Networking Applications of Industrial Switches in the Machining Industry: Unlocking New Dynamics for Smart Manufacturing

In the machining industry, digital transformation has transitioned from conceptual exploration to practical implementation. When devices such as CNC machines, industrial robots, and sensors need to achieve data interoperability, industrial switches, acting as the "nervous system" of industrial networks, are reshaping the production models across the entire industry. This article will analyze, from practical experience and combined with typical application scenarios, how industrial switches create tangible value for machining enterprises.

I. Core Value of Industrial Switches: Building a Reliable Production Network Foundation

In the fully automated intelligent production line project of Hefei Techik Intelligent Technology Group, the core challenge faced by the engineering team was how to ensure real-time transmission of large-scale image data between machine vision equipment and the main control system. The project team ultimately chose the SF/SG series industrial switches precisely for their threefold core advantages:

1. Guaranteed Deterministic Data Transmission
   Industrial switches employ a store-and-forward mechanism, controlling port latency at the microsecond level, and improving data frame forwarding efficiency by 300% compared to commercial Ethernet switches. In the Techik project, the GB-level data streams generated per second by machine vision equipment achieved zero-packet-loss transmission through the ring topology network constructed by the switches.

2. Breakthrough in Environmental Adaptability
   Machining workshops commonly face harsh conditions such as metal dust, oil contamination, and electromagnetic interference. The UT series switches, designed with an IP40 protection rating and a wide operating temperature range of -40°C to 75°C, operated faultlessly for 18 consecutive months in the sorting warehouse, reducing maintenance costs by 65%.

3. Plug-and-Play Deployment Efficiency
   The unmanaged design reduced equipment connection time from 2 hours in traditional solutions to just 15 minutes. In the renovation of Techik's 12 production lines, the entire factory's network deployment was completed in only 3 days, 5 days ahead of schedule.

II. Typical Application Scenarios: From Standalone Intelligence to System-wide Collaboration

Scenario 1: CNC Machine联网 (Networked) Transformation

A precision parts processing enterprise achieved centralized control and management of 200 CNC machines through the deployment of industrial switches. The Modbus TCP protocol conversion function supported by the switches unified the data from different manufacturers' CNC systems into the MES platform. After the transformation:

• Equipment utilization rate increased from 68% to 89%

• Fault response time reduced by 70%

• Annual maintenance costs decreased by RMB 2.3 million

Scenario 2: Intelligent Automated Warehouse

In an automated stereoscopic warehouse, the redundant ring network constructed by industrial switches enabled:

• Real-time positioning data synchronization for stacker cranes, conveyor lines, and AGVs

• Millisecond-level updates of storage location status information

• 40% improvement in inventory turnover rate

• 99.99% picking accuracy

Scenario 3: Energy Management System

An automotive components enterprise achieved, through energy consumption data collected by switches combined with AI algorithms:

• 18% energy savings in the air compressor group control system

• On-demand startup and shutdown of lighting systems, saving RMB 1.2 million annually in electricity costs

• 12 percentage point increase in equipment OEE (Overall Equipment Effectiveness)

III. Practical Guide to Technical Selection: Avoiding Three Common Pitfalls

Pitfall 1: Blind Pursuit of High Bandwidth

A machine tool manufacturer initially configured gigabit ports for each device during selection. However, in actual production, they discovered:

• 90% of data transmission volume was concentrated within 100 Mbps

• Switch costs exceeded the budget by 30%

• Heat dissipation design caused interference between devices

Correct Approach: Rationally configure port speeds based on the device communication protocol (e.g., PROFINET real-time cycle of 1 ms) and the number of concurrent connections (recommended ≤15 devices per port). For CNC systems, 100 Mbps ports can meet 95% of application scenarios.

Pitfall 2: Neglecting Network Redundancy Design

An enterprise adopted a star topology to save costs. After a lightning strike damaged the main switch:

• The entire production line was shut down for 8 hours

• Order delivery delays resulted in losses exceeding RMB 2.6 million

• Production recovery and debugging took 3 days

Best Practice: Adopt a combination of ring network + RSTP protocol to achieve 50 ms fault self-healing. Deploy dual-switch hot standby at critical points to ensure that single-point failures do not affect the overall system.

Pitfall 3: Formalistic Security Protection

An enterprise suffered a ransomware attack that infected all factory equipment within 3 hours through an industrial network without VLAN isolation:

• Production line shutdown for 15 days

• Ransom payment + recovery costs exceeded RMB 10 million

• Customer churn rate increased by 18%

Security Solution: Implement three-layer protection:

1. Physical isolation: Physically separate the production network from the management network

2. Logical isolation: Divide VLANs by device type

3. Deep inspection: Deploy industrial firewalls to filter illegal protocols

IV. Future Trends: Evolution Directions of Industrial Switches

1. TSN (Time-Sensitive Networking)
   A TSN switch being tested by an automotive OEM has achieved:

• Motion control data latency <1 μs

• Deterministic transmission of multiple protocols

• Latency synchronization with 5G networks

2. Edge Intelligence Integration
   The AI-accelerated switches launched by Guanglu Technology, equipped with a lightweight inference engine, enable:

• Real-time spectral analysis of vibration data

• Predictive maintenance of tool wear

• Edge preprocessing for visual inspection

3. Full Lifecycle Management
   Through digital twin technology, switches can provide real-time feedback on:

• Port utilization heatmaps

• Traffic anomaly warnings

• Automatic firmware upgrades

V. Actionable Recommendations for Machining Enterprises

1. Three-Dimensional Status Assessment

• Equipment networking rate: Prioritize transformation if below 30%

• Network latency: Critical devices require <10 ms

• Protocol coverage: Support for ≥5 mainstream protocols

2. Four-Step Implementation Path

1. Pilot verification: Select 1 production line for transformation

2. Standard establishment: Develop equipment communication protocol specifications

3. Scalable promotion: Complete factory-wide transformation in phases

4. Value挖掘 (Extraction): Develop value-added services such as predictive maintenance

3. Five Key Factors for Supplier Selection

• Industry cases: At least 3 projects of similar scale

• Local service: 4-hour response capability

• Compatibility certification: Mutual recognition with mainstream PLC/DCS systems

• Customization capability: Support for non-standard protocol development

• Ecosystem collaboration: Strategic synergy with MES/SCADA vendors

In the intelligent transformation of the machining industry, industrial switches have evolved from mere networking devices into bridges connecting OT (Operational Technology) and IT (Information Technology). Enterprises that take the lead in upgrading their network infrastructure are reaping compound benefits: over 30% increase in production efficiency, 25% reduction in quality costs, and 40% shortening of new product launch cycles. When industrial switches are deeply integrated with technologies such as digital twins and AI prediction, machining enterprises will truly achieve the leap from "manufacturing" to "smart manufacturing."