Westward Sales Blog

Sometimes, good network equipment is just not enough. Rugged network devices such as Ethernet switches, media converters, access points, and cellular routers must handle abusive industrial and outdoor environments. In these cases, finding the right product that meets the exact ruggedness level proves challenging. Knowing the environment and associated industry standards drives the best solutions.

What are Rugged Network Devices Tested to?

• Extreme temperatures
• Shock and vibration
• Electromagnetic compatibility
• Dust and water ingress

Areas of Ruggedness

Testing environmental tolerances ensures electronics meet the specific challenges at hand. Those tolerances include operating temperatures, physical vibrations, shock protection, ingress protection, magnetic interference, and redundancy.

Operating Temperatures

In climate-controlled data centers and offices, electronic devices are not typically exposed to severe environments. However, temperature extremes are a principal concern for mobile and outdoor applications. No universal standard for operating and storage temperatures certifies rugged networking devices. Instead, each device undergoes thermal testing, such as temperature cycling and thermal shock, to ensure safety and reliability. 

There are comparable rugged network devices with lower operating floors and higher ceilings. In most cases, ratings go well below freezing and well above the hottest possible outdoor air temperatures. Manufacturers will differentiate between storage and operating temperatures, and industrial equipment must meet both thresholds for harsh environment networking. For example, the FOI-6010 media converter operates efficiently from 0 to 50℃. In contrast, Antaira’s rugged IMC-C1000-M-T media converter has an operating temperature from -40 to 80°C.

Shock and Vibration

Electronic devices struggle when shaken vigorously. Many industrial and mobile settings experience frequent, extreme vibrations. Devices mounted in rotating machinery undergo constant vibration, and those in vehicles are subjected to both vibration and, in the case of an accident, shock. Vibration and shock can damage the electronic components, causing problems such as loosened fasteners, cracked circuit boards, deformed seals, and frayed wiring.

Using hardened design practices and certifying networking equipment meets shock and vibration levels is vital to increase reliability and the life cycle. IEC 60068-2-6 (vibration), IEC 60068-2-27 (shock), MIL-STD-810H Method 514.8 (vibration), MIL-STD-810H Method 516.8 (shock), and SAEJ1455 have precise test methods for shock and vibration.

In addition, various mounting options are available to mitigate shock and vibration, each suited for specific environments. In automation and control applications, for example, DIN provides the industry standard. DIN-rail mounts handle industrial vibration well. They stabilize equipment mounted in production equipment, solving the problem. In other environments, isolators integrated into wall, vehicle, and pole mounting brackets provide increased protection.

For instance, the Ericsson (formerly Cradlepoint) R980 mobile router meets SAE J1455 vehicle certifications and MIL-STD-810H for shock and vibration. Flange and bracket mounting options are available for further stability.

Electromagnetic Compatibility (EMC) 

Electronic equipment must operate safely in its environment without emitting or receiving unintended electromagnetic interference (EMI). EMI is a disturbance that may cause damage or degraded performance of a circuit.

Several standards ensure rugged network devices function without causing unwanted interference. Global organizations such as IEC, CISPR, and ISO, as well as national ones like EN in Europe, develop and manage EMC standards. These standards address the emission and immunity requirements of numerous electromagnetic phenomena such as conducted and radiated disturbances, electrostatic discharge (ESD), i.e., a spark, harmonics, magnetic fields, and voltage disruptions. 

Several industries require adherence to EMC standards and manufacturers comply by testing and distinguishing their products with FCC Notices, CE Mark, and regulatory approvals offering a clear idea of a device’s physical limitations. In automation applications, for instance, rugged Ethernet switches must adhere to several standards. The LNX-0500-M12-67 is a rugged switch that meets FCC, CE, EN6100, CE EN 55024, IP67, and UL 61010.

Ingress Protection

One key to creating a rugged device is to house it in a highly capable enclosure. Enclosure ratings are where Ingress Protection (IP) and National Electrical Manufacturer Association (NEMA) ratings come into play. While these are two independent standards, both use specific testing to ensure the types of exposure the housing can withstand while fully protecting the electronics within.

The IP codes are a standardized system to identify how enclosures resist dust and liquids penetrating the enclosure. They offer a code comparison of dust and water ingress; the higher the number, the more protection there is. At the highest level, the enclosure is entirely water and dust-proof, vacuum sealed, and impervious to ingress from any testable solid object. The ratings cover everything from large grains of sand to high-pressure water at various temperatures. Learn more about IP ratings from this article, Understanding IP Ratings for Industrial Electronics.

The NEMA standard also rates the effectiveness of electronic enclosures. While it closely matches IP ratings in many cases, NEMA goes further and considers corrosion resistance and the enclosure’s construction.

The protection ratings of the rugged networking device must match the operational conditions. For outdoor settings, look for a NEMA 4X rating or an IP rating of IP67 or better. Outdoor enclosures such as access points have a high ingress protection rating. The APP-AX-IP67 and ARY-7235-AC-PD wireless access points are no exception at IP67.

Redundancy

Redundancy is what separates availability from true ruggedness. No matter how well-designed a device may be, things happen, and redundancy keeps the network running in the face of adversity. Pay attention to physical and software-based redundancies. Both have value.

Examples of physical redundancy include primary and secondary power inputs, dual cellular modems with dual SIM cards, failover LAN and WAN links, and redundant hardware for safety-critical systems.

Software redundancies look at protocols and systems that help rugged network devices self-resolve issues as much as possible. Features like periodic reboots, LCP, and ICMP automatically solve many different sources of disruption. These protocols reduce downtime to optimize industrial connectivity.

In the end, a redundancy solution solves many problems, even in the most demanding environments. It’s simply matching the features and performance to a budget. 

Standards to Consider

Rigorous, tough standards produce high levels of reliability. They serve different purposes, and no single industrial standard covers every environmental possibility. Their purpose is to define test methods for a broad range of conditions, ensuring that the electronics are up to the rigors of combat, transportation, weather, and extremes. Accredited independent third-party laboratories usually perform product testing and certification. Several standards are consistently used to certify rugged networking devices. 

• MIL-STD-180G addresses high altitude, extreme operating and storage temperatures, wind-blown and freezing rain, humidity, fungus, salt fog, sand and dust exposure, shock, and vibration. 
• SAEJ1455 is an environmental standard that certifies equipment meets temperature and humidity extremes, vibrations, shocks, and more. 
• IP and NEMA offer a coding system indicating how well an electronics enclosure will withstand dust and water penetration.
• UL (North America) and IEC (global) standards focus on safety, quality, and performance. These standards are similar but also have several differences.
• FCC certification confirms that a rugged network device is safe and doesn’t emit excessive amounts of EMI.

Need Help Choosing a Rugged Device?

Westward Sales specializes in rugged networking devices that withstand the most punishing elements. Speak with one of our specialists to find a solution that meets your environmental needs. We are here to help you select the right device for the job.