What is WirelessHART?
WirelessHART is a wireless communication protocol for industrial automation, based on the existing HART protocol. It is designed to wirelessly connect Sensors and Actuators to process control systems, without compromising on reliability, safety or interoperability.
WirelessHART is particularly suitable for extending existing installations where cabling is difficult or expensive, such as in extensive or hazardous industrial environments.
🧠 How does WirelessHART work?
- Based on IEEE 802.15.4
- Operates in the 2.4 GHz ISM band
- Time-Synchronised Mesh Networking (TSMP)
- Network components
- WirelessHART field devices (sensors, actuators)
- Gateway that converts wireless data to a wired network (e.g. to DCS or SCADA)
- Network manager that handles routing, time synchronisation and security
- Security manager for key management and encryption
- Communication
- Reliable mesh networks with redundant paths
- Data is encrypted and time-synchronised
🏭 Application of WirelessHART in OT networks
- Extension of existing wired HART installations
- Installation of additional measurement points without running cables
- Temporary or mobile measurement setups
- Used in sectors such as oil & gas, chemicals, pharma and water treatment
Typical signals:
- Temperature, pressure, vibration, liquid levels
- Predictive maintenance via continuous monitoring
WirelessHART increases flexibility without modifying physical infrastructure.
🔍 WirelessHART vs. other wireless protocols
| Protocol | Application | Technology | Security |
|---|---|---|---|
| WirelessHART | Industrial sensors | IEEE 802.15.4, TSMP | ✅ AES-128, key management |
| Wi-Fi | Broadband wireless network | IEEE 802.11 | ✅ WPA2/WPA3 |
| Bluetooth | Short range, consumer | IEEE 802.15.1 | ✅, but limited in industry |
| IO-Link Wireless | Industrial IO communication | Proprietary/standard | ✅ (vendor-dependent) |
🔐 Security aspects
- AES-128 encryption at network and application layer
- Time slotting & frequency hopping prevent interference and eavesdropping
- Each device has a unique ID and cryptographic keys
- Supports network segmentation and device authentication
- Key rotation and session management via the security manager
WirelessHART is designed with safety, reliability and redundancy as core principles.
📌 In summary
WirelessHART is a reliable and secure wireless standard for industrial automation, based on the proven HART protocol. Ideal for extending measurement points without cabling, with full support for mesh networks and encrypted communication.