In the smart factory of an automobile manufacturing enterprise, welding robots experienced a lag in motion commands due to network delays, resulting in deviations in the welds on vehicle bodies. At a port, the container crane's video surveillance data stream became congested, preventing the real-time transmission of lifting images and posing operational safety hazards. These cases reveal a core issue: In the era of Industry 4.0, how can QoS (Quality of Service) technology be used to ensure bandwidth for critical business operations and prevent production accidents caused by network congestion?

This article will provide an in-depth analysis from three dimensions: the principles of QoS technology, its adaptation to industrial scenarios, and the practical configuration of the USR-G809s industrial router. If you are facing bandwidth competition issues in real-time control, video surveillance, data acquisition, and other operations, submit an inquiry to receive a customized QoS optimization plan.

1. Principles of QoS Technology: Closed-Loop Control from Traffic Identification to Resource Allocation

QoS achieves precise allocation of network resources through a four-step mechanism of "identification-classification-scheduling-rate control," with the following core logic:

1.1 Traffic Identification and Classification: Precisely Locating Critical Business Operations

• Port Marking: Identify fixed ports for applications such as video conferencing (SIP 5060, RTP dynamic ports) and industrial protocols (Modbus TCP 502, Profinet 34962), marking them as high priority.
• DSCP Field Marking: Embed DSCP (Differentiated Services Code Point) values in the IP header, such as EF (Expedited Forwarding, DSCP=46) for real-time control and AF (Assured Forwarding, DSCP=10-18) for video streams.
• Deep Packet Inspection (DPI): Identify encrypted traffic through behavioral characteristics (e.g., the SSL/TLS handshake pattern of Zoom meetings), enabling classification even without port information.
• Application Layer Identification: The USR-G809s supports the identification of over 200 industrial protocols through the USR Cloud platform, automatically marking operations such as PLC control and SCADA monitoring.

1.2 Priority Queue Scheduling: Ensuring Low-Latency Transmission

• High-Priority Queue: Real-time control data (e.g., robot commands) enters the PQ (Priority Queue) for priority forwarding, with a delay of <10ms.
• Weighted Fair Queuing (WFQ): When video surveillance and data acquisition share bandwidth, resources are allocated by weight to prevent any single type of traffic from monopolizing the bandwidth.
• Dequeuing Strategy: WRR (Weighted Round Robin) is used to ensure that critical packets are sent out promptly. For example, a steel plant reduced the transmission delay of high-temperature furnace temperature monitoring data from 200ms to 30ms through WRR configuration.

1.3 Bandwidth Limitation and Congestion Management: Preventing Non-Critical Business Operations from Occupying Resources

• Rate Limiting Non-Critical Traffic: Set maximum bandwidth limits for operations such as file downloads and backups. For example, limit employee computer download speeds to 2Mbps to prevent them from occupying production line data bandwidth.
• Packet Dropping Strategy: During congestion, prioritize dropping low-priority packets (e.g., FTP) while retaining video stream data packets. A logistics enterprise reduced the packet loss rate of AGV trolley navigation data from 5% to 0.1% using this strategy.
• Traffic Shaping: Smooth out burst traffic to prevent instantaneous peaks from causing packet loss. The USR-G809s supports traffic shaping based on the token bucket algorithm to ensure stable data flow output.

1.4 End-to-End Collaboration: Full-Path QoS Guarantee

• Intranet Deployment: Configure QoS policies on access layer and aggregation layer switches, with the出口 router (exit router) performing final scheduling. For example, a chemical enterprise increased the priority of DCS control system data transmission by three levels through intranet QoS configuration.
• Operator Network Collaboration: If the operator supports MPLS QoS or the DiffServ model, priority markings can be extended. A power company achieved QoS label transparency from substations to the dispatch center through cooperation with the operator.

2. QoS Adaptation in Industrial Scenarios: Differentiated Configuration from Real-Time Control to Big Data Transmission

Different industrial applications have significantly different QoS requirements, necessitating targeted configurations:

2.1 Real-Time Control Systems: Low Latency and High Reliability

• Requirements: Robot control, PLC communication, and other operations require a delay of <50ms and a packet loss rate of <0.1%.
• Configuration Strategy:
  • DSCP Marking: Mark control commands as EF (DSCP=46) to ensure the highest priority.
  • Link Backup: The USR-G809s supports dual 4G/wired links, automatically switching in the event of a primary link failure with a switching time of <1 second.
  • Bandwidth Reservation: Reserve 30% of the total bandwidth for control data, e.g., reserving 30Mbps for a 100Mbps link.
• Case: An automobile factory reduced the delay of welding robot control commands from 80ms to 25ms through USR-G809s QoS configuration, increasing the weld pass rate by 15%.

