Which Communication Chips Are Used in Industrial Ethernet?

Industrial Ethernet has become the backbone of modern automation systems, connecting programmable logic controllers (PLCs), distributed I/O modules, servo drives, industrial robots, machine vision systems, and supervisory control platforms into unified real-time networks. As factories move toward Industry 4.0 architectures, communication reliability increasingly determines production efficiency, equipment availability, and process quality.

Unlike conventional office Ethernet, industrial Ethernet networks must operate under conditions that include electrical noise, vibration, extreme temperatures, and strict real-time communication requirements. Achieving deterministic performance depends not only on network protocols but also on the communication semiconductors embedded within industrial equipment. Ethernet PHYs, switch controllers, protocol processors, industrial communication ASICs, microcontrollers, FPGAs, and isolation devices collectively form the hardware infrastructure that enables industrial networking.

Why Industrial Ethernet Requires Specialized Communication Chips

Traditional Ethernet was originally designed for best-effort data transmission, where occasional delays or packet loss could be tolerated.

Industrial automation environments operate under very different constraints.

Examples include:

• Motion control synchronization

• Robot coordination

• Conveyor tracking

• High-speed machine vision

• Functional safety systems

In these applications, microseconds matter.

A robotic welding cell may require synchronization accuracy better than 1 μs, while a servo drive network can require communication cycles below 250 μs.

Consequently, industrial Ethernet devices rely on communication chips specifically designed to support:

• Deterministic timing

• Low latency

• High electromagnetic immunity

• Long-term reliability

• Real-time protocol acceleration

Ethernet PHY Transceivers: The Physical Layer Foundation

Every industrial Ethernet node contains a Physical Layer Transceiver (PHY).

The PHY acts as the interface between digital controllers and Ethernet cables, converting electrical signals into data packets and vice versa.

Core Functions

Industrial Ethernet PHYs perform:

• Signal encoding and decoding

• Auto-negotiation

• Link monitoring

• Cable diagnostics

• EMI reduction

Common Industrial Ethernet PHY Specifications

Popular PHY Families

Widely adopted industrial Ethernet PHYs include:

• DP83867 Series

• KSZ9031 Series

• BCM54616 Series

• BCM54810 Series

• LAN8770 Single-Pair Ethernet PHY

• ADIN1200 Industrial PHY

These devices are frequently found in PLCs, industrial gateways, motor drives, and factory networking equipment.

Industrial Ethernet Switch Controllers

As industrial networks expand, multiple Ethernet nodes must communicate simultaneously.

Switch controllers manage this traffic.

Unlike office-network switches, industrial switch chips are optimized for deterministic communication.

Key Functions

Industrial switch ICs support:

• Packet forwarding

• Traffic prioritization

• Time synchronization

• VLAN management

• Redundancy protocols

Performance Comparison

Industrial switch controllers frequently support:

• Precision Time Protocol (PTP)

• Time-Sensitive Networking (TSN)

• Ring redundancy

These capabilities are essential for real-time automation networks.

Communication Processors and Network Controllers

As communication complexity increases, dedicated network processors often manage protocol stacks independently of the primary application processor.

Typical Responsibilities

Communication processors handle:

• Packet processing

• Protocol conversion

• Traffic management

• Security functions

• Gateway operation

Industrial controllers commonly use communication processors to separate networking tasks from control functions.

This architectural separation improves system determinism.

Performance Requirements

Modern industrial gateways may process:

• Thousands of packets per second

• Multiple protocol stacks simultaneously

• Encryption and authentication routines

Without dedicated processors, CPU loading can significantly impact machine performance.

Industrial Ethernet ASICs and Protocol Chips

Many industrial Ethernet standards require specialized hardware support.

Protocols such as:

• PROFINET

• EtherCAT

• EtherNet/IP

• POWERLINK

• Sercos III

often rely on dedicated communication ASICs.

Why Protocol-Specific Hardware Matters

Real-time communication requires deterministic packet handling.

Software-only implementations frequently introduce:

• Timing variations

• Latency increases

• CPU overhead

Dedicated ASICs process protocol frames directly in hardware.

Typical Advantages

For high-performance motion control systems, dedicated communication ASICs often provide significant benefits.

EtherCAT Slave Controllers

EtherCAT remains one of the most widely deployed industrial Ethernet protocols for motion control applications.

Its architecture minimizes communication delays by processing Ethernet frames "on the fly."

EtherCAT Communication Characteristics

EtherCAT Controller Chips

Dedicated EtherCAT slave controllers perform:

• Frame processing

• Distributed clock synchronization

• Network diagnostics

• Real-time communication management

Applications include:

• Servo drives

• Industrial robots

• CNC systems

• Packaging equipment

FPGA Devices in Industrial Ethernet Systems

FPGAs increasingly serve as communication engines within advanced automation equipment.

Unlike traditional processors, FPGAs process multiple communication channels simultaneously.

FPGA Communication Functions

Industrial Ethernet FPGAs commonly support:

• Multi-protocol communication

• TSN implementation

• High-speed packet processing

• Real-time synchronization

• Redundant network management

Parallel Processing Benefits

Consider a robotic controller connected to:

• Eight servo drives

• Multiple vision sensors

• Safety devices

• PLC networks

An FPGA can process these communication streams concurrently without software scheduling delays.

