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Industrial Automation and Wireless IoT - 5th Edition

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    Report

  • 200 Pages
  • September 2024
  • Region: Global
  • Berg Insight AB
  • ID: 4745670

The Installed Base of Wireless Devices in Industrial Automation Reached 56.5 Million in 2023

This study investigates the worldwide market for wireless IoT applications in industrial automation. The installed base of active wireless IoT devices in the industrial automation industry is forecasted to grow at a compound annual growth rate of 14.3% from 56.5 million units at the end of 2023 to 110.3 million units by 2028. Get up to date with the latest information about vendors, products and markets.

Highlights from the report:

  • 360-degree overview of the IoT ecosystem in the industrial automation industry.
  • Insights from 30 new executive interviews with market leading companies.
  • Comprehensive overview of the value chain and key applications.
  • In-depth analysis of market trends and key developments.
  • Detailed profiles of 79 key players in this market.
  • Updated market forecasts by technology, region and equipment category lasting until 2028.

Wireless technologies are integrated into a wide range of devices that can be used throughout an automation system, from the enterprise level all the way to the control and field levels. The devices can be broadly divided into two segments: automation equipment and network equipment. In the automation equipment segment, high-volume product categories featuring wireless communications capability include instrumentation such as industrial sensors, as well as wireless I/O and field devices that connect to sensors, actuators and machines. Important product categories within the network equipment segment are wireless access points, gateways, routers and switches.

The analyst estimates that annual shipments of wireless devices for industrial automation applications including both network and automation equipment reached 10.7 million units worldwide in 2023, accounting for approximately 9% of all new connected nodes. Growing at a compound annual growth rate (CAGR) of 12.3%, annual shipments are expected to reach 19.1 million in 2028. The installed base of wireless devices in industrial automation applications is forecasted to grow from an estimated 56.5 million connections at the end of 2023 to 110.3 million connected devices by 2028.

The adoption of wireless solutions in industrial environments is often a gradual process and an initial deployment typically comprises clusters of wireless devices connected to an existing wired network. Although wired networking solutions are still predominantly used for industrial communications between sensors, controllers and systems, wireless solutions are widely used as wire replacements in hard-to-reach or hazardous areas, on moving machine parts and on portable equipment. Standardised wireless technologies such as WiFi, IEEE 802.15.4 and Bluetooth have advanced to become the leading wireless technologies for industrial applications. Emerging technologies based on 5G broadens the addressable market for wireless communications as it allows for deployments where requirements related to bandwidth, latency or capacity cannot be fulfilled today.

Automation equipment such as wireless instrumentation is offered by many large automation vendors as part of complete systems for automation of industrial processes, but also by specialised providers. Emerson became the first company to market WirelessHART products in 2008 and has today an installed base of over 10 million wireless pressure transmitters worldwide. Major wireless instrumentation vendors further include Yokogawa and Honeywell, which both provide field devices based on the wireless technology ISA100.11a. Other major industrial automation vendors that provide wireless field devices include ABB, Endress+Hauser, Hitachi, OMRON, Pepperl+Fuchs, Schneider Electric and Siemens. Wireless I/O and field devices are also offered by a diverse range of players that are primarily active in the industrial communications and control markets. These include for example Advantech, Belden, Banner Engineering, Cisco, MultiTech, OleumTech, Phoenix Contact, Steute, Wago and Weidmüller.

Major providers of wired industrial network equipment also offer wireless solutions to enable customers to monitor and control devices wirelessly in parts of the plant that are normally not connected to the control room due to accessibility or wiring costs. These include Siemens, Cisco, Belden, Moxa and Phoenix Contact, which all offer industrial wireless devices such as routers, gateways and access points along their wired solutions. Additional providers of industrial WLAN devices include small to mid-size vendors such as Advantech, Ependion, Wago, HMS Networks, Red Lion Controls, Nexcom, INSYS Microelectronics, Lantronix, Welotec and Teltonika Networks.

Cellular and unlicensed proprietary radio solutions are typically used for data acquisition and backhaul communications in distributed automation applications. The largest providers of cellular IoT gateways and routers in the industrial space include Cisco, Semtech, Digi International, Moxa, GE Vernova, HMS Networks, Advantech, Robustel, InHand Networks and Teltonika Networks. Vendors of proprietary radio modems are GE Vernova, FreeWave Technologies, Banner Engineering and Schneider Electric.

