Industrial IoT Specific Design Considerations

IoT is a key technology enabler for Industry 4.0 and is increasingly being implemented in manufacturing. This subset of IoT, known as Industrial IoT (IIoT), integrates IoT functionality into industrial settings. While new production systems often come with IoT capabilities by default, many manufacturing companies still rely on legacy equipment that can be upgraded using IoT solutions. Upgrading existing machinery is especially important, as manufacturing equipment is typically designed to last for decades, making frequent replacements impractical. Consequently, IIoT is essential for modernising older machinery to meet today's data-driven production demands, enhance efficiency, reduce downtime, minimise production waste, and lower the overall carbon footprint.

Recently, a new industrial paradigm called Industry 5.0 has emerged. Industry 5.0 builds on the principles of Industry 4.0, with a stronger emphasis on human well-being, resilience, and sustainability. In this context, IoT plays a vital role in achieving these objectives.

Although the general concepts and architecture of Industrial IoT (IIoT) are similar to typical IoT, the industrial sub-domain has specific features and requirements for designing IoT solutions for industry. Industrial applications can be divided into various fields, such as manufacturing and production, energy and utilities, transportation and logistics, agriculture and farming, construction and building, and automotive. Each field has specific needs but shares common critical factors crucial for implementing IoT systems. The most common ones are listed below.

• Industry Standards: All aspects of IoT systems, such as hardware, software, interfaces, and data formats, must adhere to industry standards and protocols.
• Reliability and Robustness: In industrial environments, hardware components must withstand harsher conditions, which can often be costly to maintain or repair. The installation and management of IoT hardware components and software upgradability must be considered from the conceptual design stage.
• Enhanced Security and Safety: As IoT devices connect to real production machinery, cybersecurity and general safety play a significant role. Unauthorised access to heavy machinery can lead to substantial financial losses or even fatal injuries.
• Scalability and Interoperability: Once the system is implemented, it is common for new equipment or production lines to be added over time. The IoT system must be designed so that new production resources can be easily integrated without restarting the conceptual design. Additionally, production often involves legacy equipment, and IoT can facilitate the integration of modern and legacy systems.
• Data Protection and Privacy: Data is one of the most valuable assets in modern industry. If the workforce is included in the IoT system monitoring domain, special attention must be given to data protection and privacy concerns.
• Cost Considerations: IoT systems are intended to make industrial processes more efficient and safe. Balancing the costs of development, installation, and maintenance with the system's added value is often a critical design consideration for industrial IoT.

These aspects must be addressed early in the IoT system design process. Designing IIoT systems requires careful consideration of several critical factors to ensure the successful deployment and operation of IoT solutions in industrial environments. In addition to the listed factors, many industry domain-specific requirements may rule over general industrial requirements. A well-designed IIoT system can enhance productivity, optimise resource usage, and improve safety, ultimately providing significant value to industrial operations. By focusing on these key features during the design process, industries can fully harness the potential of IIoT to drive innovation and remain competitive in an increasingly connected world.