IoT Merged

Main Industrial Network
Internet
Secondary
Industrial Network
Gateway
Bluetooth
Profinet Industrial Internet of Things

Gateway for the Smart Factory
Master’s thesis in Embedded Electronic System Design
HENRIK JOHANSSON
Department of Computer Science and Engineering

C HALMERS U NIVERSITY OF T ECHNOLOGY
U NIVERSITY OF G OTHENBURG
Gothenburg, Sweden 2017
Master’s thesis 2017
Profinet Industrial Internet of Things Gateway

for the Smart Factory
Henrik Johansson

Chalmers University of Technology
University of Gothenburg
© Henrik Johansson, 2017.
Supervisor:
Endian Technologies AB: Andreas Henriksson
Chalmers: Lena Peterson, Department of Computer Science and Engineering
Examiner:
Chalmers: Per Larsson-Edefors, Department of Computer Science and Engineering
Master’s Thesis 2017

Chalmers University of Technology and University of Gothenburg
SE-412 96 Gothenburg
Telephone +46 31 772 1000
Typeset in LATEX
iv
Profinet Internet of Things Gateway for the Smart Factory
HENRIK JOHANSSON
Chalmers University of Technology and University of Gothenburg
Abstract
The Internet of Things revolution in industrial production environments imposes
new requirements on devices, hardware and software in the production systems.
In previous systems, each vendor could have their own proprietary protocols and
platforms but as more and more devices and sensors are connected together,
increased collaboration and standardization is necessary.
This thesis aims to aid in building the bridge connecting an industrial system and
the outside world, but also on solving an existing problem in industrial networks
regarding the set up for new devices. The thesis also aims to give a compilation
of protocols and platforms that can be used in industrial applications. A practical
solution to bridging the networks and solving the problem is done by implementing
an industrial network stack (Profinet) in a gateway device. The resulting prototype
gateway can communicate with conventional network traffic as well as the industrial
network protocol Profinet, with both master and slave functionality.
Keywords: Industrial Internet of Things, IIoT, Industrial IoT, Industrie 4.0, Indus-
try 4.0, Profinet, Gateway
v
Acknowledgements
I would first like to thank my splendid supervisor Lena Peterson at Chalmers
University of Technology for standing up with my mailbombs, broken sentences
and misspellings.
I would also like to thank my supervisors Andreas Henriksson and Peter Malmberg
at Endian Technologies AB for their ideas, technical support and guidance.
Finally I would like to thank all other colleagues at Endian for a warm welcome and
friendly work environment.
Henrik Johansson, Gothenburg, June 2017
vii
Contents
List of Figures xiii
List of Acronyms xv
1 Background 1
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 Goal and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.3 Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.4 Ethical Aspects . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.5 Thesis report outline . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 Industrial environment background 7

2.1 Programmable Logic Controller (PLC) . . . . . . . . . . . . . . . . . 7
2.1.1 PLC programming . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Ladder Diagram (LD) . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Industrial safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Industrial hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Internet of Things background 11

3.1 Internet of Things . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Cloud Computing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Industrie 4.0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.4 Industrial Internet of Things . . . . . . . . . . . . . . . . . . . . . . . 12
3.5 Industrial Internet Consortium (IIC) . . . . . . . . . . . . . . . . . . 13
3.6 Industrial Internet Reference Architecture (IIRA) . . . . . . . . . . . 14
3.7 Cloud security concerning outside threats . . . . . . . . . . . . . . . . 14
3.8 Industrial IoT platforms . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.1 Kaa . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.2 Predix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.3 OpenRemote . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.8.4 Echelon IzoT . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8.5 CloudPlugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8.6 mnubo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8.7 Nimbits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8.8 AllJoyn Framework . . . . . . . . . . . . . . . . . . . . . . . . 16
3.8.9 Node-Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9 IoT Protocols for industry . . . . . . . . . . . . . . . . . . . . . . . . 17
ix
Contents
3.9.1 Open Platform Communications Unified Architecture (OPC

UA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.9.2 Hypertext Transfer Protocol (HTTP) . . . . . . . . . . . . . . 18
3.9.3 Message Queue Telemetry Transport (MQTT) . . . . . . . . . 18
3.9.4 Constrained Application Protocol (CoAP) . . . . . . . . . . . 18
3.9.5 Data Distribution Service (DDS) . . . . . . . . . . . . . . . . 19
3.10 Security with SSL/TLS encryption . . . . . . . . . . . . . . . . . . . 19
3.11 Redis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4 Network theory 21
4.1 OSI model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2 Industrial networks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.2.1 EtherCAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.2 Ethernet Powerlink . . . . . . . . . . . . . . . . . . . . . . . . 22
4.2.3 Profibus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.4 Profinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2.5 Intelligent Distributed Automation (IDA) . . . . . . . . . . . 24
4.3 Wireshark . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.4 Personal Area Network (PAN) . . . . . . . . . . . . . . . . . . . . . . 25
5 Gateway design 27
5.1 Profinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2 Hardware and software version . . . . . . . . . . . . . . . . . . . . . . 28
5.3 Profinet stack implementation . . . . . . . . . . . . . . . . . . . . . . 28
5.3.1 Profinet slave stack . . . . . . . . . . . . . . . . . . . . . . . . 28
5.3.2 Profinet master stack . . . . . . . . . . . . . . . . . . . . . . . 29
5.4 Gateway master communication with slave . . . . . . . . . . . . . . . 30
5.5 Network traffic analysis . . . . . . . . . . . . . . . . . . . . . . . . . . 31
5.6 Redis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.7 Bluetooth alarm and signal strength . . . . . . . . . . . . . . . . . . 32
5.8 Message Queue Telemetry Transport (MQTT) . . . . . . . . . . . . . 33
5.9 Node-Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5.10 Gateway access-point function . . . . . . . . . . . . . . . . . . . . . . 34
5.11 PLC layout and programming . . . . . . . . . . . . . . . . . . . . . . 35
6 Conclusion 39
6.1 Goals vs Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2 Critical discussion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.3 The role of the technology . . . . . . . . . . . . . . . . . . . . . . . . 40
6.4 Continued development . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Bibliography 43
A Appendix 1 Node-Red setup I
B Appendix 2 Redis III
C Appendix 3 MQTT V
x
Contents
D Appendix 4 Raspberry Pi bridge setup VII
E Appendix 5 Codesys network port fix IX
xi
Contents
xii
List of Figures
1.1 Overview of how the gateway can be connected to different systems,

such as to another Profinet network, to a Bluetooth device or con-
nected to a cloud service. . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Network layout for a proxy service . . . . . . . . . . . . . . . . . . . . 2
1.3 Network as seen from the controller . . . . . . . . . . . . . . . . . . . 2
1.4 How the gateway combined with different technologies can be seen as
two blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Ladder Logic for the simplest of schematic. A high input, X, gives a
high output, Y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Electrical schematic for simple connection. A high input, X, gives a
high output, Y. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.1 Publisher/Subscriber type protocol setup . . . . . . . . . . . . . . . . 18

3.2 Client/Server type protocol setup . . . . . . . . . . . . . . . . . . . . 18
3.3 Centralised Publisher/Subscriber type protocol setup as used in MQTT 19
3.4 DDS distributed system where all nodes are connected to each other . 19
4.1 OSI 7 layer to the left compared to the TCP/IP model to the right . 22
4.2 How the time is divided to provide both Isochronous Realtime, Real-
time and conventional TCP/IP traffic . . . . . . . . . . . . . . . . . . 24
4.3 OSI 7 layer to the left compared to the different Profinet traffic types 24
4.4 Basic setup of PLC network, where all instructions are commanded
by the controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.5 IDA setup of PLC network, where the code is distributed to the I/O
devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
5.1 Overview of how the Gateway is structured internally . . . . . . . . . 27