The report answers the following questions:

  • Which are the leading wireless IoT solution providers for industrial automation applications?
  • What offerings are available from device vendors, platform vendors and service providers?
  • Which trends and developments are shaping the industrial automation market?
  • How will the market evolve in Europe, North America and Asia-Pacific?
  • What are the recent merger and acquisition activities in this market?
  • What are the key features of industrial software and IIoT platforms today?
  • How will connectivity strategies in industrial automation evolve in the future?

Who should read this report?

Industrial Automation and Wireless IoT is the foremost source of information about the adoption of wireless connectivity in the industrial automation sector. Whether you are a solution provider, device vendor, industrial automation player, telecom operator, investor, consultant, or government agency, you will gain valuable insights from this in-depth research.

Table of Contents


Executive Summary
1 The Industrial Automation Industry
1.1 Introduction to industrial automation
1.2 Factory and process automation
1.3 Factory and process operations
1.4 Industrial automation architecture overview
1.5 Industrial automation market segments
1.5.1 Industrial software
1.5.2 Industrial control systems
1.5.3 Automation equipment and instrumentation
1.5.4 Industrial robots
1.6 The industrial automation market
1.7 Industrial automation evolution

2 Wireless IoT Solutions in Industrial Automation
2.1 Wireless IoT infrastructure in industrial automation
2.1.1 Field and control segment
2.1.2 Network device segment
2.1.3 Backoffice segment
2.2 Operations management
2.2.1 Production and process management
2.2.2 Business management
2.3 Equipment management and regulatory compliance
2.3.1 Equipment diagnostics and maintenance planning
2.3.2 Security and safety
2.3.3 Regulatory compliance
2.4 Business models and project strategies

3 Market Forecasts and Trends
3.1 Market analysis
3.1.1 Installed base and unit shipments
3.1.2 Wireless technologies
3.1.3 Regional markets
3.1.4 Major vendors
3.2 Market drivers and barriers
3.2.1 Macroeconomic environment
3.2.2 Regulatory environment
3.2.3 Competitive environment
3.2.4 Technology environment
3.3 Value chain analysis
3.3.1 Industrial communications and control industry player
3.3.2 Industrial automation industry players
3.3.3 Wireless network operators and managed service providers
3.3.4 IoT platform and IT industry players
3.4 Market trends
3.4.1 Expansion of wireless capabilities in modular devices enables flexibility
3.4.2 Partnerships continue to be an integral part of business strategies
3.4.3 Solution providers bet on AI to optimise industrial operations
3.4.4 Cobots and robot ecosystems pave the way for further factory automation
3.4.5 Process industries drive the adoption of LPWA technologies
3.4.6 The maturing landscape of private LTE/5G networks at industrial sites

4 Global Automation Vendors
4.1 ABB
4.2 Bosch
4.3 Emerson
4.4 Endress+Hauser
4.5 FANUC
4.6 GE Vernova
4.7 Hitachi
4.8 Honeywell
4.9 Keyence
4.10 KUKA
4.11 Mitsubishi Electric
4.12 OMRON
4.13 Pepperl+Fuchs
4.14 Rockwell Automation
4.15 Schneider Electric
4.16 Siemens
4.17 Yaskawa Electric
4.18 Yokogawa

5 Device and Software Vendors
5.1 Industrial control solution vendors
5.1.1 ADLINK Technology
5.1.2 Advantech
5.1.3 Axiomtek
5.1.4 Banner Engineering
5.1.5 Beckhoff Automation
5.1.6 Contec (Daifuku)
5.1.7 Kontron
5.1.8 Nexcom
5.1.9 OnLogic
5.1.10 Opto 22
5.1.11 Ovarro
5.1.12 Phoenix Contact
5.1.13 Red Lion Controls (HMS Networks)
5.1.14 Steute
5.1.15 Wago
5.1.16 Weidmüller
5.2 Industrial wireless networking vendors
5.2.1 Acksys
5.2.2 Antaira Technologies
5.2.3 BEC Technologies (Billion Electric)
5.2.4 Belden
5.2.5 Cisco
5.2.6 Digi International
5.2.7 Ependion
5.2.8 Eurotech
5.2.9 Four-Faith Communication Technology
5.2.10 FreeWave Technologies
5.2.11 HMS Networks
5.2.12 Hongdian
5.2.13 InHand Networks
5.2.14 INSYS Microelectronics
5.2.15 Lantronix
5.2.16 Moxa
5.2.17 MultiTech
5.2.18 OleumTech
5.2.19 Robustel
5.2.20 Secomea
5.2.21 Semtech
5.2.22 Teltonika Networks
5.2.23 Welotec
5.3 IIoT platform and software vendors
5.3.1 Altair Engineering
5.3.2 Amazon
5.3.3 Automation Solutions
5.3.4 Braincube
5.3.5 C3.ai
5.3.6 Davra
5.3.7 Device Insight (KUKA)
5.3.8 Exosite
5.3.9 IBM
5.3.10 IFS
5.3.11 Inductive Automation
5.3.12 Litmus Automation
5.3.13 Losant
5.3.14 MaintainX
5.3.15 Microsoft
5.3.16 Oracle
5.3.17 PSI
5.3.18 PTC
5.3.19 SAP
5.3.20 Software AG
5.3.21 Telit Cinterion
5.3.22 Wind River (Aptiv)

