A new era is on the horizon
For years, dedicated ASICs, FPGAs, and specialized network boards were considered essential for achieving real-time performance in industrial networking. But today, software-based solutions are proving that hardware dependency is fading fast. Many leading industrial protocols—PROFINET, EtherNet/IP, Modbus, CC-Link IE—no longer require dedicated chips to meet performance demands. Instead, advances in processing power, real-time operating systems, and optimized network stacks are enabling high-performance industrial communication on general-purpose hardware.
So, is specialized networking hardware becoming obsolete? In many cases—yes. Here’s why.
1️⃣ Blazing-Fast CPUs Have Changed the Game
The rapid advancement of multi-core processors and higher clock speeds has shattered the myth that dedicated silicon is required for real-time networking. Modern industrial automation hardware—whether embedded controllers, industrial PCs, or edge computing platforms—can now handle real-time industrialnetworking purely in software. With the right optimizations, a general-purpose processor can process industrial Ethernet frames with sub-millisecond jitter, previously achievable only with hardware acceleration.
2️⃣ Real-Time Linux is Now Part of the Kernel
For years, running a real-time operating system (RTOS) alongside Linux meant relying on custom patches or dual-system architectures. But with the PREEMPT_RT patch set now integrated into the mainline Linux kernel, low-latency scheduling, deterministic task execution, and precise interrupt handling are possible out of the box. This means that standard Linux-based industrial controllers can now deliver the real-time guarantees once thought to be the exclusive domain of specialized RTOS-based systems. Read the actual git commit here.
Alternatively, a hybrid approach using a dual-core or multi-core processor allows Linux to run on one core for application tasks, while a dedicated RTOS runs on the other to manage industrial communication with strict timing constraints. This model enables real-time networking without external networking chips while preserving the flexibility and scalability of Linux for application logic.
3️⃣ Optimized Network Stacks and Drivers Close the Performance Gap
Industrial network stacks have evolved significantly, with software-based protocol implementations now rivaling hardware-accelerated solutions. Optimized drivers and high-performance protocol libraries for industrial communication—PROFINET, EtherNet/IP, Modbus TCP, and CC-Link IE —can now be fine-tuned to run with minimal jitter on standard hardware.
4️⃣ Scalable, Software-Defined Flexibility Wins
With traditional hardware-based industrial networking, changing protocols or adding new features often required costly redesigns and re-certifications. A software-based approach eliminates these constraints, enabling manufacturers to deploy new networking features, switch protocols, and integrate enhancements through software updates—without touching the hardware.
This software-defined flexibility is especially valuable in multi-protocol environments, where devices may need to communicate over multiple industrial networks (e.g., PROFINET and EtherNet/IP) without requiring separate hardware implementations for each protocol. By abstracting networking functions into software, manufacturers can streamline development, reduce product SKUs, and accelerate time-to-market.
5️⃣ Lower Costs, Faster Upgrades, and Simplified Maintenance
Eliminating or reducing specialized networking hardware directly cuts down BOM (Bill of Materials) costs, making industrial devices more cost-effective. Additionally, removing proprietary chips simplifies firmware updates, security patching, and long-term maintenance, ensuring that industrial systems remain resilient, secure, and adaptable to future networking advancements.
By leveraging software-based industrial communication, manufacturers can roll out new networking features faster, reduce long-term support costs, and enhance cybersecurity—all without the constraints of aging or vendor-locked hardware.
What Does This Mean for Your Automation Projects?
The shift toward software-defined industrial networking is accelerating. Whether you’re designing new industrial devices or upgrading legacy systems, the ability to achieve real-time communication without dedicated hardware is a game-changer. One of RT-Labs’ key offerings is U-Phy, a multi-protocol industrial communication software that allows devices to support PROFINET, EtherNet/IP, Modbus TCP and EtherCAT devices.
If you’re curious about how to simplify and future-proof your industrial networking, RT-Labs is here to help. Our software solutions enable seamless, high-performance industrial communication—without the hardware overhead.