February 25, 2026
CloudRAN.AI and Firecell Partner to Cut the Cost and Complexity of Private 5G
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BREAKING NEWS: Firecell and Accelleran Merge to Deliver Sovereignty-Compliant Industrial Private 5G Learn more
Redundant 5G networks are transforming industrial automation by ensuring continuous connectivity, even in challenging environments like factories. These systems use multiple data paths and failover mechanisms to maintain reliability, reduce latency, and prevent downtime. By strategically placing multiple transmission points and integrating advanced technologies like Time-Sensitive Networking (TSN), they meet the strict demands of modern manufacturing.
Redundant 5G networks are essential for coordinating robots, autonomous vehicles, and other equipment in industrial settings. They not only prevent disruptions but also enable flexible, efficient production systems.
Comparison of 5G Redundant Network Topologies for Industrial Automation
Redundant 5G network topologies play a critical role in industrial automation by ensuring uninterrupted data flow and reducing downtime. Industrial facilities typically rely on three main topologies to maintain connectivity, each tailored to address specific failure scenarios. These range from base station outages to core network disruptions. Choosing the right approach depends on your priorities – whether that’s zero-latency failover, carrier diversity, or protection against infrastructure failures.
Dual-connectivity enables devices to maintain simultaneous links to multiple base stations (gNBs). As a 3GPP-standardised solution, it transmits data over independent paths, ensuring that if one link fails, the data from the alternative path is already available.
"PRP can be realised in cellular networks through the dual connectivity (DC) solution." – Adnan Aijaz, IEEE Communications Standards Magazine
This Active/Active topology ensures data is distributed across both links simultaneously. 3GPP Release 18 highlights redundant packet transmission as a key method to achieve ultra-reliable communication.
When setting up dual-connectivity, engineers must decide where to place the replication logic. Placing it in the gNB safeguards against core network failures but leaves the system vulnerable to base station outages. On the other hand, locating it within the User Equipment (UE) provides protection against both gNB and UPF (User Plane Function) failures, though it increases energy consumption and network load.
PREOF provides 1+1 path protection by replicating packets at a Protection Tunnel Ingress (PTI), transmitting them over separate paths, and removing duplicates at a Protection Tunnel Egress (PTE). This ensures redundant packets are already en route, allowing for seamless failover at the packet level.
In February 2025, the Fraunhofer Institute for Production Technology IPT demonstrated a 5G-TSN prototype using IEEE 802.1CB (FRER) for smart sensors in a milling process. This system required latency below 10 ms for 99.99% of packets to detect issues like tool wear. By employing FRER across multiple 5G paths (mid-band and mmWave), researchers Pierre E. Kehl and Junaid Ansari reduced the 99.99th percentile latency from over 11 ms to 8.28 ms, maintaining a 99.99% packet delivery ratio.
"The likelihood that errors are induced at the same time on multiple independent links using FRER is significantly reduced; thereby, an increase in reliability of the 5G transmissions is observed." – Pierre E. Kehl et al., Fraunhofer Institute for Production Technology IPT
However, PREOF has its challenges. Encapsulation can obscure the original UE IP header from the UPF, potentially requiring a "protection proxy" using eBPF to maintain Quality of Service policies.
Dual-SIM redundancy leverages two SIM cards from different network operators to provide hardware-level backup. This ensures that a network-wide outage from one carrier won’t disrupt both primary and backup connections.
Industrial 5G routers can achieve failover in less than 30 seconds. These systems use intelligent health checks, such as ICMP ping tests to reliable targets (e.g., 8.8.8.8), with failure parameters like "3 failures every 10 seconds" to trigger a switch.
"The difference between a frustratingly unreliable failover system and a truly ‘unbreakable’ one lies in the intelligence of its execution." – Robert Liao, Technical Support Engineer, Robustel
For better efficiency, configure automatic failback to return to the primary connection once it’s stable – typically after five minutes of consistent performance. This prevents "flapping" between connections and helps control data costs. Additionally, set thresholds for latency or signal strength (RSSI/RSRP) to trigger failover before a total connection loss occurs.
| Feature | Dual-Connectivity (DC) | PREOF (1+1 Protection) | Dual-SIM Failover |
|---|---|---|---|
| Primary Goal | Low latency & seamless failover | Path resilience & zero packet loss | Carrier/Network redundancy |
| Standard | 3GPP (Cellular) | IETF DetNet / 3GPP Rel 18 | Industrial Router Logic |
| Failover Time | Near-zero (packet-level) | Near-zero (packet-level) | Typically < 30 seconds |
| Complexity | High (requires 5G core support) | High (requires PTI/PTE nodes) | Moderate (device-side config) |
These approaches provide a strong foundation for creating reliable 5G networks in industrial settings.