5.2 Network as seen from the Profinet Controller (master) . . . . . . . . 29
5.3 Profinet Controller (master) layout for the modules. The large win-
dow to the left is the controller itself, in the middle a Profinet switch
and to the right is the gateway . . . . . . . . . . . . . . . . . . . . . 29
5.4 Setup in Codesys, where 1200_20inout is GSD file for the Profinet
I/O device used . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.5 Normal network setup without network analysing . . . . . . . . . . . 31
5.6 Network setup with hub to extract network messages . . . . . . . . . 31
xiii
List of Figures
5.7 Network setup with a switch used to extract network messages be-
tween PLC Cntrl and the top PLC IDA . . . . . . . . . . . . . . . . . 32
5.8 Network setup with a Raspberry Pi configured as a network bridge
that can analyse the traffic . . . . . . . . . . . . . . . . . . . . . . . . 32
5.9 Node-Red web interface as seen from Chromium Browser . . . . . . . 34
5.10 Webservice as seen by a phone, with a graph and dashboard of signal
strength. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.11 Lower part of the web-service, where the signal strength graph and
alarm status can be seen. . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.12 Photo of how the actual system hardware is connected. Top left is
the Raspberry Pi Gateway. Top right is the wireless router. The sec-
tion in the middle contains the power-supply to the left, the Profinet
switch in the middle and the Profinet Controller/Master to the right.
The I/O device (1200_20inout) with the red button can be seen at
the bottom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.13 Bit toggle generator: Output, “Q0.0”, oscillates between 0 and 1,
holding each value one second each (0.5 Hz cycle) . . . . . . . . . . . 37
A.1 Configuration layout of Node-Red . . . . . . . . . . . . . . . . . . . . II
xiv
List of Acronyms
ASCII: American Standard Code for Information Interchange

AWS: Amazon Web Services
BLE: Bluetooth Low Energy
DDS: Data Distribution Service
FPGA: Field Programmable Gate Array
GNU: Recursive acronym for “GNUs not Unix”
GSD: General Station Description
HTTP: Hypertext Transfer Protocol
HTTPS: Hypertext Transfer Protocol Secure
I/O: Input/Output
IDA: Intelligent Distributed Automation
IIC: Industrial Internet Consortium
IIRA: Industrial Internet Reference Architechture
IIoT: Industrial Internet of Things
IP (Copyright): Intellectual Property
IP (Networking): Internet Protocol
IRT: Isochronous Real-time
IT: Informational Technology
IoT: Internet of Things
LAN: Local Area Network
MQTT: Message Queue Telemetry Transport
OBD: On-board diagnostics
OS: Operating system
OSI: Open Systems Interconnection Model
OT: Operational Technology
PAN: Personal Area Network
PLC: Programmable Logic Controller
PaaS: Platform as a Service
RT: Real-time
SSL: Secure Sockets Layer
SaaS: Software as a Service
TCP: Transmission Control Protocol
TLS: Transport Layer Security
UDP: User Datagram Protocol
VLAN: Virtual Local Area Network
WAN: Wide Area Network
xv
List of Acronyms
xvi
1
Background
The fourth industrial revolution, so called Industrie 4.0, is ongoing [1]. Manufac-
turing companies are digitizing their entire value chain, factories and machines get
connected, and data analysis is essential in what is called the Industrial Internet
of Things (IIoT) [1, 2]. New technologies are emerging such as network-connected
sensors, 3D printing and new tools for the operator such as augmented reality and
collaborative robots [1]. An important business potential can be found in help-
ing companies to introduce wireless technology in production systems, to ease the
introduction of new sensors and to provide information to and from the factory.
1.1 Introduction
A major hurdle for implementation of the IIoT, is the industry’s reluctance to
embrace the new technology [3, 4]. The reluctance has been problematic because it
is currently necessary to make changes in the already established system which is
time consuming and expensive. In large industrial systems the time to implement
new functionality is even longer, which leads to long expensive down-times. The
down-times can in turn cause companies to update their systems even more
infrequently, resulting in aging devices that are even more difficult to replace. How
do we break this negative spiral?
One way to prevent the spiral is to make it easier to update the devices, such as
PLCs and input/output (I/O) nodes. One such way is to decentralize the work
with more dynamic modular nodes. In this thesis project a gateway will be created
between the outside world and the industrial network (Profinet) [5, 6]. Profinet will
be combined with the Intelligent Distributed Automation (IDA) interface, without
modification to existing hardware or architectural layout, see Figure 1.1.
IDA is a system, created by the company SEVAB, that is designed to cre-

ate a plug-and-play functionality making it possible to add, move or remove
a Programmable Logic Controller (PLC) unit [7, 8] without any reprogram-
ming [9]. However, there are still issues during the setup. When a new node
or PLC I/O device is introduced to the system, the controller PLC will need to
account for all possible hardware configurations that could be used by the new node.
To make the network more scalable, we could introduce a new level of abstraction
by implementing the gateway between the new node and the controller PLC. As the
1
1. Background
Internet
Controller PLC
IDA Bluetooth LE
IIoT Gateway
Profinet
IDA
Profinet
I/O devices
Figure 1.1: Overview of how the gateway can be connected to different systems,
such as to another Profinet network, to a Bluetooth device or connected to a cloud
service.
controller PLC only needs to see the gateway as a new PLC node with a fixed set
of hardware, the tedious setup work concerning the controller PLC is reduced. See
Figure 1.2 and 1.3 for illustration.
Controller PLC Controller PLC
IDA IDA
IDA Gateway PLC IDA Gateway PLC
Profinet Profinet
Profinet Profinet
x
IDA IDA
bo
k
I/O devices I/O devices PLC
ac
node
Bl
Figure 1.2: Network layout for a Figure 1.3: Network as seen from the
proxy service controller
Another, easier, way to see the dynamic features this gives is to imagine that there
are two blocks. The top one is always the same and only communicates with the
Profinet IDA interface, and the bottom one is whatever function that is desired.
The desired function can be the proxy service, a network connected IoT gateway
or simply communication with a Bluetooth Low Energy (BLE) device [10], see
Figure 1.4.
Additional feature, other than the proxy service, is the ability to connect to the
outside of the industrial network, for example to a wireless BLE device. The
gateway is connected to the Profinet network on one side and can have any number
of technologies on the other side. By combining the gateway with the IDA system,
it is possible to create a flexible production with reduced changeover times. At the
same time, information about factory status will be available outside the industrial
network, for example to a cloud service. There are already available cloud services
2
1. Background
Controller PLC
IDA
IDA Gateway PLC

Profinet
Top part
Bottom part
I/O devices
Bluetooth, Cloud service, Profinet network etc
Figure 1.4: How the gateway combined with different technologies can be seen as
two blocks
for Profinet, such as Proficloud [11], but none with the IDA protocol.
1.2 Goal and Purpose

The work is carried out at Endian Technologies AB, and their two main objectives
are to:
• Evaluate what the Industrial Internet of Things (IIoT) is and any predictions
on the direction it is headed in the future, both as an overall guideline but
also focusing on where Profinet fits into the future.
• Develop a proof of concept gateway that connects to a Profinet network on
one side and to an arbitrary service on the other. The key focus is to provide
a dynamic gateway that can be used to connect Profinet devices to other,
previously unavailable, services.
The overall goals of this thesis project are to:

