The current Industry 4.0 is transforming the development of the industrial sector and creating trillions of dollars in new market opportunities. Energy-efficient manufacturing, supply chains, and asset-intensive places can all be realized with Industrial Internet of Things (IIoT) smart solutions. Low-power Wi-Fi wireless connectivity for IIoT connections will support various IIoT applications in challenging RF (Radio Frequency) environments and harsh conditions. This article will introduce you to the application requirements of IIoT, the characteristics of low-power Wi-Fi wireless connectivity, and the low-power Wi-Fi wireless connectivity solutions offered by Silicon Labs.
Wireless connectivity for industrial IoT equipment and systems
Wireless connectivity technology has brought significant changes to various industries, including industrial automation, building automation, agriculture, healthcare, and more. These industries benefit from the advantages of real-time sensor data, automation, and remote control. IIoT leverages wireless technology to gain deeper insights into machine conditions, eliminate unplanned downtime, and optimize throughput.
Firstly, wireless connectivity offers rapid time to market and mobility. Expanding wired networks in industrial environments requires meticulous planning and cumbersome hardware installation. With wireless technology, businesses can deploy new devices more flexibly, avoiding design limitations. Sensors and edge devices can be added more easily to facilities, whereas wiring would require installation or routed beneath floors, behind walls, or above ceilings.
In contrast, setting up wireless networks can save a substantial amount of costs, as wired connections incur expenses related to wiring and labor. Furthermore, if a wire were to malfunction, the cost of repairing or replacing it could be high. Additionally, wireless networks make remote monitoring and asset management more accessible. Workers can avoid dealing with potentially hazardous conditions that typically require wired connections, improving safety and efficiency.
Wi-Fi is currently the most widely used wireless protocol, thanks to its extensive installed base. Wi-Fi has become an attractive protocol for IoT wireless applications due to its wide adoption, established infrastructure, and interoperability. Many manufacturing and industrial applications rely on Wi-Fi.
On the other hand, remote monitoring through the cloud remains a top priority for most enterprises. Cloud services can be easily deployed within existing Wi-Fi networks. With the rise of edge artificial intelligence/machine learning (AI/ML) technologies, more companies are turning to edge computing. Edge computing involves running AI/ML algorithms closer to the devices to reduce latency and scale processing. By making decisions near the devices, it can offer higher reliability and faster response times for applications that require preventive and predictive measures, necessitating high bandwidth for transmitting large amounts of data. Additionally, when significant data transfer or Over-the-Air (OTA) firmware updates are desired, Wi-Fi is a good choice for carrying substantial data quantities within a limited amount of time.
The added value of low-power Wi-Fi in industrial IoT
Industrial applications often present more challenging environments compared to other sectors. Connected devices and sensors are often placed in remote areas, leading to logistical issues related to battery life and maintenance. Traditional Wi-Fi used in infrastructure devices like routers, mobile phones, and gateways may not be suitable for industrial settings where low-power devices are the backbone of these systems, and battery life is crucial.
On the other hand, low-power Wi-Fi provides significant advantages in terms of power consumption during transmit, receive, and sleep modes, significantly extending the battery life of all end node devices. This creates substantial value for many industrial IoT applications. Using low-power Wi-Fi becomes highly advantageous because battery-operated wireless devices have become the preferred design choice for new remote monitoring applications. Low-power Wi-Fi can be combined with Bluetooth/Bluetooth LE to extend the capabilities of local connections and clients.
When deploying low-power, cost-effective IIoT applications, careful consideration of energy consumption when using Wi-Fi is essential. Battery-powered end node devices require low power, and traditional Wi-Fi is not suitable for such applications. However, Wi-Fi offers excellent speed and bandwidth, giving it an advantage in industrial setups.
Furthermore, integrating wireless and network stacks is crucial in simplifying the IoT development process. Therefore, wireless and networking stacks integration is expected to go hand-in-hand with wireless solutions. Additionally, cloud connectivity and complete cloud connectivity with the major cloud providers is a key requirement, with security being essential to prevent online and physical attacks in mission critical operations. Cost and size are also critical factors in IoT, varying depending on the use case.
Low-power Wi-Fi finds applications across a wide range of industries and fields within IIoT, including asset trackers, smart meters, clinical medicine, point-of-sale systems, garage door openers, HVAC systems, body worn recorders, power tools, aftermarket telematics, data loggers/wireless sensors, industrial wearables, and more.
Wi-Fi 6 will facilitate wireless adoption in IIoT
Most IIoT devices today use 2.4 GHz Wi-Fi 4 because of its low power consumption, low cost, and extended range. However, due to limited channels and other protocols like Bluetooth Classic, Bluetooth Low Energy, and Zigbee also using the same spectrum, the spectrum is becoming increasingly crowded, which is where Wi-Fi 6 comes into play.
Most routers and laptops already have Wi-Fi 6 capabilities, and IIoT end node devices with Wi-Fi 6 capabilities are now gaining momentum. Wi-Fi 6 is well-suited for environments with a large number of coexisting devices, even in the 2.4 GHz spectrum, thanks to features like OFDMA and MU-MIMO, which support many coexisting devices in dense environments. This enables a large number of IIoT devices to coexist in the 2.4 GHz spectrum without the need to move to 5 GHz or 6 GHz, which would increase costs and power consumption. Applications include clinical medicine, power tools, and industrial wearables.
Furthermore, power consumption can be reduced through Target Wake Time (TWT), a new feature introduced in Wi-Fi 6. TWT allows end devices to wake up and check for data at specified times rather than waking up periodically, significantly reducing power consumption, which is crucial for all battery-powered devices.
