Industrial routers must support protocol conversion (e.g., Modbus to Ethernet), VPN security, edge AI computing, and operation in extreme environments. The importance of chip architecture lies in:

Performance: Determines packet processing speed and multitasking capabilities. For example, high-performance architectures like x86 support complex virtualization, while low-power architectures like ARM are ideal for edge computing.
Power Consumption: In remote or battery-powered scenarios, low-power architectures (e.g., RISC-V with <1W) extend operational time and reduce cooling needs.
Cost and Customization: Open-source architectures (e.g., RISC-V) eliminate licensing fees and offer high customizability, reducing development costs. Specialized architectures (e.g., FPGA) enable protocol-specific optimizations.
Ecosystem: Robust software support (e.g., ARM’s Linux ecosystem) accelerates development, while mature supply chains (e.g., Intel’s x86) ensure production stability.
Adaptability: Different architectures cater to diverse needs, such as Xtensa for wireless communication or NPU for AI inference.

Classic architectures dominate due to their mature ecosystems, while emerging architectures drive innovation for AI, wireless communication, and flexibility.

2. Chip Architecture Selection by Application Scenario

The following sections analyze suitable chip architectures for industrial router applications and their selection rationale.

2.1 Low-Cost IoT and Edge Access

Typical Applications: Sensor networks, small-scale factory device connectivity, remote metering.

Suitable Architectures: MIPS, RISC-V, ARC

Rationale: These architectures are cost-effective and low-power, ideal for budget-sensitive, lightweight protocol conversion scenarios.

MIPS: Efficient RISC architecture with high code density, suitable for low-cost gateways and simple network tasks.
RISC-V: Open-source architecture with no licensing fees and strong customizability, ideal for low-power IoT devices.
ARC: Optimized for performance-power-area (PPA) efficiency, suitable for embedded gateways and protocol conversion.

Selection Rationale: MIPS’s mature network processor design reduces hardware costs; RISC-V’s open-source nature avoids vendor lock-in; ARC’s high code density lowers chip costs.

2.2 General Industrial Routing and 5G/Edge Computing

Typical Applications: Smart manufacturing, intelligent transportation, energy management.

Suitable Architectures: ARM, Xtensa (wireless optimized)

Rationale: ARM’s mature ecosystem supports AI acceleration and 5G connectivity; Xtensa optimizes wireless communication for multi-protocol IoT gateways.

ARM: Low-power, multi-core design with extensive Linux/RTOS support, ideal for edge computing and 5G routers.
Xtensa: Supports DSP and signal processing, optimized for Wi-Fi, Zigbee, LoRa, and other wireless protocols.

Selection Rationale: ARM’s robust ecosystem and AI acceleration meet smart manufacturing needs; Xtensa’s wireless optimization simplifies multi-protocol development.

2.3 High-Performance Enterprise and Virtualization Scenarios

Typical Applications: Enterprise industrial gateways, software-defined routers requiring virtualization or complex OS.

Suitable Architectures: x86, PowerPC

Rationale: x86 offers high performance and broad compatibility for virtualization; PowerPC supports real-time processing and high reliability.

x86: CISC architecture with strong computational power, supporting complex software stacks like Windows and VMware.
PowerPC: RISC architecture suited for SCADA systems and real-time tasks.

Selection Rationale: x86’s compatibility facilitates enterprise software integration; PowerPC’s network acceleration and reliability suit mission-critical tasks.

2.4 AI-Driven and Intelligent Analytics

Typical Applications: Industrial visual inspection, traffic monitoring, predictive maintenance.

Suitable Architectures: NPU/AI accelerators (ARM+NPU, RISC-V+NPU, standalone NPU like NVIDIA Jetson)

Rationale: NPUs provide efficient AI inference with low latency for edge analytics.

NPU: Dedicated AI chips with 4-100 TOPS, outperforming general-purpose CPUs in AI tasks.
ARM+NPU: Combines ARM’s general computing with NPU’s AI acceleration for hybrid tasks.
RISC-V+NPU: Open-source architecture with AI acceleration, reducing costs.

Selection Rationale: NPU’s high computational power and low energy consumption meet real-time AI analytics needs, ideal for video surveillance and predictive maintenance.

2.5 High-Flexibility and Customized Scenarios

Typical Applications: Military, aerospace, specialized protocols (e.g., CAN, Profibus, avionics bus).

Suitable Architectures: FPGA, programmable SoC (ARM+FPGA hybrid)

Rationale: FPGAs support hardware-level programmable logic for rapid adaptation to non-standard protocols; ARM+FPGA hybrids balance general computing and customization.

