Networking with Industrial Routers and Industrial Switches: A Practical Guide to Building a Stable Industrial Network

Networking with Industrial Routers and Industrial Switches: A Practical Guide to Building a Stable Industrial Network

In the field of the Industrial Internet of Things (IIoT), the stability of the network architecture directly determines production efficiency, equipment collaboration, and data security. Whether it's the automated production lines in smart factories or the energy monitoring systems in smart cities, the collaborative networking of industrial routers and industrial switches is the core of constructing a reliable network. This article will analyze how to achieve "zero-fault" operation of industrial networks through scientific networking.

1. Role Division of Industrial Routers and Switches: From "Commanders" to "Traffic Hubs"

1.1 Industrial Routers: The "Commanders" of Cross-Network Segment Communication

Industrial routers are the "boundary guardians" of industrial networks, with their core functions lying in cross-network segment communication and security policy management. Taking the USR-G806w as an example, this device supports the integration of 4G/WiFi/wired networks and has built-in VPN functionality, enabling remote networking across different geographical locations. For instance, in a remote operation and maintenance project for a wind farm, operation and maintenance personnel can remotely access the wind turbine PLCs through the IPSec VPN function of the USR-G806w without requiring a public IP address. This allows for real-time adjustment of control parameters, reducing the fault response time from 4 hours to just 15 minutes.

Key Technical Points:

• VPN Tunneling Technology: Supports multiple protocols such as PPTP, L2TP, and IPSec to ensure encrypted data transmission.
• Intelligent Multi-Network Switching: Automatically switches to the 4G network when the wired network is interrupted, ensuring business continuity.
• Firewall and ACL: IP/MAC-based access control to prevent unauthorized device access.

1.2 Industrial Switches: The "Traffic Hubs" within Local Area Networks

Industrial switches are the "data transfer stations" of industrial networks, responsible for the high-speed interconnection of devices within the local area network. The USR-ISG series of switches support VLAN segmentation, ERPS ring network redundancy, and PoE power supply, making them suitable for high-density device access scenarios. For example, in a smart park project, through the ERPS ring network protocol of the USR-ISG, the system can automatically switch to a backup link within 50ms when a link fails, ensuring uninterrupted video surveillance data transmission.

Key Technical Points:

• ERPS Ring Network Protocol: A fast ring network self-healing technology based on IEEE 802.1Q, suitable for high-reliability scenarios such as rail transit and power monitoring.
• VLAN Isolation: Segments different businesses (such as video surveillance and production control) into independent VLANs to avoid broadcast storms.
• PoE Power Supply: Single-port output power ≤ 30W, supporting the deployment of cameras, wireless APs, and other devices without power cables.

2. Networking Scheme Design: From "Single-Point Breakthrough" to "Global Optimization"

2.1 Star Topology: The "Cost-Effective Choice" for Small and Medium-Sized Factories

In small and medium-sized factories, it is recommended to adopt a combination of "industrial router + star topology switch." For example, a food processing plant uses the USR-G806w as the core gateway to connect multiple USR-ISG 8-port switches, forming a star network. PLCs, sensors, and other devices are connected through the switches, and the router is responsible for interfacing with the headquarters' ERP system. The advantages of this scheme include:

• Low Cost: No complex cabling is required, and switches can flexibly expand the number of ports.
• Easy Maintenance: Configuration can be completed through a web interface or CLI command line.
• High Scalability: When new devices are added, only ports need to be added on the switch.

2.2 Ring Topology: The "High-Reliability Solution" for Large Parks

In large parks or rail transit projects, it is recommended to adopt a combination of "industrial router + ring topology switch." For example, a smart port connects multiple USR-ISG 16-port switches through the USR-G806w to form a ring network structure. When a link fails, the ERPS protocol can complete the link switching within 50ms, ensuring that the data transmission of AGV carts, cranes, and other equipment is not affected. The advantages of this scheme include:

• High Redundancy: A single-point failure does not affect the overall network.
• Low Latency: The ring network self-healing time is much lower than that of traditional STP protocols.
• Long-Distance Transmission: Supports optical fiber SFP interfaces to meet park-level coverage needs.

3. Practical Cases: A Complete Closed Loop from "Theory to Implementation"

Case 1: Remote Operation and Maintenance Network for Smart Factories

Requirement: A car parts factory needs to achieve remote PLC programming and monitoring across different geographical locations.
Solution:

• Deploy the USR-G806w industrial router, configure the IPSec VPN tunnel, and connect the headquarters' network with the factory network.
• Install USR-ISG 8-port switches within the factory and isolate the production equipment from the office network through VLAN segmentation.
• Achieve centralized device management and real-time network status monitoring through the USR Cloud Platform.
  Effect:
• Remote programming efficiency is increased by 70%, and the fault response time is shortened to within 30 minutes.
• The network fault rate is reduced by 90%, and the annual maintenance cost is reduced by 500,000 yuan.

Case 2: Video Surveillance Network for Smart Parks

Requirement: A chemical park needs to achieve real-time transmission of high-definition video surveillance data.
Solution:

• Deploy the USR-G806w as the core gateway, supporting 4G/wired dual-link backup.
• Adopt USR-ISG 16-port switches to form a ring network and connect all cameras within the park.
• Simplify camera deployment through PoE power supply.
  Effect:
• Video transmission delay is <100ms, meeting the needs of real-time monitoring.
• The link self-healing time is <50ms, ensuring uninterrupted monitoring data.

4. How to Convey Value to Customers?

4.1 Addressing Pain Points: The Three Major Concerns of Customers

• Stability: Industrial networks must ensure 7×24-hour uninterrupted operation.
• Security: Prevent data leakage and unauthorized device access.
• Cost: Reduce initial investment and long-term maintenance costs.

4.2 Solutions: From "Product Combination" to "Service Closed Loop"

• Product Combination: Recommend the "USR-G806w + USR-ISG" golden combination, covering all scenarios from the core gateway to edge access.
• Service Closed Loop: Provide one-stop services from scheme design, equipment installation, to post-maintenance, ensuring customers can get started with "zero threshold."

4.3 Case Endorsement: Speaking with Real Data

• Showcase cases where a customer achieved a 30% increase in production efficiency and an 80% reduction in the fault rate after networking transformation.
• Provide industry white papers or third-party test reports to enhance customer trust.

Conclusion: The Future of Industrial Networks: From "Connection" to "Intelligence"

With the advancement of Industry 4.0, the roles of industrial routers and switches will no longer be limited to "data transmission" but will evolve towards "intelligent decision-making." For example, the USR-G806w already supports edge computing functionality, enabling local data preprocessing; the USR-ISG switch realizes intelligent traffic scheduling through AI algorithms. In the future, industrial networks will place more emphasis on "self-healing capabilities" and "predictive maintenance," and the foundation of all this is scientific and reasonable networking design.