With the increasing number of connected devices, growing data demands, and the need for protocols that can interoperate with multiple devices, Wi-Fi is penetrating the industrial market more and more. Silicon Labs now offers IoT Wi-Fi 4 products, providing integrated wireless stacks, networking stacks, cloud connectivity, and best-in-class security for the Internet of Things. Following this, Silicon Labs has introduced IoT Wi-Fi 6 products, including SoCs and modules, to further meet the demands of IIoT applications.
Highly integrated solution combining Wi-Fi and Bluetooth
Silicon Labs has introduced a range of Wi-Fi chips, including SiWx915, SiWx917, RS9116, and WF200. SiWx915 is suitable for use with Wi-Fi®, Bluetooth Low Energy, Matter, and IP networks, targeting line-powered or energy-efficient IoT devices. SiWx917, on the other hand, is designed for battery-powered IoT devices seeking ultra-low power and always-on cloud connectivity. RS9116 provides a comprehensive, multi-protocol, ultra-low-power solution, including Wi-Fi 4 and dual-mode Bluetooth 5. WF200 is an ideal Wi-Fi transceiver for secure, low-power IoT Wi-Fi applications.
SiWx915 is a Wi-Fi 6 plus Bluetooth Low Energy 5.4 wireless SoCs. It features a low-power Wi-Fi 6 SoC with Bluetooth Low Energy capabilities, enabling energy-efficient IoT devices with the highest security (WPA3, PSA level 2). It comes with up to 8 MB of flash memory and integrates an ARM® Cortex®-M4 with FPU, making it suitable for various applications and supporting the Matter protocol.
The SiWx915 SoCs includes a Wi-Fi 6 plus Bluetooth Low Energy wireless CPU subsystem, an integrated microcontroller (MCU) application subsystem, security features, memory, peripheral subsystems, all integrated into a single 6x6 mm QFN package. The wireless subsystem comprises a multi-threaded processor (ThreadArch®) running at frequencies of up to 160 MHz, baseband digital signal processing, analog front end, 2.4 GHz RF transceiver, and a power amplifier.
Silicon Labs' SiWx917, on the other hand, is a Wi-Fi 6 plus Bluetooth Low Energy 5.4 wireless SoCs designed for battery-powered IoT devices. It integrates an AI/ML accelerator, an ARM® Cortex®-M4 with FPU, enhanced security (WPA3, PSA level 2), PSRAM, up to 8 MB of flash memory, and supports the Matter protocol.
The SiWx917 SoC is the lowest-power Wi-Fi 6 SoC, making it highly suitable for ultra-low-power IoT wireless devices that require long battery life while using Wi-Fi®, Bluetooth, Matter, and IP networking for secure cloud connectivity. The SiWx917 SoC includes an ultra-low-power Wi-Fi 6 plus Bluetooth Low Energy 5.4 wireless CPU subsystem, an integrated microcontroller (MCU) application subsystem, security features, peripherals, and a power management subsystem, all integrated into a single 7x7 mm QFN package.
To accelerate product development, Silicon Labs has introduced the SiWx917 Wi-Fi 6 plus Bluetooth Low Energy 5.4 Pro Kit. The SiWx917 Pro Kit is designed to support the development of wireless IoT devices based on the SiWx917 ultra-low-power SoC.
Another offering from Silicon Labs is the RS9116 Wi-Fi NCP SoCs, which provides a comprehensive multi-protocol ultra-low-power solution, including support for Wi-Fi 4 and dual-mode Bluetooth 5. When coupled with the EFR32MG24 as a host, the RS9116 NCP also supports the Matter protocol.
The RS9116 QMS single-band wireless SoC from Silicon Labs provides a comprehensive multi-protocol wireless connectivity solution, including 802.11 b/g/n (2.4 GHz) and dual-mode Bluetooth 5. The wireless SoCs offers high throughput, extended range, and power-optimized performance. It has received FCC, IC, and ETSI/CE certifications.
Silicon Labs has also introduced the RS9116X EVK1 Wi-Fi plus Bluetooth development kit. The RS9116 single-band evaluation board offers a complete multi-protocol wireless connectivity solution, including 802.11 b/g/n (2.4 GHz) and dual-mode Bluetooth® 5, to support RS9116 family of SoCs and modules.
The WF200 series 2 Wi-Fi transceiver IC is suitable for secure and low-power IoT Wi-Fi applications. It is a Wi-Fi 4 pre-certified SiP with low transmission and receive power consumption. When coupled with EFR32MG24, WF200 also supports the Matter protocol. This transceiver is optimized for low power and optimal RF performance in crowded RF environments. It supports Linux-based and RTOS-based host systems to provide a complete Wi-Fi solution. It offers high-speed SPI and SDIO host interfaces, providing flexibility and throughput. The optional secure link interface enhances security. The WF200's package size can be as small as 4x4 mm, and it associated to DTIM3, with a current consumption of less than 298 µA.
The WF200 Wi-Fi expansion kit, SLEXP8022A, includes a built-in Raspberry Pi connector for immediate Linux development and an EXP connector for development on Silicon Labs' MCUs and wireless MCUs.
Conclusion
Low-power Wi-Fi wireless connectivity for IIoT is driving the Fourth Industrial Revolution, where IIoT smart solutions can eliminate unplanned downtime, optimize operational processes, and maximize production. The market potential is substantial. Silicon Labs' low-power Wi-Fi solutions, plus with Bluetooth protocols and security features, meet the requirements of IIoT wireless connectivity applications and are an ideal choice for developing IIoT devices.