This capability substantially reduces jitter.

Case Example

A multi-axis motion platform experienced synchronization errors approaching 3 μs under peak network traffic.

After migrating critical communication processing from software to FPGA hardware, synchronization accuracy improved to below 200 ns.

The improvement directly increased positioning precision during high-speed operation.

Microcontrollers Supporting Industrial Ethernet

Microcontrollers frequently integrate industrial Ethernet peripherals.

These embedded communication controllers reduce system complexity.

Common MCU Functions

Industrial Ethernet MCUs typically manage:

• Sensor acquisition

• Local control logic

• Communication stacks

• Diagnostics

Integrated Communication Features

Modern industrial MCUs often include:

• Ethernet MAC

• TSN support

• Security acceleration

• Industrial protocol interfaces

The integration reduces component count while improving reliability.

Applications include:

• Remote I/O modules

• Smart sensors

• Embedded controllers

• Human-machine interfaces

Time-Sensitive Networking and Emerging Communication Chips

TSN is increasingly becoming a major technology within industrial Ethernet systems.

Unlike conventional Ethernet, TSN introduces deterministic communication capabilities.

Key TSN Functions

• Time synchronization

• Scheduled traffic

• Traffic shaping

• Low-latency delivery

Semiconductor Requirements

TSN-capable communication chips require:

• Precision timing hardware

• Advanced packet scheduling

• Hardware timestamping

• Deterministic switching functions

TSN adoption is expected to accelerate as factories converge information technology (IT) and operational technology (OT) networks.

Industrial Isolation Devices in Ethernet Systems

Communication reliability depends not only on data transmission chips but also on electrical isolation components.

Industrial facilities frequently contain:

• High-voltage motors

• Inverters

• Welding systems

• Electromagnetic interference sources

Isolation Functions

Industrial isolation ICs provide:

• Ground loop protection

• Noise immunity

• Operator safety

• Equipment protection

Typical Specifications

Without proper isolation, network reliability can deteriorate significantly in harsh environments.

Risk Factors When Selecting Industrial Ethernet Communication Chips

Component selection requires balancing performance, lifecycle, and supply-chain considerations.

Lifecycle Risk

Industrial equipment often remains in service for 10–20 years.

Communication chips approaching:

• NRND status

• End-of-life announcements

• Limited manufacturing capacity

may create long-term maintenance challenges.

Cybersecurity Considerations

Communication processors increasingly incorporate:

• Secure boot

• Hardware encryption

• Authentication engines

Industrial infrastructure faces growing cybersecurity requirements.

Supply Chain Stability

A communication controller shortage can halt production even when all other components remain available.

Procurement teams therefore evaluate:

• Manufacturer support

• Multi-source availability

• Long-term supply commitments

alongside technical specifications.

Case Study: Industrial Robot Ethernet Network Upgrade

An industrial robot manufacturer sought to improve synchronization performance across multiple servo axes.

Existing System

Architecture included:

• Standard Ethernet PHY

• Software protocol stack

• Conventional switch controller

Performance challenges included:

• Communication jitter exceeding 5 μs

• Increased cycle-time variation

• Motion synchronization limitations

Upgrade Strategy

The engineering team implemented:

• Industrial-grade Gigabit PHYs

• EtherCAT slave controllers

• FPGA-based synchronization

• TSN-capable switching devices

Results

The improvements demonstrated how communication chip selection directly influences machine performance.

Communication Chip Categories Commonly Found in Industrial Ethernet Equipment

PLC Systems

• Ethernet PHYs

• Industrial switch controllers

• Communication processors

• Isolation ICs

Servo Drives

• EtherCAT controllers

• Real-time communication ASICs

• PHY transceivers

• FPGAs

Industrial Robots

• Gigabit PHYs

• Multi-port switches

• TSN controllers

• FPGA communication engines

Industrial Gateways

• Network processors

• Security processors

• Protocol conversion ASICs

The specific combination depends on network architecture, protocol requirements, and real-time performance objectives.

Industrial Ethernet Semiconductor Sourcing and Quality Assurance

Selecting communication chips for industrial Ethernet applications requires more than comparing datasheets. Long-term availability, protocol compatibility, reliability verification, and traceability are equally important, particularly in automation systems where downtime can create substantial operational losses.

At semi, sourcing services support industrial communication projects involving Ethernet PHYs, switch controllers, EtherCAT processors, industrial communication ASICs, FPGAs, network processors, isolation ICs, and long-lifecycle automation semiconductors. Global inventory access, obsolete component sourcing, alternative part recommendations, and lifecycle risk management help customers maintain supply continuity throughout extended product lifecycles.

Comprehensive supplier qualification procedures, incoming quality inspections, authenticity verification programs, traceability documentation, and controlled procurement processes ensure component reliability. Through rigorous quality management and supply chain expertise, industrial equipment manufacturers gain access to communication semiconductors capable of meeting the demanding performance, longevity, and reliability requirements of modern industrial Ethernet networks.

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