• Evaluate what other industrial network protocols, other than Profinet, used in
industry that could be used in the thesis project and what protocols to expect
in the future.
• Identify the security and ethical aspects of having the gateway connected to a
cloud-based service.
• Develop a demonstrator that is connected to the industrial network (Profinet)
at one side, and to sensors or a cloud platform at the other. The connected
sensor should use Bluetooth and serve as an wireless emergency stop that
workers can carry with them.
• The gateway should also be able to implement the proxy service shown in
Figure 1.2 and 1.3, by connecting the Profinet network and a PLC node to
elevate the abstraction level for setup of new nodes.
3
1. Background
1.3 Limitations
The project focus is to connect a gateway to the Profinet network, and although
research will be done about other industrial networks that could be used, no testing
or implementation of other networks than Profinet will be done. Only hardware that
run a GNU/Linux system will be evaluated to use for the gateway, i.e. no Windows
Embedded or other proprietary devices will be taken into consideration. Profinet
will be implemented purely in software, no external chips or soft-cores in FPGAs
will be used. The constructed gateway should only serve as a proof of concept and
not a finished product to be used in industry.
1.4 Ethical Aspects

The biggest concerns found during this thesis project would be regarding the
cloud service. If you yourself (the company) do not have control over the server
that runs the service, there is no guarantee that the information only will be
used in your best interests. If one company is responsible for all factories cloud
service, they could either leak information to other competing businesses or worse,
security details to other countries. But having all services connected to one
cloud service also make it more vulnerable as the interest to crack the security
might be higher. Another issue that might arise is if the cloud service has sensors
connected, such as cameras or microphones, the workers could be under surveillance.
Another concern would be regarding implementing a commercial Profinet stack,

as the software would not be “free”. Here meaning free as in “freedom not free
beer” [12]. By implementing a commercial stack, there are some restrictions that
one has to follow. The stack for the slave side is given in C code, which gives
better transparency. The master side, however, is run as an application and can be
considered as a black box, which makes it difficult to see what other instructions is
executed other than that of the Profinet drivers.
In the project a prototype wireless emergency switch is implemented which has some
ethical concerns regarding whoever is responsible if this does not work correctly. Ad-
ditionally by implementing the proxy functionality in between two Profinet network,
another concern can be raised if the gateway does not forward security and safety
critical messages in time.
1.5 Thesis report outline

This paper starts with some background information on industrial environments,
such as programmable logic controllers (PLC) and how to program them, some
information about industrial security and industrial hardware.
Next, some information will be given about Internet of Things and the industrial
variant, with some of the most used protocols and platforms and a short section
4
1. Background
about SSL/TLS encryption. Following that is a chapter about network models and
how conventional traffic is different from the industrial variants.
In the Gateway design chapter, the demonstrator design decisions and implementa-
tion choices are explained and evaluated, and finally the results and conclusions are
given.
5
1. Background
6
2
Industrial environment
background
This chapter covers information regarding industrial environments, such as hard-

ware, software and programming but also security concerns.
2.1 Programmable Logic Controller (PLC)

A programmable logic controller [8], or PLC for short, is a computer designed
for industry and is used in the automation of the processes in a manufacturing
system. PLCs were designed to replace earlier technologies used, such as relays and
timers. They are made to withstand harsh environment such as large temperature
deviations, excessive vibrations, high humidity and dusty conditions. The logic
controllers are used to control timing-critical operations such as milling, lathing,
drilling and printing, they are hard real-time systems with deterministic timing [8].
2.1.1 PLC programming

There are a number of different ways to program a PLC, and five languages for
programming languages and programmable control systems are defined in the
standard IEC 61131-3 [13]. Two of the five languages are text-based, whereas the
rest are graphical. The two text based ones are Instruction List (IL) and Structured
Text (ST). The graphical ones are called “Sequential Function Chart” (SFC),
“Function Block Diagram” (FBD) and “Ladder Diagram” (LD) [14], where the
latter (LD) is the one used in the project, and is the only one that is being evaluated.
2.1.2 Ladder Diagram (LD)

Ladder Diagram originated as a way to represent the layout of relay logic [15]. It
is a graphical way to program, which is visually similar to how an actual electric
circuit looks like. A basic function can be seen in Figure 2.1 with its equal electrical
schematic drawing in Figure 2.2.
In Figure 2.1 the input X, called “normally open input” in Ladder Diagram terms,
is used to control the output Y, noted as a “coil”. The name “coil” can be somewhat
7
2. Industrial environment background
confusing, and is a remnant from previous relay logic where you control a relay by
activating a magnetic field in a coil to close the circuit. The output does not have
to go to the coil part of a relay, but can be used to control anything. The result of
the circuit is that with a high input, the output also goes high.
X Y
Figure 2.1: Ladder Logic for the sim- Figure 2.2: Electrical schematic for
plest of schematic. A high input, X, simple connection. A high input, X,
gives a high output, Y. gives a high output, Y.
The usefulness of having a graphical way to program the PLCs is mostly for
engineers with an electrical background, as the layout is very similar to that
of how actual hardware would be connected, but for software- or computer
engineers, a text based variant is often more familiar. Another positive feature for
simple designs, is the way to debug, as one can easily see what parts are high and low.
2.2 Industrial safety

To maintain a high level of safety in an industrial environment, there are a number
of different systems and devices in place, such as emergency stops. Another safety
approach is by equipping the machines and robots with sensors that activate when
humans are nearby and either slow down the production or completely halt until
the persons have left the danger zone [16].
Another view concerning personal safety is protective clothing, such as glasses, hel-
mets, gloves and steel boots. A relatively new idea is concerning personal emergency
stops where the workers themselves all have individual emergency stops that once
pressed, stop the nearest machines [17]. This could be combined with some type of
smart textile that senses if the fabric has been ripped or smashed, and the clothing
would itself send the distress signal to halt nearby machines. Another approach
where it might be easier to implement this type of emergency stop, is in industries
with hardhat requirements. The hat might already have a battery to provide power
for a headlamp, and the company would thus not be too foreign to having another
battery and emergency stop installed. Having the emergency stop installed in the
helmets also makes them distributed around the workplace and in the case that
one stop does not work, another one can be located more quickly than if it would
8
be a conventional wireless emergency stop. Another feature of the emergency stop

would be to also alert if a worker has a dangerous health status such as a weak or
non-existing pulse, and would then contact medics or other nearby workers, with
the coordinates and the health status of the worker.
2.3 Industrial hardware

Other than the human safety part, there are other demands for industrial compo-
nents such as the demands on the hardware. The main requirement of industrial
grade hardware is to be durable. Once replacement is necessary, there should exist
replacement parts even after the parts’ end-of-life. The hardware should also be
able to operate in harsh environments with large temperature fluctuations from -40
to +100 degrees centigrade [18], to have a low power consumption without active
cooling such as fans, be able to sustain vibration and shocks [19], high humidity,
corrosive liquids and electromagnetic interference [20].
9
10
3
Internet of Things background
This chapter covers basic background information regarding Internet of Things

(IoT), both conventional IoT but also the Industrial IoT. Further some platforms
and protocols are described with their different pros and cons, it should also be noted
again that one of the main goals of the thesis is to evaluate and compare different
platforms and protocols. Too understand the practical part of the thesis, meaning
the gateway, it is only necessary to read the sections regarding Node-Red, OPC UA,
MQTT and Redis. The other sections are meant for evaluation and comparison
purposes.
3.1 Internet of Things

Internet of Things, or IoT, is the term for networking physical devices or “things”
together. The IoT term is usually used for all types of “smart” or connected devices,
however there are four main branches or areas concerning IoT. The branches are
commercial, enterprise, consumer and industrial IoT [1]. Consumer is the one most
people might think about when they hear IoT, which is devices used for personal
applications, such as having the refrigerator notifying once the milk is soon to expire,
or wireless speakers that sense in which room people are located. Commercial IoT is
used by organizations to increase some business value such as marketing, Enterprise
IoT is also used by organizations but the primary focus is not to make more money
or increase profit, it is more about collecting information about process status and
information gathering [21]. An interesting example of how collecting information
and distributing it can be seen in smart visors designed to help firefighters. The
helmets uses a “heads up display” (HUD) that shows the image from a thermal
camera, the helmets will also be connected together so that both the firefighters and
other personnel outside the buildings can get get an idea of where they are located
relative to each other. Industrial IoT concerns connected devices in industrial and
manufacturing environments [1, 2], more about this in the section 3.4.
3.2 Cloud Computing