Glossary
List of Figures
Figure 1.1: History of process and machine control systems for industrial automation
Figure 1.2: Examples of industrial automation market verticals
Figure 1.3: Manufacturing value chain
Figure 1.4: Architecture of industrial automation systems
Figure 1.5: Business activities of key global automation vendors
Figure 1.6: Relationship between ERP, MES and PLM systems
Figure 1.7: Examples of automation equipment and instrumentation
Figure 1.8: Annual shipments of industrial robots (World 2012-2022)
Figure 1.9: Annual shipments of industrial robots by sector (World 2022)
Figure 1.10: Operational stock and density of industrial robots by region (World 2022)
Figure 1.11: Industrial automation market value (World 2013-2023)
Figure 1.12: Industrial automation market value by vertical and region (World 2023)
Figure 2.1: Overview of wireless IoT infrastructure in industrial automation
Figure 2.2: Examples of control devices
Figure 2.3: Examples of cellular router and gateway
Figure 2.4: Latency and reliability requirements on TCP/IP and Ethernet traffic
Figure 2.5: Common wireless technologies in industrial automation
Figure 2.6: Example of backoffice segment in a connected automation system
Figure 3.1: New connected nodes in industrial automation by technology (World 2023)
Figure 3.2: Unit shipments and installed base by equipment category (World 2023-2028)
Figure 3.3: Unit shipments and installed base by technology (World 2023-2028)
Figure 3.4: Unit shipments and installed base by region (World 2023-2028)
Figure 3.5: Major vendors in the industrial communications market
Figure 3.6: Key data for industrial communications and control solution providers
Figure 3.7: M&As in the industrial communications and control sector (2020-2024)
Figure 3.8: Major industrial automation vendors
Figure 3.9: Key data for companies active in industrial automation
Figure 3.10: M&As in the industrial automation sector (2020-2024)
Figure 3.11: Top 10 mobile operators by IoT connections (World Q4-2023)
Figure 3.12: Top 10 IoT managed service providers by IoT connections (Q4-2023)
Figure 3.13: Key data for IIoT platform, cloud service and industrial software providers
Figure 3.14: Cisco’s modular Catalyst IR1101 industrial routers
Figure 3.15: Recent announcements of partnerships and collaborations (2023-2024)
Figure 3.16: Lifecycle of an edge AI application
Figure 3.17: Examples of a collaborative robot and an industrial robot
Figure 3.18: Performance requirements for demanding industrial use cases
Figure 4.1: ABB’s OmniCore family of robot controllers
Figure 4.2: Endress+Hauser’s Netilion IIoT ecosystem
Figure 4.3: Overview of FANUC’s MT-LINKi operational management software
Figure 4.4: GE Vernova’s MDS Orbit data acquisition and networking platform
Figure 4.5: Honeywell’s Versatilis line of wireless transmitters
Figure 4.6: Overview of the KUKA iiQoT platform
Figure 4.7: Mitsubishi’s iQ Platform
Figure 4.8: Pepperl+Fuchs’ industrial communications product portfolio
Figure 4.9: Sensia’s QRATE HCC2 edge controller
Figure 4.10: Schneider Electric’s Instrument Area Network wireless architecture
Figure 4.11: Siemens’ SCALANCE series of network devices
Figure 4.12: Yokogawa’s gateways and wireless access point based on ISA100.11a
Figure 5.1: Advantech’s WISE-4250 series of wireless I/O modules
Figure 5.2: Axiomtek’s AIE100-ONA industrial edge computers
Figure 5.3: Example of an operation monitoring solution based on Contec’s devices
Figure 5.4: Kontron’s KBox A-151 industrial embedded box PCs
Figure 5.5: OnLogic’s Helix 500 and 600 series of industrial computers
Figure 5.6: Opto 22’s Groov EPIC system
Figure 5.7: Ovarro’s TBox remote terminal unit
Figure 5.8: Phoenix Contact’s cellular routers and remote maintenance gateways
Figure 5.9: Wago’s automation technologies and solutions
Figure 5.10: Weidmüller’s portfolio of industrial Ethernet devices
Figure 5.11: Belden’s NB1800 series industrial router
Figure 5.12: Cisco’s Catalyst IW9165E and IW9167E industrial wireless access points
Figure 5.13: Digi International’s Digi IX40 industrial cellular router
Figure 5.14: Westermo’s industrial WLAN devices
Figure 5.15: Eurotech’s modular IoT edge platform
Figure 5.16: HMS Networks’ cellular IoT gateways
Figure 5.17: Hondian’s X2 industrial gateway for CNC fleets
Figure 5.18: INSYS icom’s industrial 4G LTE routers
Figure 5.19: Lantronix’s G520 Series cellular IoT gateway
Figure 5.20: MultiTech’s MultiConnect rCell 100 Series cellular router
Figure 5.21: Robustel’s IoT routers
Figure 5.22: Secomea’s turnkey IIoT solution
Figure 5.23: Altair Engineering’s IoT Studio platform solution
Figure 5.24: AWS IoT services
Figure 5.25: Overview of the AWS IoT SiteWise managed service
Figure 5.26: AUTOSOL’s ACM platform
Figure 5.27: C3 AI Platform’s data modules and extensions
Figure 5.28: Exosite’s ExoSense condition monitoring application
Figure 5.29: IBM’s business portfolio
Figure 5.30: Overview of IBM’s Maximo Application Suite
Figure 5.31: Components of the IFS Cloud platform
Figure 5.32: Inductive Automation’s Ignition software platform architecture
Figure 5.33: Litmus Automation’s industrial edge computing platform
Figure 5.34: Microsoft’s Azure IoT technologies and solutions
Figure 5.35: Azure IoT Operations Architecture Overview
Figure 5.36: PTC’s ThingWorx platform
Figure 5.37: Components of the Cumulocity IoT platform
Figure 5.38: Telit Cinterion’s deviceWISE IIoT Platform