FPGA: Highly customizable, supporting complex protocols and real-time processing with field-upgradable logic.
ARM+FPGA: Combines ARM’s ecosystem with FPGA’s flexibility for complex industrial scenarios.

Selection Rationale: FPGA’s parallel computing and field-upgradability meet high-security and long-lifecycle needs; hybrid architectures balance performance and flexibility.

3. Application-Oriented Comparison Table

The following table compares mainstream chip architectures based on key metrics for industrial applications.

Industry Application	Recommended Architecture	Key Advantages	Representative Vendors
Low-Cost IoT / Sensor Networks	MIPS, RISC-V, ARC	Low cost, low power	Broadcom, SiFive, Synopsys
5G Edge / Smart Manufacturing	ARM, Xtensa	Mature ecosystem, AI acceleration, wireless optimization	NXP, Qualcomm, Cadence
Enterprise Gateway / Virtualization	x86, PowerPC	High performance, strong compatibility	Intel, AMD, NXP
AI-Driven Routing	NPU, Jetson, ARM+NPU	High AI performance, low-latency inference	NVIDIA, Arm, Google
Military / Aerospace / Specialized Protocols	FPGA, ARM+FPGA	Flexible programmability, non-standard protocol support	Xilinx, Intel (Altera)

4. Classic Architectures: The Foundation of Industrial Routers

Classic architectures are widely used due to their maturity and versatility, supporting scenarios from low-end gateways to enterprise-grade devices.

4.1 MIPS

Features: RISC architecture with high code density, historically dominant in networking equipment, supporting multithreading and network optimization.

Applications: Low-end industrial routers, embedded gateways (e.g., factory floor network connectivity, simple protocol conversion).

Selection Rationale: Low cost and mature network processor design suit budget-constrained, low-performance scenarios; high code density reduces memory requirements for small devices.

Why This Solution: MIPS is used in IIoT for low-power applications due to its RISC design, simplifying instruction sets to reduce power and cost while maintaining network optimization.

Advantages:

High code density reduces memory needs and hardware costs.
Mature network processor design ensures stable data transmission.
Moderate power consumption (0.5-2W), suitable for small, low-cost devices.

Limitations:

Ecosystem declining as ARM gains dominance, reducing software support.
Limited performance (typically 500MHz-1GHz), unsuitable for AI or high-throughput tasks.
Reduced support in new projects and weakening supply chain.

Typical Vendors: Broadcom (BCM series), MediaTek.

4.2 ARM

Features: Low-power RISC architecture, widely used in embedded and mobile devices, supporting multi-core and AI acceleration (e.g., Cortex-A series).

Applications: General industrial routers, 5G edge routers, IoT gateways (e.g., MQTT-enabled sensor networks).

Selection Rationale: Low power consumption and a robust ecosystem suit scenarios requiring extensive software support and edge computing; multi-core and AI acceleration support 5G and IoT applications.

Why This Solution: ARM is used in energy management and intelligent transportation due to its RISC design, ensuring low power and efficient AI integration for battery-powered and high-temperature environments.

Advantages:

Low power (0.1-1W per core), ideal for battery-powered or high-temperature settings.
Rich ecosystem (Linux, RTOS support) for streamlined development.
AI acceleration support (4-8 TOPS NPU) for edge computing needs.

Limitations:

Higher licensing fees increase development costs.
High-performance multi-core chips (e.g., Cortex-A76) are expensive, requiring cost trade-offs.
Less competitive in extreme high-performance scenarios compared to x86.

Typical Vendors: Arm Holdings (Cortex series), Qualcomm, NXP (i.MX series).

The IoT Runs on Arm

4.3 x86

Features: CISC architecture with high performance and broad compatibility, commonly used in Intel Atom or Celeron series.

Applications: High-performance industrial gateways, enterprise routers (e.g., virtualization devices supporting Windows, VMware).

Selection Rationale: High performance and compatibility suit complex enterprise software or virtualization; extensive driver support simplifies integration.

Why This Solution: x86 is used in high-performance applications like robotics control and data acquisition due to its CISC design, enabling complex instructions and high computational efficiency despite higher power consumption.

Advantages:

Strong computational power (>2GHz, multi-core) for complex tasks.
Extensive driver and software support for third-party application integration.
Ideal for enterprise-grade operating systems with high compatibility.

Limitations:

High power consumption (5-20W) requires cooling, increasing size and cost.
Unsuitable for low-power or battery-powered scenarios.
High chip costs and development complexity.

Typical Vendors: Intel (Atom, Celeron), AMD (Ryzen Embedded).

5. Emerging Architectures: Exploring the Future of Industrial Routers

Emerging architectures address IIoT, AI, and wireless communication needs, offering low power, flexibility, or specialized optimization to drive innovation.