Cloud computing is where resources, processes and data may be shared with re-
motely located servers, either in remote countries, cities or closer. A primary benefit
of utilizing cloud computing is that the set-up cost is minimized as one does not
have to purchase any physical hardware and servers, but instead rely on the sup-
plier’s hardware [22]. Another positive feature is that the computational power that
11
3. Internet of Things background
a company or organization needs can be changed dynamically, certain months might

have high demands whereas the next could be less and it is possible to compensate
these fluctuations by changing how much hardware/computer power you use at the
cloud servers. A negative side of using cloud computing is that the organization or
company does not have total insight on what computations are run on the data, as
they would if it was on one of their own servers. A similar type of network-based
computing is fogging or fog computing [23]. Instead of having the servers located
remotely, as in cloud computing, in fogging the servers are located at the edge of
the organization network. Fogging does not help in the dynamical sense as with
outsourcing cloud computing, however, it does make it more transparent to the
organization.
Proficloud
Proficloud is a Profinet Cloud service created by Phoenix Contact [11]. The units,
PCs, PLCs etc, are connected to the cloud service, Proficloud, and the traffic is
encrypted using TLS [24, 25]. See section 3.10 for more information about SSL and
TLS.
3.3 Industrie 4.0

Industrie 4.0 is a term that is often used in discussions about Industrial IoT and
Industrial Internet. Industrie 4.0 is the name that the German government issued
to their project of being “the leader of the industrial market” as both manufacturer
and provider [26], hence the German word, industrie, for industry. The name is
based around the three industrial revolutions that have occurred previously and we
are now traversing into the fourth. The first revolution was in late 1700 to early 1800
when machines, such as the weaving loom and steam or petroleum powered devices,
were introduced [27]. The second revolution was in late 1800 with production lines
and mass production were initiated, and the third revolution was in the 80s with
computer controlled automated robots. The fourth revolution is believed to hap-
pen now with smart devices such as actuators and sensors being connected together.
3.4 Industrial Internet of Things

Industrial Internet of Things, Industrial IoT, IIoT or Industrial Internet [3] are some
of the names given to the technology of connecting industrial machines and devices
together, henceforth called Industrial IoT throughout this report. Industrial IoT is
geared towards connecting devices to add a higher level of abstraction that makes
it possible to get an overview of everything in the organization. There already are
methods, such as quarterly reports, used to give an indication of the current status
of the organization. An improvement can be made by having the devices connected
as the results would be more frequently updated and any abnormal data could
be addressed right away. Another direction of Industrial IoT is to have sensors in
12
concumable parts, such as bearings, brakes or lights. By having sensors in these parts
and components, maintenance needs can more easily be predicted and avoidable
down times or unnecessary replacements can be prevented. The sensors could also
make it easier in remote locations, where it takes a long time for replacement parts
to arrive, such as for wind turbines or boats far out at sea.
An extension to the idea of predicting how worn parts are and when to replace them
is the concept of “virtual copies” or “digital twins” [28, 29], where actual physical
hardware is given a virtual software based copy. The hardware sends data on how
much it has been used and what parts have been changed, the digital version then
updates its values and an overview of the hardware can be made without access to it.
Another term that comes up is Industry 5.0 [30], where some argue that Industrie
4.0 and Industrial Internet is about connecting the devices together, Industry 5.0 is
more focused on the human-machine interaction and collaboration. Where humans
can work alongside machines but also somewhat about augmented reality [31], where
the operator gets graphical illustrations through a transparent screen which make
it possible to depict images and objects as they would in reality. These types of
features makes it easier for workers with assembly and repairs. Imagine that instead
of having a somewhat confusing technical documentation of how to install a piece
of furniture, you would instead put on a pair of goggles that visually shows how to
assembly the parts. Or perhaps a more business worthy example where the goggles
connect to the car computer, and the on-board diagnostic (OBD) service tells what is
wrong with it. The goggles would then be able to visually show what part to replace
and where it is located on the car. Even though there are differences between 4.0
and 5.0, it is doubtful that technologies emerging so close would be given different
industrial “revolutions”, which is why both the connectivity and the human-machine
integration are often termed as Industry 4.0.
3.5 Industrial Internet Consortium (IIC)
The Industrial Internet Consortium, or IIC for short, is a consortium created by

AT&T, Cisco, General Electric, Intel and IBM [32], with more than 200 mem-
bers [33]. The IICs main focus is to collaborate and share knowledge about emerg-
ing technologies and recommendations regarding the Industrial IoT. The IIC does
not participate in directly developing open standards for industrial use, but instead
focus on designing frameworks, test beds and use cases in areas such as health-care,
manufacturing and security [34]. One of the frameworks that has been created by the
IIC is the Industrial Internet Reference Architecture, or IIRA for short [35], which
is a framework designed to aid in documentation, development and communication
of Industrial IoT.
13
3.6 Industrial Internet Reference Architecture

(IIRA)
The IIRA is a reference architecture created by the IIC [35], which was designed to
aid in the development of a industrial system with IIoT in mind. The Reference
Architecture document is divided in two main parts, where the first is regarding
the fundamentals and context for a system under construction but also on different
viewpoints. The second part is concerning sections that are under continuous
analysis.
The different viewpoints focused on in the Reference documentation are: Business,

Usage, Functional and Implementation.
• Business: Focus on the business visions and information that is interesting for
business related decision makers.
• Usage: The central systems capabilities and use cases.
• Functional: The devices and components functional relationship between each
other and with external parts.
• Implementation: The implementation part of the functional devices and life-
cycle plan.
3.7 Cloud security concerning outside threats
There are three main categories for how to secure an industrial environment, the
first and easiest to implement is to have no traffic in or out of the enterprise. Only
the internal network can be used, making it impossible for external attacks to occur
without direct access to the network. However, it also cripples any remote diagnos-
tics or repair of the system that is not performed on site, and makes it impossible to
connect it to a cloud service. Another alternative is to only allow traffic going out
of the factory and none going in, which will make it possible for an outsider to get
continuous data about what is going on inside the factory but not possible to request
information, other than what is transmitted. However if the factory transmits all
valuable information about sensors and devices to a server located outside of the
factory, other computers could then connect to this server and see information about
their devices. This would move the security risk out from the factory onto the server
and in the case of an attack it would only be the information that is threatened and
not the actual control systems, i.e. the Operational Technology (OT) threat has
been moved to an Informational Technology (IT) threat. A third alternative is to
have all connections preset beforehand, and any deviating or new connections would
then simply be denied access. This final method still leaves vulnerabilities against
man-in-the-middle and similar attacks.
14
3.8 Industrial IoT platforms