Setting up redundant 5G networks in industrial environments starts with careful planning and configuration. The focus should be on the 5G core setup and the deployment of radio equipment.
Redundancy begins at the 5G core, where the best approach involves creating multiple Protocol Data Unit (PDU) sessions using separate User Plane Functions (UPFs). This ensures traffic can reroute seamlessly if one UPF fails, achieving up to 99.97% reliability in simulations.
To handle different failure scenarios, configure replication logic at specific protocol layers:
For critical devices like robotic arms or CNC machines, deploy multiple User Equipment (UE) devices. Group these devices by unique identifiers (e.g., IMSI) to ensure traffic replication across separate wireless links, removing single points of failure.
Once redundant paths are in place, the next step is to integrate these networks with time-sensitive protocols.
Industrial automation demands precise time synchronisation and low latency. Configure your 5G network as a logical IEEE-compliant virtual Ethernet-TSN bridge to meet these needs. This involves using a TSN Application Function (AF) to communicate 5G system bridge capabilities to a Centralised Network Configuration (CNC) entity .
Add TSN Translators at the network edge – one at the UE and another at the UPF – to bridge protocol differences and map TSN traffic streams to corresponding 5G QoS flows . The system’s 5G clock (Grandmaster) must synchronise all elements as an IEEE 802.1AS "time-aware system", supporting up to 128 gPTP time domains.
For zero recovery time, implement IEEE 802.1CB FRER. This method replicates frames at their source and sends them over separate 5G paths, with duplicates removed at the destination. In February 2025, researchers at the Fraunhofer Institute for Production Technology (IPT) in Germany tested this on a 3.7–3.8 GHz mid-band and a 26 GHz mmW network. They achieved a 99.99% packet delivery success rate with latency under 10 milliseconds, meeting the requirements for real-time tool wear detection.
"FRER replicates each frame at source over multiple paths and provides an elimination mechanism for redundant frames at the destination… providing zero recovery time." – Adnan Aijaz, Toshiba Europe Ltd
To extend reliability across large industrial sites like ports or manufacturing plants, consider these strategies:
| Redundancy Method | Implementation Layer | Reliability Benefit |
|---|---|---|
| Multiple PDU Sessions | Core/Transport Layer | Protects against UPF or core network failures |
| Dual-Connectivity (MgNB/SgNB) | RAN/Air Interface | Guards against local radio link outages and interference |
| Frequency Diversity | Physical/Spectrum | Combines wide coverage (sub-6 GHz) with high capacity (mmW) |
| FRER (IEEE 802.1CB) | Data Link Layer | Ensures zero recovery time by discarding redundant duplicates |
These approaches ensure the continuous operation essential for industrial processes, even in large, complex facilities.
Firecell offers tailored, ready-to-deploy solutions for industrial 5G networks, building on the robust redundant network setups discussed earlier.
Firecell provides private 5G bundles that are factory-ready and can be deployed in just 12 weeks. These bundles are designed for seamless integration, offering both cloud-based and on-premise options, making it easier to transition from legacy Wi-Fi systems.
The platform ensures 99.99% uptime with deterministic connectivity under 20 ms latency. Pre-configured Quality of Service profiles optimise performance for IoT alerts, video streams, and safety-critical applications. Additionally, edge computing integration adds less than 5 ms of processing time.
A financial model from 2026 demonstrates the cost-effectiveness of Firecell’s solution. For a manufacturing site, the initial investment of approximately €400,000 yielded a return on investment in just eight months, with operational gains of €50,000 per month. The system integrates effortlessly with existing enterprise LANs, allowing IT teams to manage and monitor devices across multiple locations through a single, unified interface.
