However, in order to fully leverage the advantages of the industrial metaverse and realize the vision of seamless sensor-to-cloud Ethernet connectivity, key infrastructure challenges must be addressed, for which Single Pair Ethernet (SPE) technology provides a solution.
Let's examine the ecosystem of the metaverse and the Industrial Internet of Things (IIoT). If we consider the metaverse as a digital twin of the physical world, it can serve as a useful training ground and testbed where engineers and product developers can test the impact of new product designs, manufacturing strategies, logistics strategies, and much more. It allows for thorough assessments of the impact of new products or strategies, helping stakeholders understand their strategic decisions and direction, and significantly reducing the time and cost required from concept to implementation.
On the other hand, the Industrial Internet of Things (IIoT) plays a role in the real world, allowing for the real-time collection of data and its sharing from machines to the entire MES and ERP system. This records data and increases production efficiency to levels impossible before the advent of Ethernet and the Internet. Ideally, the metaverse and the IIoT do not operate independently but are interconnected. Artificial intelligence models residing in cloud servers influence the factory floor, helping it make real-time decisions. Simultaneously, data from the factory floor can be used to further refine these AI models and digital twins, contributing to the industry's continuous development of digital models that increasingly accurately reflect the real world.
One might argue that one of the most critical areas contributing to the digital and artificial intelligence models comprised of the Industrial Internet of Things (IIoT) and the metaverse is sensor technology. Sensors act as eyes, ears, and fingers, informing MES systems when to execute commands, when to perform maintenance or process improvements, and reporting production capacity to ERP systems. Ultimately, the metaverse, by inputting data into reports and comparing expected and actual results, to some extent judges the accuracy of real-world functional models. Surprisingly, most sensors and actuators used in today's factory and process automation do not reside directly on Ethernet, but rather on non-Ethernet-based fieldbuses.
Problems with existing industrial networks
In the logistics sector, the so-called "last-mile delivery problem" is receiving increasing attention. As consumers' expectations for next-day delivery in online shopping continue to rise, "last-mile delivery" is considered the most critical link in the delivery process, ensuring customer satisfaction and maintaining cost competitiveness. When considering the journey of a product from the factory to the warehouse, to the delivery truck, and finally to the customer's doorstep, the journey from the warehouse to the customer's doorstep is considered the "last mile." Last-mile delivery is affected by factors such as delivery route distance, traffic, construction conditions, and weather. Furthermore, the time and cost associated with the final step of the delivery process constitute a considerable proportion of the total cost, estimated to be over 50%.
Industrial Ethernet faces similar challenges in factory and process automation. TCP/IP-based Ethernet technology is commonly used to connect cloud, ERP, MES, production cells, and machine-level control devices. However, the sensors and actuators of these systems are at the very edge of the ecosystem, and many factories still cautiously connect them to another fieldbus via cabling, then transmit the data over Ethernet via bridges or gateways. End users require additional software and hardware to support these fieldbuses, incurring additional costs, which in some cases is a real obstacle to implementing smart technologies. Therefore, it is reasonable to say that the metaverse and the Industrial Internet of Things (IIoT) face a "last mile" problem.
A single Ethernet pair can turn the tide
To address these issues, the SPE Industrial Partners Network was established in 2019. Now, the network alliance boasts over 50 member companies (all genuine cabling and connector suppliers), and its mission is to bring industry organizations together to develop new networking standards.
SPE is an abbreviation for "Single Pair Ethernet." As the name suggests, its key innovation is reduced cabling, meaning that a single twisted pair replaces two or four pairs of wire. The obvious benefits of this technology are significantly reduced cable weight and diameter, making the cable noticeably more flexible and easier to route. Furthermore, SPE addresses other major pain points in industrial networks: bandwidth, power, and coverage. This technology supports signal transmission rates up to 1Gbps over a single cable up to 40 meters long, with Power over Data Line (PoDL) power up to 50 watts. Compared to previous technologies, Single Pair Ethernet uses fewer wires, transmits more data, and provides significantly more power.
Furthermore, SPE can support signal transmission at 10 Mbps over 1000 meters of line length, 10 times longer than industrial Ethernet. More importantly, the electronics associated with the socket are optimized for size, making it easier to place SPE ports in confined spaces. This technology reduces the number of cables and enables power delivery, allowing for connector miniaturization. Therefore, it eliminates one of the major obstacles to mounting sensors on Ethernet—previous cable and connector technologies were limited by physical space.
The baseline cabling system, named T1 SPE IP20, is rugged and durable, meeting IP20 protection requirements. It operates in temperatures ranging from -40 to +85 degrees Celsius and can withstand up to 1000 mating cycles. For harsher environments, the M12 T1 SPE IP67 system is available, utilizing Molex connectors with IP67 protection.
Blueprint for the future
Standardization is a core prerequisite for implementing SPE. To avoid the fragmentation problems that occurred in early industrial networks, the more than 50 members of the SPE Industrial Partners Network have committed to designing standardized mating surfaces according to IEC 63171-6/-7. This network alliance also actively collaborates with a wide range of standardization committees on the following standards:
IEEE 802.3 Transmission Method
IEC SC46C - Symmetrical Copper Cable
IEC SC 48B Connector
ISO/IEC JTC 1/SC 25/WG3 - Wiring
IEC SC65C - Industrial Network
ANSI/TIA TR042 - Cabling System
Due to the strong focus on standardization, single-pair Ethernet is expected to become the preferred network architecture for Industry 4.0 implementations. Advances in industrial automation across multiple functional areas will become easier and more cost-effective. Sensors and actuators can be easily integrated into existing Ethernet environments without the need for additional interfaces.
It also allows fragmented legacy networks to be consolidated into a unified Ethernet-based solution, resulting in better communication, faster response times, and better IT maintenance operations.
This new product can connect more seamlessly to a wider range of IoT infrastructures, such as smart sensors, valves, actuators, drives, control panels, and other process automation equipment. Potential industry applications include building, factory and plant automation, machine-to-machine communication, lighting systems, elevator and escalator control, and robotics.
As a senior member of the SPE industrial partner network, Molex's SPE can transmit data at rates up to 1Gbps over 40-meter cables, with future versions capable of transmitting 10Mbps over 1-kilometer cables. With the SPE system, the future of the industrial metaverse looks brighter and more promising than ever before.