Platforms concerning IoT are commonly denoted as middleware, as the platform is
the distributor of information between the “things”/devices and the more abstract
application layer. For a platform to be useful and practical it is necessary that the
application scope is large enough to cover the uses and can scale easily with an
increasing number of nodes. A platform that is specified and focused to do certain
tasks might be overtaken by another, more sluggish implementation if this is more
dynamic or has a larger set of possible implementations. However, it might also be
that the area of use is so niched that there is really only one platform available that
satisfies the demands. The following subsections cover some of the more recognized
platforms concerning IoT, some of them with more or less focus on Industrial side
of IoT.
3.8.1 Kaa
Kaa is an open-source and free IoT platform [36], which claims to have essential
middleware for Industrial IoT application, by having a set of methods that can be
used to predict future failures and simplify troubleshooting errors. It is also possible
to implement a cluster of Kaa servers located in different geographical locations, and
when the primary server either gets disconnected or crashes, a new node is given
the “primary” tag. Kaa clients can be executed on a number of systems, from
large fast ones to smaller devices with less than 10 KB of RAM [37]. The server or
middleware functionality can be implemented on either private servers or by directly
using Amazon Web Services (AWS) [38].
3.8.2 Predix
Predix is a proprietary cloud platform [39], created by General Electric (GE) [40]
as a Platform as a Service (PaaS), designed for the Industrial IoT field. The plat-
form is sometimes referred to as an “ecosystem of services” or as the “app store for
Industrial IoT”, due to the fact that it hosts solutions for a number of different ap-
plications. The implementations for the different applications range from anomaly
detections, text analytics and machine learning to data management, security ser-
vices and indoor positioning [41].
3.8.3 OpenRemote
OpenRemote is an open-source project to make it possible for devices, with different
protocols, to communicate and cooperate with each other [42]. It initially started
as a tool to use in home automation but has now expanded to other applications
such as health care and entertainment. The three main features of OpenRemote are
integration of devices, user interface design and service management. The managing
services are account management, which allows for creation and management of
several users, a messaging service for status notifications and data analytics which
is used to analyze the received data.
15
3.8.4 Echelon IzoT

IzoT is a platform family of chips, stacks, interfaces, software development kits
(SDK) and management software focused on the Industrial IoT [43]. The name
IzoT has no directly abbreviated meaning, however the ’z’ can be interpreted as
a power of 2, hence the name IzoT could be written as I 2 oT hinting at Industrial
Internet of Things. Echelon sells IzoT enabled devices and services such as sensors,
routers and cloud servers. The devices are multi-protocol enabled and can, amongst
other protocols, communicate on the conventional Internet Protocol (IP).
3.8.5 CloudPlugs
CloudPlugs is an IoT cloud service without focus on industrial use [44]. It aids in the
development of IoT applications by providing libraries that simplifies the connection
to either their cloud service or an in-house server. The primary communication with
the cloud service is done using either MQTT or HTTP. See section 3.9 for more
information about MQTT, HTTP and other communication protocols.
3.8.6 mnubo
Mnubo’s primary goal is to help retrieve the valuable information in a large ocean of
sensor data by using smart analytics [45]. The five main focus areas are consumer,
smart home, commercial, agriculture and light industrial devices. Light industrial
refers to industrial devices that are more focused on the consumer end-use rather
than a business, such as heating, ventilation and air conditioning. Other than
offering “analytics as a service”, by aiding to visualise and analyse data, mnubo
has two other services, “data as a service” and “intelligence as a service”. “Data
as a service” helps to organize, modelize and store data , whereas “intelligence as a
service” aids in building predictive and machine learning models.
3.8.7 Nimbits
Nimbits is an open-source IoT Application Programming Interface (API) [46] that
is used to process and store timeseries data. The source code consists of a server and
a client software that runs on Java embedded devices. The information gathered is
structured in a treelike fashion and the server can be set up to either store the data
and visually represent it, or to trigger an event to happen when a certain condition
is met.
3.8.8 AllJoyn Framework

AllJoyn is an open-source framework to simplify discovery and communication be-
tween devices [47]. A combination of mDNS and UDP packets are used to enable
communications with IP traffic [48]. By using mDNS it is not necessary to have a
dedicated DNS server for “name-to-IP-adress” translation. The fact that it is not
necessary to have a dedicated DNS server is important as AllJoyn focuses on IoT
16
connectivity without a cloud service. However, if a cloud service is desired it can

also be implemented as an optional added feature.
3.8.9 Node-Red
Node-Red is a tool designed for the IoT by “wiring together hardware devices, APIs
and online services” [49]. Node-Red is set up using a web browser by connecting
different blocks/nodes together. The blocks/nodes range from publication of web
pages, hardware specific functionality such as Raspberry Pi GPIO pin control, send-
ing and receiving MQTT messages to email and twitter messages. Node-Red can be
used with a number of systems, such as Raspberry Pi, BeaglehBone, IBM Bluemix
and Amazon Web Services.
3.9 IoT Protocols for industry

There are many protocols competing to be the foremost used in different fields
of the Internet of Things, some emerging from the IoT directly as completely
new protocols and others evolve from already established techniques in industrial
applications. A special tailored protocol for IoT might be better in terms of usage
and speed, however, that alone does not make it successful. Already established
protocols are more acknowledged and accepted and the threshold to move to a
new protocol might be steep. Another challenge is that it is necessary that the
protocols can be used by essentially all different fields and applications as one of
the main objectives in IoT is to connect everything. Instead of, as many previous
protocols, being proprietary with closed source code, many of the protocols for IoT
are collaboratively being developed by many companies and organizations with
public and open-source-code. Having the code developed in “the open” helps both
the spread of the protocol, because of easier availability, but also helps in the fact
that aid can be received during the development process.
The protocols used can be divided in two main groups which are, client/server and
publisher/subscriber. The client/server type relies on point-to-point communica-
tion and is therefore often deemed more secure [50]. Hovewer, using point-to-point
communication makes it difficult to scale up to large networks.By using a publish-
er/subscriber type of communication the publisher sends data to a central node,
usually called the broker. The broker has connected nodes that subscribe to differ-
ent topics, and once a publisher has sent new data the broker will forward the data
to all subscribing nodes of that topic. See Figures 3.1 and 3.2 for comparison. Some
of the predicted protocols to be used in the future for Industrial IoT are OPC UA,
HTTP, MQTT, CoAP, DDS and AMQP.
3.9.1 Open Platform Communications Unified Architecture

(OPC UA)
OPC UA stands for Open Platform Communications Unified Architecture and is
a client/server protocol. The protocol has evolved from OPC, which sometimes
17
Publishers Subscribers Clients Clients
Broker Server
Figure 3.1: Publisher/Subscriber Figure 3.2: Client/Server type proto-

type protocol setup col setup
is described as “Classic OPC” [50] to help differentiate between the new and old
protocol, but at the same time maintain the recognizable name. The new protocol
is open-source, but not free, and is used in industrial environments to model and
deliver information [51].
3.9.2 Hypertext Transfer Protocol (HTTP)

Hypertext Transfer Protocol (HTTP) [52, 53] is a protocol used to carry hypertext
messages and is the main protocol used to transfer data over the Internet. HTTP
itself is not very useful as a protocol to use with IoT nodes as it has a large overhead.
The data traversing the IoT network usually consist of short messages that update
quite frequently, and by having a large overhead on all of these messages congests
the network. Another approach to use HTTP, in IoT applications, would be to
buffer up some data before sending it, leading to a lower relative overhead. HTTP
could therefore be used to send data gathered inside a factory or organization and
once every hour or day send it to a cloud service.
3.9.3 Message Queue Telemetry Transport (MQTT)

MQTT stands for Message Queue Telemetry Transport [54, 55] and is a centralized
publisher/subscriber type protocol, with a broker that relays messages. Contrary
to HTTP, MQTT has a small overhead of about 2 byte [56] and is data agnostic,
meaning that the transmitted data does not have to be formatted in a specific way.
3.9.4 Constrained Application Protocol (CoAP)

CoAP stands for Constrained Application Protocol [57] and is a similar protocol to
HTTP but made to be lighter with a smaller overhead. CoAP is useful in imple-
mentations where data is sent often with small payloads and where HTTP would
otherwise be used if not for the large overhead.
18
3.9.5 Data Distribution Service (DDS)

