Open-Source Cloud-Based

Monitoring and Control System

for Industrial Automation
Applications

www.nu.edu.kz
Industrial IoT and Industry 4.0

www.nu.edu.kz
Benefits of IIoT
Real-time monitoring • Improve operational
Team productivity equipment uptime and
Security availability
Diagnostics • Increase operations
Maintenance automation speed
Cost reduction • Improve product quality
• Improve safety

www.nu.edu.kz
Previous work at NU with MPS
Towards enhancing modular production systems by integrating a collaborative robotic
manipulator, equipped with a camera
Digital twins development of automatic storage and retrieval station in a production line and
an integrated robotic manipulator
Design and Implementation of a Fault Inspection System for the Festo Modular Production
System (MPS) using image processing and pattern recognition

www.nu.edu.kz
Examples of potential issues
faced in MPS
The robotic manipulator runs out of parts
The robotic manipulator faces errors (low battery, getting stuck, etc.)
One station fails to perform its task successfully
Distribution station needs refilling
The parts are not placed properly by the operator (oriented wrongly) at the Distribution station
An actuator does not perform normally (Receives the command to actuate, but does not
actuate normally)

www.nu.edu.kz
Proposed architecture
User
interface

MPS 500 www.nu.edu.kz

Motivation
The rising demand for industrial automation and remote monitoring necessitates
engineers equipped with relevant skills.
Open-source tools present cost-effective and accessible avenues for
experimentation and practical learning.
The FESTO MPS 500 provides a compact and versatile platform for simulating
real-world manufacturing processes.

www.nu.edu.kz
Objectives
Design and implement a cloud-based communication system for the FESTO MPS 500
using open-source tools.
Develop dashboards for remote monitoring of key operational parameters like sensor
data, power consumption, and system status.
Investigate and potentially implement basic control functionalities remotely accessible
through internet-connected devices.
Document the project methodology, findings, and challenges encountered for future
iterations and knowledge sharing.

www.nu.edu.kz
Required tools
Industry standard IoT protocols such as:
OPC UA
MQTT
Modbus

www.nu.edu.kz
Required tools
A platform to exchange Data between MPS and the cloud such as:
Node-RED

www.nu.edu.kz
Required tools
Cloud platform (AWS IoT Core, Azure IoT Hub, etc)

www.nu.edu.kz
Required tools
Data visualization tool such
FlowFuse
FUXA (The Open Source HMI-SCADA-Dashboard full web-
based Platform): https://frangoteam.org/
Grafana,
Kibana,

www.nu.edu.kz
Project phases
Phase 1: System design, tool selection, and initial setup
Phase 2: Communication system development and data monitoring
Phase 3: Control functionality exploration and implementation
Phase 4: Testing, evaluation, documentation, and presentation

www.nu.edu.kz
Expected Outcomes
A functional cloud-based monitoring and control system for the FESTO MPS 500.
Enhanced student understanding of industrial automation, IoT principles, and open-source tools.
Project documentation and presentation to share knowledge and learnings.

www.nu.edu.kz
Potential research directions and
questions
Optimizing communication efficiency (data compression, protocol selection) to
minimize latency and maximize data security: Compare and evaluate different
communication protocls like MQTT, OPC UA, etc.
Developing machine learning models to predict system behavior, detect anomalies,
or optimize process parameters based on real-time sensor data
User interface and interaction design: Develop web-based or mobile dashboards for
data visualization, implement user-friendly control functionalities, and evaluate user
experience through usability testing.
Cost-effectiveness and scalability analysis: how to design and implement a similar
cloud-based monitoring and control system for larger and more complex system

www.nu.edu.kz
References:
T. Hagino, N., Practical Node-RED Programming, O’Leary, available online at NU library
Giacomo Veneri, Antonio Capasso, Hands-On Industrial Internet of Things, O’Leary
C. A. Osaretin, et. al., (2020). Open Source IoT-Based SCADA System for Remote Oil
Facilities Using Node-RED and Arduino Microcontrollers, IEEE IEMCON, 2020.
Lee, J., Bagheri, B., & Kao, H.-A. (2015). A cyber-physical systems architecture for industry
4.0 manufacturing systems. Manufacturing Letters, 3, 18-23.
Wu, Q., Ding, S., Yu, S., & Liang, X. (2017). Cloud computing for scalable and service-
oriented manufacturing. The Journal of Systems and Software, 134, 152-162.
Maksimović, M., Vujović, B., & Milovanović, M. (2018). Open-source platforms for
developing industrial internet of things (IIoT) applications. In 2018 42nd International
Conference on Telecommunications and Signal Processing (TSP; pp. 312-317). IEEE.
Festo Didactic (2023). MPS 500 - Modular Production
System. https://manualzz.com/doc/23514931/festo-didactic-mps-500-fms

www.nu.edu.kz
Thanks for your attention!

www.nu.edu.kz