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Sciencedirect: © 2018, Ifac (International Federation of Automatic Control) Hosting by Elsevier Ltd. All Rights Reserved
Sciencedirect: © 2018, Ifac (International Federation of Automatic Control) Hosting by Elsevier Ltd. All Rights Reserved
From the technological point of view, there are several This communication protocol works on the principle of
possible ways to communicate within individual devices. In transmissioning messages between clients who are connected
the industry, it is often better to use cable transmission (e.g. to the server (MQTT Broker). Each client can be either
ethernet, profinet, profibus) due to the reliability of data Subscriber or Publisher. The publisher is usually given a
transmission. However, wireless communication buses such as sensor that sends measured values to a broker. A subscriber is
Wi-Fi, Bluetooth (less energy-intensive), NFC, ZigBee, Z- usually a control unit that processes the values and then works
Wave and more are also used. Pohanka (2017) with them. The main advantages of MQTT include energy
saving, publish/subscribe model and two-way communication
(via both directions) capabilities. Inductive automation (2018)
2. DESIGN OF SOLUTION
Usually, students work on projects in laboratories, which
contain various devices and specific laboratory tasks.
Therefore, in this case, it is not possible to access the
individual tasks remotely. The main aim of this article is to
present a user-friendly solution for process data processing in
the laboratory based on IIoT (control of PLC and selected
Fig. 3. Communication between devices based on IoT
CLOUD platforms). This solution is conceived as remote
(possibilities of using in consumer IoT), see Green (2017)
control and processing of relevant data. It allows to clients
In this study is the most relevant part the segment of (students) access real projects via a web-based interface
Industrial IoT (IIoT), which represents application of the IoT outside the laboratory. Johnson (2013) and Colak et al. (2007)
to the manufacturing industry, improves manufacturing by
enabling accessibility of far greater amounts of data and far 2.1 Existing solution
more efficiently than before. It is not only a future, because
several innovative companies have started to implement the The difference between traditional control (programming in
IIoT. These companies find benefits from lower consumption software interface from specific company) and offered control
as a result of foreseeable maintenance, improved safety and is considerable. At first, you need to build the program,
more operational efficiency. Networks of IIoT can greatly compile it, upload it to the PLC, and test the functionality. Of
improve interconnection, efficiency, scalability, time savings, course, these steps need to be repeated several times during
and cost savings for industrial organizations. The networks testing. All operations have to always take place on the
also enable industry organizations to link all their employees, machine, so that the result is immediately visible, and the
data and processes from the factory. Leaders of companies can programmer can correctly writes a code to the device for the
use IIoT data to get a complete and accurate idea of how their function.
business works, which will help them to make better decisions
in different situations. Green (2017) and Inductive automation
(2018) 2.2 Solution based on Cloud platforms
Interoperability and safety are probably the two biggest This solution represents significant progress in work with
challenges in implementing of IIoT. One of the problems that process data (transmission between PLC, IoT Gateway and
can be encountered when switching to IIoT is the fact that CLOUD platforms). From the beginning it is necessary to
unique devices use different protocols for sending and create the “raw” program. Based on it there is no need to
receiving process data. There are a few of different significantly interfere to the standard programming interface
communication protocols which are currently in use (for (solution tested, no relevant changes are expected in the
example OPC-UA). However, the MQTT transmission future). This method of data processing offers several
protocol becomes the standard for IIoT (Fig. 4). Inductive advantages:
automation (2018)
- Backup (archiving) of data in the Cloud Platform
(from a security point of view is better to use
commercial cloud platform)
- Data processing outside the PLC (real experiments
via internet). PLC can even be controlled directly
from the Cloud platform (in practical demonstration).
- If software PLC program correctly programmed in
the PLC, then it really is a user - friendly solution,
which is a useful tool for teaching and efficient data
processing in industrial applications.
Fig. 4. Communication based on MQTT protocol, see Vojáček - An IP camera can be installed for the better access
(2017) outside the laboratory
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This study is a solution (Fig. 5) that allows the device to 2.3 Available hardware
be remotely controlled by transferring of process data between
the PLC and IoT Gateway (it have to be connected to Internet). As part of Industry 4.0, the IIoT continues to expand.
Two-way communication between these devices is possible Processed data are collected and evaluated in the cloud to
via the libraries, which are available in the powerful optimize the production. Making the networking based on
programming tool for connecting hardware devices, API and existing devices is in this case a great challenge, because
other online services. This tool is Node-RED. Initially, an open machines from different companies and at different
source project was created in the IBM Technologies group of technological levels often do not communicate with the same
members (this article uses in practical demonstration of results data language. The solution is often time consuming. An
a commercial Cloud platform directly from company IBM). intelligent gateway, which harmonises communication
The main aim is therefore to simplify the process of connected between different data sources, is analyses and transmits data
systems and sensors to building technologies for customers. to the appropriate recipients. The IoT Gateway, which is
Node-Red provides an editor that makes it easy to link flows capable of accepting and processing process data from a PLC,
via a wide range of nodes in a palette (for example, nodes for is after that used to store the process data from the PLC into
MQTT protocol) in an internet browser (multiplatform the Cloud platform and then it controls real device remotely
solution). Heidoloff (2015) via the web application. Controlling can take place at the IoT
Gateway level or directly from the CLOUD platform (both
examples are available in a practical demonstration of results).