5.1 PowerPC

Features: RISC architecture developed by IBM, Apple, and Motorola, supporting multi-core and network acceleration (e.g., PowerQUICC).

Applications: High-performance edge routers, SCADA system routers, power grid gateways.

Selection Rationale: High performance and reliability suit real-time processing and high-reliability scenarios; low-power versions fit harsh environments.

Why This Solution: PowerPC is used in SCADA and power grids due to its robust computing and network acceleration, ensuring real-time tasks, avoiding overheating, and providing historical reliability.

Advantages:

High performance (>1GHz, multi-core) for real-time data processing.
Low-power versions (1W@200MHz) with high durability for harsh environments.
Mature supply chain with strong historical reliability.

Limitations:

Less robust ecosystem than ARM, with limited software support.
Declining adoption in new designs, gradually replaced by RISC-V.
High-performance versions are costly.

Typical Vendors: NXP (PowerQUICC), IBM.

5.2 RISC-V

Features: Open-source RISC architecture developed by UC Berkeley, highly customizable, supporting AI acceleration.

Applications: Low-power IoT routers, smart manufacturing gateways, sensor networks.

Selection Rationale: Open-source with no licensing fees, ideal for cost-sensitive projects; high customizability supports edge AI and specific optimizations.

Why This Solution: RISC-V is used in smart manufacturing and sensor networks due to its open-source nature, reducing costs, avoiding vendor lock-in, and supporting edge AI with balanced performance and power.

Advantages:

Open-source with no licensing fees, lowering development costs.
Highly customizable, balancing performance and power (<1W).
Supports edge AI (4 TOPS NPU) and avoids vendor lock-in.

Limitations:

Developing ecosystem with less mature toolchains and software support than ARM.
Smaller supply chain, potentially causing chip production cost fluctuations.
High-performance implementations need further optimization.

Typical Vendors: SiFive, StarFive, Alibaba T-Head.

Quality Assurance and Open-Source Advantages of RISC-V Cores in Industrial-Grade Applications

5.3 ARC

Features: Synopsys’s configurable RISC architecture, optimized for embedded applications, focusing on performance-power-area (PPA) efficiency.

Applications: Embedded industrial gateways, custom protocol routers, data compression or encryption devices.

Selection Rationale: High PPA efficiency suits low-power, task-optimized scenarios; code density optimization reduces costs.

Why This Solution: ARC is used for custom protocols and encryption routing due to its configurable design, optimizing code density and power to reduce chip costs in embedded systems.

Advantages:

Optimized PPA efficiency with low power (<1W).
High code density reduces chip costs.
Suitable for specific tasks (e.g., encryption, protocol processing).

Limitations:

Narrow application scope, less versatile than ARM or RISC-V.
Licensing fees increase costs.
Smaller ecosystem with limited development resources.

Typical Vendors: Synopsys (ARC HS, EM series).

5.4 Xtensa

Features: Cadence’s extensible RISC architecture, supporting DSP and signal processing, optimized for wireless communication.

Applications: Wireless industrial routers, multi-protocol IoT gateways (e.g., Wi-Fi, Zigbee support).

Selection Rationale: DSP and wireless optimization suit multi-protocol IoT devices; low power and high code density reduce development complexity.

Why This Solution: Xtensa is used in wireless sensing and multi-protocol gateways due to its scalability, supporting complex signal processing and Wi-Fi integration, reducing complexity in industrial IoT.

Advantages:

Supports complex signal processing and high code density.
Optimized for wireless communication (e.g., Wi-Fi integration), reducing development complexity.
Low power (<0.5W), suitable for small devices.

Limitations:

High licensing fees increase development costs.
Performance tailored to DSP tasks, weaker in general computing compared to ARM.
Narrow ecosystem, reliant on specific vendor support.

Typical Vendors: Cadence, Espressif (ESP32 series).

5.5 AI Accelerator Chips / NPU Architecture

Features: Dedicated neural processing units integrated into ARM, RISC-V, or standalone chips (e.g., Google TPU, NVIDIA Jetson), optimized for AI tasks.

Applications: Edge AI routers, video analytics gateways (e.g., industrial monitoring, intelligent transportation).

Selection Rationale: Efficient AI inference performance suits edge AI and real-time analytics; low-power AI processing enhances efficiency.

Why This Solution: NPUs are used in video analytics and monitoring routers due to their dedicated design, offering high TOPS performance and low-power AI processing, avoiding general CPU latency.

Advantages:

High AI performance (4-100 TOPS) for machine learning inference.
Low-power AI processing, outperforming general CPUs.
Easy integration with existing architectures (e.g., ARM Cortex-A).