DDS stands for Data Distribution Service [58] and is a publisher/subscriber type
protocol. DDS systems are distributed which means that instead of communicating
with a central part, as with MQTT and the broker, all nodes can communicate with
each other directly [50]. See Figures 3.3 and 3.4 for comparison of a distributed and
centralized type protocol.
Publishers Subscribers
b b
Broker
b b
b b
Figure 3.3: Centralised Publisher/- Figure 3.4: DDS distributed

Subscriber type protocol setup as used system where all nodes are con-
in MQTT nected to each other
3.10 Security with SSL/TLS encryption

Secure Sockets Layer (SSL) [59] is an obsolete version of the newer encryption
protocol Transport Layer Security (TSL) [25, 24]. However, the standard is often
referred to as SSL/TLS even when it is the newer TLS that is used. The security
is initialized with a series of handshakes between a client and a server.
The client initializes the communication with a “hello” message to the server, which
includes what type of acceptable protocols that the client allows. The server then
responds with a server “hello” that acknowledges the message from the client, and
selects what encryption to use from the allowed list. The server also sends its digital
certification. The client then checks that the certification from the server is correct
and uses that to encrypt a private key and sends that to the server. Both sides now
have a symmetric private key that makes it possible to encrypt the communication
between the server and client.
3.11 Redis
Redis is an open-source data-structure database and message broker [60], that sup-
ports a variety of different data types such as strings, hashes, lists, sets and bitmaps.
A strong feature of Redis is its versatility, as it can can be used directly via a Bash
command line or by using libraries for several different languages such as C, C++,
C#, Erlang, Java, Node.js, Rust, Go among others. Redis is written and developed
19
in C to be executed on UNIX type operating systems, such as GNU/Linux and OS

X, there is currently no support for Windows machines.
20
4
Network theory
This chapter covers basic information about computer networks which might seem
unnecessarily simple to a reader with an engineering background in computer
science. However, it is useful to refresh some information about how conventional
network models are constructed, to be able to compare them to the industrial
variants described throughout the report.
A network is a structure of interconnected computers or nodes, which communicates

and shares information with each other. The network can be a local one that only
houses a few computers or it can be a global one with millions of connected devices
spanning several countries. To be able to communicate between each other, on even
the simplest of networks, it is necessary that all involved parties follow a common
standard, one such is the Open Systems Interconnection Model [61, 62], or OSI
model for short.
4.1 OSI model

The OSI model is a layered standard for communication functions in computer net-
works. The OSI model contains several layers [61, 62], where the layers communicate
directly to their respective on the other side of the communication, i.e. layer 2 on
the transmitter side communicates with layer 2 on the receiver side, and it does
not know or care about what specifications the other layers have. The OSI model
usually consists of seven (7) layers which are the Application, Presentation, Session,
Transport, Network, Datalink and Physical layer [61, 62]. Another similar model
is the TCP/IP Model that only uses five (5) layers, which is done by merging the
three top layers together into one Application layer and also merging together the
data link and physical layers [63]. See Figure 4.1 for an illustration of the models
compared to each other.
4.2 Industrial networks

The demands on industrial networks are greater than that of commercial products.
They have to be more ruggedly designed in terms of physical layout to be able to
withstand a harsher environment. Industrial networks also have to be able to provide
reliable, consistent information and deterministic real-time services to the end users.
An often occurring term in these types of contexts is Industrial Ethernet, which is
simply Ethernet used in industrial environments. It is the same as the conventional
21
4. Network theory
Application
Application
Presentation
Session
Transport Transport
Network Network
Data Link
Network Access
Physical
OSI 7 layer TCP/IP model
Figure 4.1: OSI 7 layer to the left compared to the TCP/IP model to the right
Ethernet but with more rugged ports, connectors and switches. Special network
protocols are used in Industrial Ethernet and there are more than a dozen different
solutions [64]. Even though only Profinet is used in this project, it is interesting to
see how different industrial Ethernet-based networks function to see similarities and
differences, the following subsections describe some of the most widely used ones.
4.2.1 EtherCAT
Ethernet for Control Automation Technology, or EtherCAT for short, is a field bus
system [65], which consists of master and slaves. The master is the only one allowed
to actively send frames, meaning that no slave is allowed to send frames without
being commanded. This is done to maintain a predictable real-time behavior. The
master uses a normal MAC protocol whereas the slaves use a special controller. The
controller is called the EtherCAT Slave Controller or ESC for short, which processes
the message purely in hardware to maintain the real-time service. The messages are
sent in standard Ethernet frames and any resulting jitter is less than 1 µs [65].
4.2.2 Ethernet Powerlink

Ethernet Powerlink is a completely software-based real-time field bus system [66].
The implementation is based on standard Ethernet and the real-time demand is cre-
ated by a mix of polling and time slicing. The system is made up of a Manager Node
(MN), and several Controlled Nodes (CN), the Manager Node controls who gets to
speak on the network by polling the Controlled Nodes for information. The polling
is done in such a way that each CN gets a specific slot in time to speak. A major
advantage of Ethernet Powerlink is that it is completely software based which means
that it can more easily be implemented on present systems, without any change in
22
4. Network theory
hardware, there are also open source protocol stacks such as openPOWERLINK [67]
that can be implemented free of charge.
4.2.3 Profibus
Profibus, acronym for Process Field Bus [68, 69], is not based on Ethernet but in-
stead on the serial line RS485 [70]. Profibus is maintained by “Profibus & Profinet
International”, the network consists of Master and Slave nodes, where the mas-
ters poll the slave devices for controlling and information gathering. The Profibus
network has a relative slow transmission speed, compared to the other protocols
evaluated above, of about 12 Mbits/s.
4.2.4 Profinet
Process Field Net or Profinet is an industrial Ethernet protocol which like Profibus,
is maintained by “Profibus & Profinet International” [71]. Profinet is an open
technology, that is independent of vendor. However, to receive information and
support it is necessary to be a member of “Profibus & Profinet International”.
There are two versions of Profinet; Profinet IO and Profinet CBA [72]. Profinet
CBA is the older one [73] and stands for Component Based Automation [74, 72],
it is suitable for communication machine-to-machine [73] and is centered around
distributing automation applications [75]. Profinet IO, which stands for Input
Output, on the other hand is centered around distributing the I/O units. In this
project only Profinet IO will be used and no further evaluation or information of
CBA will be given.
There are three levels or classes in the IO protocol, Class A, B and C [76].
Normal TCP/IP traffic in Class A, Real-time or RT in Class B and Isochronous
Real-time or IRT in Class C. TCP/IP is used for normal low priority traffic and
is sent the same way as in conventional TCP traffic, see Section 4.1. The second
level, Real-time (RT), can also be used with conventional Ethernet devices and
infrastructure. To be able to provide the real-time property, the RT-frames are
marked with a VLAN tag with the ID 0 and a priority of 6. These frames are
called priority tagged frames [77] and will be given priority over other messages.
As of now, no physical difference have been made to implement Profinet, however
in the third level, Isochronous Real-time (IRT), special hardware is needed to fulfill
the requirements. In Isochronous Real-time the cycle times of transmitted data
is less than 1 ms [71]. To solve the problem of having Real-time and at the same
time being able to connect to a normal channel, the channel is divided in “time
sections”, one channel for IRT specific transmissions and the other an open channel
for normal communication. See Figure 4.2 for illustration.
Since IRT traffic does not coexist in the same time frame as the normal traffic there
is no need to use the VLAN tag in the transmitted IRT frame. In Figure 4.3 the
layers of the different implementations can be seen.
23
4. Network theory
Cycle time
IRT TCP/IP IRT TCP/IP IRT TCP/IP IRT TCP/IP IRT TCP/IP IRT TCP/IP IRT TCP/IP IRT TCP/IP IRT TCP/IP
Profinet IRT traffic Profinet RT or conventional TCP/IP traffic
Figure 4.2: How the time is divided to provide both Isochronous Realtime, Real-
time and conventional TCP/IP traffic
Application
Profinet Profinet Profinet
Presentation Application Application Application
Session RT RT
Transport TCP/UDP TCP/UDP TCP/UDP
Network IP IP IP
b
Data Link Ethernet