Firecell’s scalable architecture supports deployments ranging from 2 to over 30 Radio Units (RUs), with typical manufacturing setups using 4–12 units. High-availability edge servers and network slicing ensure critical safety traffic is prioritised over standard data. Furthermore, the platform supports hybrid 5G-Wi-Fi configurations, where 5G handles essential traffic and mobility, while Wi-Fi is used for non-critical data. This hybrid approach aligns with the broader goal of maintaining uninterrupted industrial automation through redundant network topologies.
Before committing to full-scale deployment, Firecell enables rigorous testing with its dedicated lab kits. These kits are designed to validate redundant network configurations, ensuring they meet the ultra-reliable standards required for industrial automation.
The Orion Labkit, priced at €11,900 with an annual fee of €5,580, is suitable for areas ranging from 10 m² to 1,000 m². It includes one 5G access point and offers O-RAN options. For larger-scale testing, the Orion Network supports areas exceeding 10,000 m² with up to 10 access points.
These lab kits help manufacturers transition from trials and proofs of concept to live deployments. They enable acceptance testing for specific industrial needs, such as Time Sensitive Networking (TSN) integration and comprehensive communication for automation. Testing includes verifying download/upload speeds, measuring round-trip latency, and running interactivity tests that combine emulated traffic with latency metrics to confirm real-time performance.
"The reliability of wireless connections is mostly realised by redundancy schemes… This redundancy concept needs to be verified with network testing solutions." – Arnd Sibila, Rohde & Schwarz
Additionally, the MX-PDK lab kit provides a testing environment for O-RAN, xApp, and rApp, ensuring redundant network paths and performance meet industrial standards. By validating the network’s ability to deliver ultra-reliable, low-latency connectivity, manufacturers gain confidence in its capacity to coordinate machines and robots in real time.
Redundant 5G networks are reshaping industrial automation by delivering the reliability, efficiency, and adaptability that modern factories demand. Unlike older wireless systems prone to inconsistent performance, these advanced architectures use multiple transmission points and automatic failover mechanisms to maintain seamless connectivity. This ensures dependable operations even in environments filled with obstacles like metal structures and electromagnetic interference.
By eliminating single points of failure, redundant 5G networks guarantee high availability and ultra-low latency. This is crucial for coordinating robots, autonomous vehicles, and other time-sensitive production processes in real time.
Additionally, cloud-native 5G architectures make scaling operations much simpler. Manufacturers can reconfigure production lines, deploy mobile robots, and expand their facilities without the need for extensive wired infrastructure. Features like network slicing allow different processes to run on isolated virtual networks, ensuring critical safety communications always take precedence.
Through a combination of spatial diversity, edge computing, and predictive network management, these networks support the development of modular, flexible factories capable of meeting shifting industrial needs. Beyond just preventing downtime, redundant 5G networks open the door to automation strategies that were previously out of reach with older technologies. They represent more than just a safeguard – they’re a driving force for innovation in industrial automation.
Redundant 5G networks improve reliability in industrial automation by offering multiple communication routes, ensuring data keeps flowing without interruptions. If one route encounters a problem, another steps in automatically, avoiding downtime and keeping operations steady.
This kind of reliability is crucial for mission-critical tasks like autonomous robots, manufacturing processes, and logistics. In these scenarios, even small disruptions can cause delays or pose safety concerns. By using redundancy, industrial systems can achieve highly reliable connectivity with minimal packet loss, ensuring processes remain smooth and efficient.
Time-Sensitive Networking (TSN) plays a crucial role in boosting 5G network reliability by delivering deterministic, low-latency communication – a must-have for mission-critical industrial operations. When TSN is paired with 5G, industries gain the ability to transmit data with high precision and reliability, even in the most demanding and intricate environments.
This integration is a game-changer for applications like autonomous robotics, precision-driven manufacturing, and real-time system monitoring. By ensuring that critical data traffic is prioritised, TSN helps minimise downtime and keeps industrial automation systems running smoothly and efficiently, even under challenging conditions.
Dual-connectivity and dual-SIM configurations play a key role in keeping networks reliable. These setups allow devices to seamlessly switch to a backup connection if the main network goes down, ensuring uninterrupted connectivity – a crucial factor for the smooth functioning of industrial automation systems.
With redundant cellular links in place, the likelihood of downtime is greatly reduced. This ensures continuous communication for critical applications such as autonomous robots, manufacturing machinery, and logistics operations. The result? Improved operational efficiency and consistent performance, even in the most challenging industrial settings.
