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When Wires Meet Wireless: How bridging TSN and 5G could unlock the next era of industrial automation

Picture this: a surgeon operates a robotic arm from another continent. An excavator digs a tunnel with no one inside. A swarm of factory robots choreographs itself in milliseconds. None of this works if the network hiccups. The problem? Wired networks are reliable but rigid. Wireless is flexible but unpredictable. New research from Mälardalen University asks: what if we stopped choosing—and built a bridge instead?

The challenge

Modern industries rely on networks to connect machines, sensors, and controllers. Wired networks like TSN are great for reliability and timing, but they lack flexibility. 5G can provide the missing flexibility and scalability while delivering high-bandwidth, ultra-low latency, and enhanced reliability. The question is: how do we combine the best of both worlds without losing speed or reliability?

The solution

The team led by Zenepe Satka, Mohammad Ashjaei, and Saad Mubeen designed and tested a TSN–5G gateway that acts as a translator between the two technologies.

  • It maps priorities from TSN to 5G so critical data (like safety signals) gets through first.
  • It ensures time synchronization across devices for real-time control.
  • It was tested in a real-world scenario: remotely controlling a robot car over an integrated TSN–5G network.

“Our goal was to make wired and wireless networks work together without compromising timing or reliability,” says Zenepe Satka, lead researcher.

Impact

The concept was prototyped and tested with encouraging results:

  • Latency under 20 ms for small packets, fast enough for many industrial applications.
  • Successful QoS mapping: critical traffic maintained priority even when the network was under heavy load.
  • Real-world demo: remote control of a vehicle using TSN–5G integration proved feasible.

However, the study also revealed challenges: larger packets and multiple devices can cause jitter and delays, highlighting the need for smarter scheduling in 5G.

Why It Matters to You:

From autonomous vehicles to smart factories, industries are moving toward Industry 4.0 where machines talk to each other and to humans in real time. Without flexible and reliable communication, these systems can fail, causing downtime or even accidents. This research shows how combining TSN and 5G can make these visions a reality.

How This Supports UN Sustainability Goals:

  • Goal 9 – Industry, Innovation, and Infrastructure: Enables robust, future-ready communication for smart factories and industrial automation.
  • Goal 11 – Sustainable Cities and Communities: Supports safe and efficient remote operations, reducing risks in construction and urban projects.

Find out more in the publication from Journal of Systems Architecture -> ScienceDirect.