Ethernet with scheduling
Ethernet with VLAN tag
Physical for real-time
OSI 7 layer Normal/non critical Real-time Isochronous Real-time
Figure 4.3: OSI 7 layer to the left compared to the different Profinet traffic types
The Profinet IO system contains three different types of devices, IO Controller, IO

Device and the IO supervisor [78, 72]. The IO Controller is a PLC or computer that
controls and monitors the IO devices. The IO Devices are the nodes that read IO
data with sensors or control actuators. The IO Supervisor is used to set different
parameters in the IO Controllers but also to diagnose separate IO Devices and the
network itself. The IO Devices are configured with General Station Description files
or GSD for short.
General Station Description (GSD)

The GSD files are saved in the file format GSDML which is formatted as an XML file.
The files contain information about the capabilities of the devices, such as vendor
and model name, identification number, maximum polling frequency, supported
baud-rates and the configuration of any IO ports.
4.2.5 Intelligent Distributed Automation (IDA)

The basic setup of automation in an industrial environment is that the PLC
has control over the I/O nodes directly and micromanages their functions. An
illustration of this can be seen in Figure 4.4. This compute-centralised way has
some drawbacks in that if one of the I/O nodes needs to be replaced, it is very time
24
4. Network theory
consuming as the code in the PLC Controller has to be modified to fit the new
node. If this is a large system there can be several thousands of lines of code, and
the programmer needs to separate out the ones concerning the replacement node.
PLC Controller PLC Controller

PLC PLC
Cntrl Cntrl
I/O I/O PLC PLC

Node Node IDA IDA
Figure 4.4: Basic setup of PLC net- Figure 4.5: IDA setup of PLC net-
work, where all instructions are com- work, where the code is distributed to
manded by the controller the I/O devices
The company SEVAB has developed a technique to simplify the transition when
implementing new nodes. Instead of having the PLC manage each and every I/O
node, the code is instead distributed across what they call PLC IDA nodes. Each
IDA node has its own code to control the functionality, and the PLC Controller
instead has more simple instructions for the nodes, such as start and stop. When
implementing new nodes, the code can remain the same in the controller since the
new node can have the same abstract functions as the last one, i.e. start or stop.
See Figure 4.5 for illustration.
4.3 Wireshark
Wireshark is an open-source network protocol analyzer [79], that can be used under
several platforms such as GNU/Linux, Windows and OS X. Wireshark can be used
to inspect network traffic, troubleshoot firewalls and decode several encapsulations
and protocols, one being Profinet [80].
4.4 Personal Area Network (PAN)

Personal Area Network, PAN for short, is a close range, usually around 10
meters [81], wireless network that is centered around one person [82]. There are
a number of different technologies, but only Bluetooth will be used in the thesis
project so no other techniques will be compared.
Bluetooth is a standard for wireless communications that was developed by the

Swedish company Ericsson in 1998 [83]. Unlike other PAN network technologies
25
4. Network theory
in the nineties, Bluetooth does not transmit infrared waves, which has a frequency
range between 430 THz and 300 GHz, but is instead located around 2.4 GHz [84].
The current version of Bluetooth is 5.0, which has a transfer speed of around 2
MBit/s. A frequently used term in Bluetooth contexts is “Bluetooth Low Energy”,
also known as Bluetooth LE or BLE [85]. BLE is a sub-part of Bluetooth 4.0 which
has a different protocol than that used in conventional Bluetooth to reduce the
energy consumption.
26
5
Gateway design
The designed demonstrator/prototype is a gateway that can be connected to a

Profinet network on one side and to an arbitrary network or technology on the
other, such as Bluetooth or WiFi. It is also possible to connect the gateway as
a “proxy”, separating two Profinet networks from each other, see section 5.3.2.
The following sections covers the approach and layout of the gateway, the overview
of the gateway can be seen in Figure 5.1 and each sub-part is discussed in their
representative section. The first sections cover some basic background regarding
where the information was collected and what underlying software and hardware
was used.
Gateway
Profinet Slave
Main Profinet Network
Stack
Bluetooth LE
Bluetooth
Redis Script
OPC UA MQTT
Wifi access
Machine-to-Machine Profinet Master

Profinet Network Node-Red
Stack
Web interface
Figure 5.1: Overview of how the Gateway is structured internally
5.1 Profinet
To gather the necessary information and knowledge about how the Profinet protocol
is implemented, the automation community Profibus and Profinet international
(PI) was used [86]. Usually a yearly fee is paid to remain a member, however, by
carrying out non-profit research, a free license was used during the 20 weeks of the
thesis.
The reason to why Profinet was used and not any of the other Industrial Ethernet
protocols is that Siemens is one of the largest suppliers of PLCs in Europe and they
27
5. Gateway design
use Profinet, but also because the demonstrator should be able to fix the addressing
problem in section 1.1.
5.2 Hardware and software version

Some time was spent on what type of hardware could be used that both runs on
GNU/Linux and is dependable enough to be used in an industrial environment.
However, even though there exists hardware that suits both of these demands, a
Raspberry Pi 3 was used in the project to simplify the implementation and to
reduce the time necessary before prototyping could be done. The development was
done on “Raspbian Jessie with Pixel” [87], kernel version 4.4.
Even though the Raspberry Pi 3 does not comply with the industrial demands on
hardware, there is a “Raspberry Pi 3 Compute Module” that is used in already
available industrial Profinet gateways such as in the “Kunbus Profinet IRT Gate-
way” [88]. Since it is the same microprocessor in the Compute Module as in the
Raspberry Pi 3, porting the software to the compute module should be trivial. Note
that the Kunbus Gateway only acts as a slave and not as both controller (master)
and device (slave) as the designed prototype/demonstrator does.
5.3 Profinet stack implementation

The initial approach was to evaluate whether it would be feasible to create a stack
from the core. However, after some investigation by reading the documentations
from PI and analyzing the network traffic with Wireshark, it is a large undertaking
to get all functionality to work correctly but also to be able to certify any final
product. By implementing an existing software stack this certification time is much
shorter. The problem has therefore been moved from creating a stack from scratch
to finding already available master and slave stacks that can be merged together.
5.3.1 Profinet slave stack

The slave stack was received from the German company “Port” [89], and comes as
source code written in the programming language “C”. The slave software is com-
piled together with the hiredis library and related libraries. The Profinet slave stack
on the gateway communicates with the main Profinet network and therefore with
the original Profinet Controller (master), this controller has to be set up which is
done using SIMATIC 7. In Figure 5.2 the layout is illustrated, however as ear-
lier described, in section 1.1 and Figure 1.3, from the controller point of view the
secondary Profinet network is unknown and only the gateways’ interface has to be
considered. The setup in SIMANTIC 7 therefore only has the gateways’ Profinet
slave stack as a module, see Figure 5.3 for SIMATIC 7 layout.
28
5. Gateway design
Controller PLC
IDA
IDA Gateway PLC
Profinet
Profinet
x
IDA
bo
k
I/O devices PLC
ac
node
Bl
Figure 5.2: Network as seen from the Profinet Controller (master)
Figure 5.3: Profinet Controller (master) layout for the modules. The large window
to the left is the controller itself, in the middle a Profinet switch and to the right is
the gateway
5.3.2 Profinet master stack