2.2 Video Surveillance Systems: High Traffic Volume and Low Jitter

• Requirements: 4K video streams require 5-10Mbps of bandwidth with a jitter of <10ms.
• Configuration Strategy:
  • DSCP Marking: Mark video streams as AF41 (DSCP=34), with a priority second only to control data.
  • Bandwidth Limitation: Limit the maximum bandwidth of non-critical operations (e.g., employee internet access) to 5Mbps to prevent them from occupying video stream bandwidth.
  • Multi-Path Transmission: The USR-G809s supports load balancing across dual 4G+wired links, with video streams automatically selecting the optimal path.
• Case: A port reduced the video stuttering rate of crane monitoring from 30% to 2% through USR-G809s QoS configuration, increasing operational efficiency by 20%.

2.3 Data Acquisition Systems: High Throughput and Low Packet Loss

• Requirements: Sensor data needs to be uploaded regularly with a packet loss rate of <1%.
• Configuration Strategy:
  • DSCP Marking: Mark data acquisition traffic as AF21 (DSCP=18), with a priority lower than video streams.
  • Buffer Optimization: The USR-G809s supports a large-capacity buffer to prevent packet loss during sudden data bursts.
  • Scheduled Transmission: Configure data acquisition tasks to transmit during off-peak hours through the USR Cloud platform to reduce competition.
• Case: A wind farm increased the completeness rate of wind turbine vibration data uploads from 92% to 99.8% through USR-G809s QoS configuration, improving fault prediction accuracy by 25%.

3. USR-G809s Industrial Router: Hardware and Software Collaboration for QoS Optimization

The USR-G809s is a 4G routing gateway designed specifically for industrial scenarios, with its QoS optimization capabilities validated through multiple rigorous tests:

3.1 Hardware-Level QoS Support

• Dual-Core Processor: Equipped with a high-performance CPU, it can process over 2000 QoS rules in real-time, ensuring scheduling efficiency in complex scenarios.
• Independent QoS Engine: Built-in hardware acceleration modules support operations such as DSCP marking and queue scheduling, reducing CPU load.
• Multi-Network Port Design: It features 1 WAN port + 4 LAN ports, supporting VLAN division to isolate different business traffic.

3.2 Software-Level QoS Configuration

• Visual Interface: Through the USR Cloud platform or Web interface, QoS rules can be intuitively configured, supporting classification based on IP, port, and application.
• Intelligent Tuning: Built-in AI algorithms can automatically identify critical business operations and adjust priorities, e.g., automatically increasing the DSCP value when PLC communication is detected.
• Remote Management: Supports the SNMP protocol for remote monitoring of QoS effects and real-time policy adjustments.

3.3 Practical Case: Remote Operation and Maintenance Optimization for a Machine Tool Enterprise

A machine tool manufacturing enterprise deployed over 5000 CNC machine tools for global customers, requiring remote diagnosis via 4G networks. The original solution used ordinary routers, resulting in the following issues due to improper QoS configuration:

• Video surveillance data occupied PLC control bandwidth, causing equipment shutdowns.
• High diagnostic data upload delays resulted in fault response times exceeding 2 hours.

USR-G809s Solution:

• Traffic Classification: Mark PLC control data as EF, video surveillance as AF41, and diagnostic data as AF21.
• Bandwidth Allocation: Reserve 30% of bandwidth for PLC control, 20% for video surveillance, and 50% for diagnostic data.
• Dual-Link Backup: The primary link is 4G, and the backup link is wired, ensuring uninterrupted network connectivity.

Implementation Effects:

• The delay of PLC control data was reduced from 120ms to 15ms, reducing equipment shutdowns by 90%.
• Diagnostic data upload time was shortened from 2 hours to 10 minutes, increasing customer satisfaction by 40%.

4. Submit an Inquiry for a Customized QoS Optimization Plan

If your industrial scenario is facing the following challenges:

• High real-time control delays: Robots, PLCs, and other devices experience lagging motions due to network delays.
• Video surveillance stuttering: 4K video streams freeze due to insufficient bandwidth.
• Data acquisition packet loss: Sensor data loses critical information due to network congestion.
• Multi-business competition: Production, office, and surveillance operations share the network, causing mutual interference.

Submit an inquiry immediately to receive:

• Free Scenario Assessment: Based on your business type, network scale, and reliability requirements, we recommend an adapted QoS configuration plan.
• Customized Tuning Guide: Provide detailed configuration steps based on the USR-G809s, including DSCP marking, queue scheduling, and bandwidth limitation.
• 7×24-Hour Technical Support: Remote assistance to resolve technical issues during the configuration process, ensuring QoS effectiveness.
• Practical Case References: Share successful cases from industries such as automobile manufacturing, port logistics, and energy and power, providing replicable experience.

QoS optimization is the "invisible guardian" of industrial network stability. With its powerful QoS capabilities, the USR-G809s has become the preferred choice for industries such as automobile manufacturing, port logistics, and energy and power.