Limitations:

Highly specialized, limited general computing capabilities.
Complex development requiring specialized AI frameworks (e.g., TensorFlow Lite).
High costs, suitable for high-budget projects.

Typical Vendors: Google (TPU), NVIDIA (Jetson), Arm (Ethos-N NPU).

2025 Edge AI and IoT Overview: Covering Industrial Application Trends, Including the Role of NPUs in Routers and Edge Devices

5.6 FPGA / Programmable Architecture

Features: Field-programmable gate arrays offering hardware-level programmable logic, supporting custom protocols and acceleration.

Applications: Highly flexible industrial routers, specialized protocol gateways (e.g., aerospace, military communication).

Selection Rationale: High customizability suits complex protocols and real-time processing; field updates support rapid iteration.

Why This Solution: FPGAs are used in aerospace and military gateways due to their parallel computing and field-upgradability, supporting complex protocols and extending device lifecycles in harsh environments.

Advantages:

Highly customizable, supporting complex protocols and real-time processing.
Strong parallel computing for task-specific acceleration.
Field-upgradable, extending device lifecycle.

Limitations:

Complex development requiring hardware description language (VHDL/Verilog) expertise.
High costs (chip and development), unsuitable for low-budget projects.
Higher power consumption (1-10W), requiring cooling design.

Typical Vendors: Xilinx (Zynq series), Intel (Altera), Lattice.

A simple tutorial demonstrates implementing an Ethernet interface on an FPGA for industrial data transmission. Verilog code and board testing showcase programmable flexibility, such as rapidly modifying protocols to adapt to network requirements.

6. Architecture Comparison Table

The following table compares classic and emerging architectures based on key metrics for industrial routers.

Architecture	Performance (Typical Clock)	Power (Typical)	Cost (Licensing/Development)	Selection Rationale	Key Advantages	Typical Industrial Applications	Key Limitations	Typical Vendors
MIPS	Medium (500MHz-1GHz)	Medium (0.5-2W)	Low	Low cost, mature network processor	High code density, network optimization	Low-end gateways, factory networks	Declining ecosystem, limited performance	Broadcom, MediaTek
ARM	High (1-3GHz, multi-core)	Low (0.1-1W)	Medium	Low power, rich ecosystem, AI support	Low power, AI acceleration, rich ecosystem	5G routers, IoT gateways	High licensing fees	Arm, Qualcomm, NXP
x86	High (>2GHz, multi-core)	High (5-20W)	High	High performance, complex software compatibility	High performance, strong compatibility	Enterprise gateways, virtualization routers	High power, high cost	Intel, AMD
PowerPC	High (>1GHz, multi-core)	Medium (1-5W)	Medium	High performance, reliability	Real-time processing, network acceleration	SCADA systems, power grids	Limited ecosystem, declining use	NXP, IBM
RISC-V	Medium (1-2.5GHz)	Low (<1W)	Low (open-source)	Open-source, customizable, edge AI	Customizable, edge AI	IoT gateways, sensor networks	Immature ecosystem, small supply chain	SiFive, StarFive, T-Head
ARC	Medium (configurable)	Low (<1W)	Medium	PPA efficiency, task-specific optimization	PPA efficiency, code optimization	Custom protocol gateways, encryption routers	Narrow application, small ecosystem	Synopsys
Xtensa	Medium (500MHz+)	Low (<0.5W)	Medium	DSP and wireless optimization	DSP support, wireless integration	Wireless industrial routers, multi-protocol IoT	High licensing fees, weak general computing	Cadence, Espressif
AI Accelerator/NPU	High (4-100 TOPS)	Low (AI tasks)	High	Efficient AI inference, edge analytics	High AI inference efficiency	Edge AI routers, video analytics	Specialized, complex development	Google, NVIDIA, Arm
FPGA	High (configurable)	Medium-High (1-10W)	High	High flexibility, real-time processing, field updates	Highly customizable, real-time processing	Specialized protocol gateways, aerospace/military	Complex development, high cost	Xilinx, Intel, Lattice

Classic architectures excel in maturity and versatility, while emerging architectures offer potential in flexibility and specialized optimization.

7. Future Trends and Recommendations

With 5G, AI, and open-source trends driving innovation, RISC-V and ARM will dominate IIoT, while AI accelerators and FPGAs will grow in edge AI and specialized scenarios. MIPS and PowerPC may gradually phase out. Recommendations:

High-Performance Scenarios: x86, PowerPC.
Low-Power IoT: ARM, RISC-V.
Wireless Integration: Xtensa.
AI Tasks: NPU or ARM+RISC-V.
High Flexibility: FPGA.