Companies Mentioned (Partial List)

A selection of companies mentioned in this report includes, but is not limited to:

  • ABB
  • Acksys
  • ADLINK Technology
  • Advantech
  • Altair Engineering
  • Amazon
  • Antaira Technologies
  • Automation Solutions
  • Axiomtek
  • Banner Engineering
  • BEC Technologies (Billion Electric)
  • Beckhoff Automation
  • Belden
  • Bosch
  • Braincube
  • C3.ai
  • Cisco
  • Contec (Daifuku)
  • Davra
  • Device Insight (KUKA)
  • Digi International
  • Emerson
  • Endress+Hauser
  • Ependion
  • Eurotech
  • Exosite
  • FANUC
  • Four-Faith Communication Technology
  • FreeWave Technologies
  • GE Vernova
  • Hitachi
  • HMS Networks
  • Honeywell
  • Hongdian
  • IBM
  • IFS
  • Inductive Automation
  • InHand Networks
  • INSYS Microelectronics
  • Keyence
  • Kontron
  • KUKA
  • Lantronix
  • Litmus Automation
  • Losant
  • MaintainX
  • Microsoft
  • Mitsubishi Electric
  • Moxa
  • MultiTech
  • Nexcom
  • OleumTech
  • OMRON
  • OnLogic
  • Opto 22
  • Oracle
  • Ovarro
  • Pepperl+Fuchs
  • Phoenix Contact
  • PSI
  • PTC
  • Red Lion Controls (HMS Networks)
  • Robustel
  • Rockwell Automation
  • SAP
  • Schneider Electric
  • Secomea
  • Semtech
  • Siemens
  • Software AG
  • Steute
  • Telit Cinterion
  • Teltonika Networks
  • Wago
  • Weidmüller
  • Welotec
  • Wind River (Aptiv)
  • Yaskawa Electric
  • Yokogawa

Methodology

 

 

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