobility. Wireless freedom enables operators to move easily, rotate tasks across different stations, and increase efficiency while reducing task times. These traditional wireless networks are ideal for factories that require straightforward deployment, maintenance, and scalability, making training and operations easier. But with the advent of newer technologies like private 5G networks, manufacturers now face a choice. Each has its use cases and understanding your factory's unique needs is crucial to selecting the right connectivity.

Evaluating 5G connectivity requires a close look at the specific challenges posed by traditional wireless networks. These challenges—high latency, limited device capacity, interference from machinery and other devices, security vulnerabilities, and the demands of real-time data processing—are crucial in deciding whether to make the switch.

Latency is a critical issue, particularly when workers move throughout the production line to perform different tasks. High latency can affect real-time control loops, which in turn can diminish production efficiency, product quality, and safety. The key lies in striking a balance between speed and reliability, ensuring seamless data transmission without sacrificing performance.

Additionally, traditional wireless networks may face limitations with local mobility and scalability. Although they offer more flexibility than wired systems, operators may still face constraints due to network boundaries. As the number of connected devices increases, managing the network becomes more complex. Ensuring seamless connectivity is vital for avoiding disruptions on the assembly line, and maintaining process control and quality assurance.

Moreover, should your production interrupt your production? Traditional wireless technology is susceptible to interference from machinery, large metal structures, and other electronic devices – including personal Bluetooth devices and rogue Wi-Fi access points. This interference can disrupt critical communication channels needed to ensure process control. Guaranteeing reliable connectivity requires careful frequency management and implementing redundancy mechanisms, which can significantly drive up costs and complexity.

Lastly, security is a major concern for manufacturing today. Traditional wireless networks face risks such as unauthorized access, data breaches, and cyberattacks, which can impact production continuity, safety, and intellectual property. While advanced security protocols and intrusion detection systems can mitigate these risks, they may complicate the network’s simplicity and agility. Therefore, balancing security with efficiency becomes a key challenge for modern factories.

By carefully evaluating the challenges, you can better determine whether your current wireless network meets your needs. If it does not, you may need to upgrade to newer Wi-Fi versions like Wi-Fi 6 or consider whether the capabilities of 5G are a better fit for your manufacturing requirements. 5G emerges as an innovative technology that addresses your concerns, seamlessly blending sophistication with simplicity. 

Ultra-low latency is guaranteed by 5G networks delivering reliable real-time responsiveness that outperforms the unpredictability of Wi-Fi and Bluetooth. 5G allows for the consistent management of thousands of tools with less than 20ms latency, even while moving around in the production environment. This minimized and predictable delay streamlines production and maximizes efficiency. Additionally, 5G pioneers a deterministic quality of service, prioritizing specific services to ensure predictability in mission-critical activities. 

By operating on dedicated spectrum bands, 5G also avoids interference and ensures consistent connectivity. Together with advanced frequency modulation, this caters to much better coverage than other wireless technologies, typically being 10 times better than Wi-Fi, and penetrating walls, buildings, and other structures.

Unlike Wi-Fi, which grapples with channel contention and a limited spectrum, 5G’s seamless connectivity spans throughout factories and beyond— from a single base station. This extended coverage enables more precise repairs and reworks, commonly undertaken outside factory walls where accessibility is constrained. Moreover, 5G supports a higher density of connected devices per square kilometer than Wi-Fi, ensuring connection for all devices in an ever-expanding connected environment in manufacturing.

Lastly, advanced authentication methods and secure, isolated spheres propel the security of private 5G networks beyond traditional wireless technology. Organizations wield robust centralized control over access, ensuring heightened security. Additionally, mutual authentication between devices and the network eliminates unauthorized connections, fortifying defenses against cyber threats. This authentication, powered by a SIM card, provides identity and access control for each device. As SIM authentication cannot be shared or written down, it creates an ultra-secure manufacturing environment.

Atlas Copco's commitment to process control and quality assurance is supported by data collection; however, that data alone doesn’t create value unless it can be reliably shared and acted upon in real-time. With 5G connectivity, this process becomes even more reliable and secure on the entire factory floor. Whether you seek to enhance the density of connected tools, extend coverage to outdoor repair and rework areas, or demand instant responsiveness on the assembly line, our suite of 5G-connected tightening tools are ready to meet your needs.

Ready to take your factory to the next level? Discover how Atlas Copco's 5G connected tools can transform your manufacturing processes. Contact us today to learn more!