IIoT Gateway from company Siemens (Simatic IoT
2040) was selected for collection, processing and transmission
of process data. It is a reliable gateway that can be used as an
interface between Cloud platforms and production. It can
either collect data from the device or transfer the analysed data
from the Cloud Platform to the device. The openness of the
Fig. 5. Transfer of process data from PLC to one of Cloud system to support multiple communication protocols and
platform and back writing code in higher programming languages points to a
wider filed of using in the context of specific solutions. The
Communication between Cloud Platforms is provided by Simatic IoT2040 can be easily integrated into an existing
the MQTT protocol (it described in chapter 1.1). However, the device. It is therefore an economic and safe alternative to the
whole solution depends on several factors that can be defined complete additional equipment of older machines. This device
as possible limitations: supports a few of programming languages, such as C ++, Java,
- The PLC and primary the controlled device can be in or Python, and it is possible to connect or perform local or
operation for several days (higher consumption of remote control of peripherals via various communication
energy). protocols (such as MQTT, SQLITE3). The IOT2040 is
characterized an IP20 protection that guarantees safe
- The IIoT Gateway must be connected to the Internet installation in machines and electrical panels. The Shield is
(remote control often via VPN client, some larger made of durable industrial components and therefore allows
companies may have a problem with an access "from continuous operation even in demanding conditions.
the outside"). W3siemens (2017) and Rs-online (2017)
- In this manner you can control individual parts of the 3. LABORATORY BASED ON IOT CONCEPT
device, yet it is not a complex tool and for the
programmer is often more than important to be Laboratory of industrial automation and distributed control
directly next of the device (primary for safety of Systems is located at the Faculty of Electrical Engineering and
work). Computer Science within the VSB - Technical University of
Ostrava. In this laboratory are available industrial PLCs from
- Selected process data can be delayed by transmission different companies. Devices for real-time control are also
to (from) Cloud platforms (it is a big problem when available, including mechatronic tasks that are controlled by
it works on free cloud platform). Eventually it can Siemens PLC (Simatic S7-1200). Each PLC have to contains,
occur in case of random network outage to some as mentioned earlier (it based on Fig. 5 – in part „Data“ in
deformation or loss of process data. PLC), fundamental program. It was created an elementary
By moving data to the Cloud platform, backups of data can be concept of this program (Fig. 6). The main aim of program will
achieved, which can be further exploited due to two-way gradually change the states of predefined variables or different
communication to control of the PLC, respective to the structures that can be defined via the IIoT Gateway or directly
technological part. However, Free Cloud Ubidots allows to the Cloud platform.
control some variables (Bool, Word) directly from the Cloud Communication between the PLC and the IoT Gateway
platform based on visualization elements in Dashboard can be performed via the official S7 libraries. These libraries
(programmable interface). IBM commercial solution does not sort out a large quantity of required PLC items and decide what
offer this option. total data blocks will be occupied. Then it groups a few small
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(IBM cloud – commercial data storage) and pink (Ubidots For better comparison of both Cloud platforms, there is a
Cloud – free data storage) node. To save data on IBM cloud it graph (Fig. 10), which compares response speed when
is important to have a registered device on the special website changing process data. It is a counter of pucks within
called IBM Watson IoT Platform. This platform represents individual stock positions. The graph shows that latency is
interface for makes a new device, which have to contains quite different for both Cloud platforms when adding or
unique ID, type and authorization token. Saving data on free removing a puck. Based on the measurements it is possible to
cloud platform Ubidots takes the form of protocol MQTT. This argue that commercial solution IBM Cloud reacts with a
protocol have to contains parameters topic and authorization maximum delay of one second. The second Cloud, Free
token (it assigned to the user upon registration). platform Ubidots, shows worse results. According to the input
data has been always measured longer accidental delay via
Based on the data received from the selected Cloud comparing with commercial IBM Cloud (up to 5 seconds).
Platform, process can be reversed (unless only some data
backup is needed). After that Control of PLC is possible either
directly from the selected Cloud platform (this functionality
contains only the Free Cloud platform Ubidots) or from IIoT
Gateway. The following program blocks (Fig. 8) are used to
turn on the laboratory model of mechatronic tasks.
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ACKNOWLEDGEMENT
This work was supported by the European Regional
Development Fund in the Research Centre of Advanced
Mechatronic Systems project, project number
CZ.02.1.01/0.0/0.0/16_019/0000867 within the Operational
Programme Research, Development and Education.
REFERENCES
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