The master stack is used to set up the gateway to work as a Profinet Controller
that controls one I/O device or Profinet PLC. To be able to have both master and
slave properties on the gateway it is necessary to have two separate networks and
therefore two physical Ethernet ports on the gateway.
As the Raspberry Pi 3 is used as the gateway demonstrator, which only has one
(1) Ethernet port, it is necessary to add another port. This port is added using a
USB-to-Ethernet adapter.
The master stack used comes from “Codesys” [90], and is set up by first installing
29
5. Gateway design
a Debian package on the Raspberry Pi and then, via their development system, set
up any slave devices. Once starting the program it will use network port 34964 on
all available addresses on the local machine (0.0.0.0:34964), making it impossible
for any other application to communicate on the Profinet network. A fix for this
can be found in Appendix E. The setup is similar to that of SIMATIC 7 and can
be seen in Figure 5.4.
Figure 5.4: Setup in Codesys, where 1200_20inout is GSD file for the Profinet
I/O device used
5.4 Gateway master communication with slave

As the master stack is implemented with the program Codesys, and not as C source
code, it is not possible to add the hiredis C library. However, it is possible to
implement OPC-UA server in Codesys that transmits the desired signals. Another
program then listens to the messages transmitted from Codesys and relays them to
both the Redis database and to Node-Red. The idea behind sending the data to
both Redis and Node-Red is to make the program easier to implement with another
30
5. Gateway design
Profinet Controller (master) stack. If another stack were to be implemented it could

send the data to Redis and be used by any other program that wants the information.
By using MQTT to send the traffic to Node-Red it is easy to re-route it to another
web server.
5.5 Network traffic analysis
In Figure 5.5 the normal network layout is shown. There are a few different ways
to analyze the traffic between the Controller and the I/O devices (PLC IDA). The
easiest way would be to implement a hub between the desired I/O device and the
Profinet switch. A hub works by forwarding all incoming messages to all other
ports, making it possible to sniff the traffic by just connecting to one of the other
ports. By connecting a computer with Wireshark installed to *3 in Figure 5.6 it
is possible to see the traffic between the Controller and the Device. The biggest
problem with this approach, however, is that hubs are rarely used today and are
therefore somewhat difficult to obtain.
PLC Controller PLC Controller

PLC PLC *3
Cntrl Cntrl Hub
PLC PLC
IDA *1 IDA
Profinet Profinet
*2
Switch Switch
PLC PLC
IDA IDA
Figure 5.5: Normal network setup Figure 5.6: Network setup with hub
without network analysing to extract network messages
If we were to implement a switch instead of the hub, it would only forward the
messages from the Controller to the IO Device, i.e. from *1 to *2 in Figure 5.7. It
is possible to configure some switches to act like a hub and forward the traffic to
port *3 as well. In the project a TP-link TL-SG1005E switch was used to forward
the traffic however, only non real-time traffic was forwarded to port *3 and the
high priority real-time messages were only sent to port *2. A dirty hack to fix this
would be to flood the switch with fake MAC addresses, which would fill up the
memory and make it impossible for the switch to know which port the IO device is
located, forcing it to send the data to all ports.
31
5. Gateway design
PLC Controller
PLC PLC Controller
*3
Cntrl Switch PLC
Cntrl Pi
PLC Bridge
*1 IDA PLC
Profinet *1 *2
*2 IDA
Switch Profinet
PLC
Switch
IDA PLC
IDA
Figure 5.7: Network setup with a
switch used to extract network mes- Figure 5.8: Network setup with a
sages between PLC Cntrl and the top Raspberry Pi configured as a network
PLC IDA bridge that can analyse the traffic
Instead of filling the memory of the switch with fake adressess, another Raspberry
Pi was placed in the position of the switch and configured to act as a bridge between
the two networks. The commands necessary to set up the bridge can be found in
Appendix D. By implementing the bridge as can be seen in Figure 5.8, Wireshark
can be executed on the Raspberry Pi analyzing any of the ports (*1 or *2) to show
the real-time network traffic. The initial use of the Pi Bridge was to sniff the traffic
and to try to replicate it with another program, however this proved to be too time
consuming and the bridge was instead used to verify that correct packets were sent
and that there were not to many lost packets.
5.6 Redis
As one of the goals in the project was to create a demonstrator that could be used
as a platform in the future, it is useful that the program is flexible and dynamic.
It is also important that the device can be extended with more functions in the
future. By using Redis it is easy to implement additional features, as the database
structure can be accessed with a number of libraries for different languages. If
additional functionality is already implemented in in another system, porting it to
fit could be as easy as to implement the Redis library and send any relevant data to it.
In the project Redis clients for “Bash” and “C” were used. Before starting the clients
it is necessary to have the “Redis Server” installed and running on your machine,
see Appendix B for setup.
5.7 Bluetooth alarm and signal strength

To simulate an emergency stop that can give a rough estimate of distance, a Blue-
tooth Remote Shutter from Linocell was used. The remote has two buttons, one
being used to activate and the other to deactivate the alarm. The distance to the
emergency stop is measured by polling the strength of the Bluetooth signal twice
32
5. Gateway design
every second (2 Hz). This gives a very poor estimate of the distance since just plac-
ing an object between the transmitter and receiver will decrease the signal strength
drastically. However, since the objective is to demonstrate the distance measuring
functionality rather than an actual application, the distance accuracy is not crucial.
5.8 Message Queue Telemetry Transport

(MQTT)
To be able to send the signal strength, alarm signals and other messages to a remote
cloud server or similar IoT device, the protocol MQTT was used. However, instead
of sending the messages to an outside server the Gateway works as both publisher,
broker and subscriber. Publications are made in the program that handles the
Bluetooth communication with the emergency alarm, and sent to the local broker
that forwards the messages to the Node-Red web-client. See Appendix C for on
how to set up MQTT.
33
5. Gateway design
5.9 Node-Red
Node-Red was used because it is one of the simplest and fastest ways to implement
a web interface with aid for MQTT and for a graphical interface. Node-Red was
set up to show a graph and a bar of the current Bluetooth signal strength and
with four text values, the status of the alarm, the connectivity of the alarm, the
toggling value from the Profinet Controller stack and the status of the red button,
see Figure 5.9 for layout.
Figure 5.9: Node-Red web interface as seen from Chromium Browser
Raspbian Jessie was used during the project which, as of November 2015, has Node-
Red preinstalled. However as it does not come with the most updated version it is
necessary to run an update.
5.10 Gateway access-point function

For easy access without an Ethernet connection, the gateway is set up to work as
a WiFi access point. It is not broadcasting as a public device, but instead it is
necessary to have the SSID to access it. By implementing this wireless function
34
5. Gateway design
on the Gateway it is possible to gain access with a large variety of devices such as
laptops, tablets and phones. Figures 5.10 and 5.11 illustrates what the interface
looks like from a phone.
Figure 5.10: Webservice as seen by a Figure 5.11: Lower part of the web-
phone, with a graph and dashboard of service, where the signal strength graph
signal strength. and alarm status can be seen.
5.11 PLC layout and programming

The test system or demo rig consists of six devices; a WiFi router, a PLC controller
(master), a Profinet switch, a 24V DC power-supply, an I/O device (slave) and the
Gateway. See Figure 5.12 for the actual components.
35
5. Gateway design
Figure 5.12: Photo of how the actual system hardware is connected. Top left is
the Raspberry Pi Gateway. Top right is the wireless router. The section in the
middle contains the power-supply to the left, the Profinet switch in the middle and
the Profinet Controller/Master to the right. The I/O device (1200_20inout) with
the red button can be seen at the bottom.
36
5. Gateway design
To prove that it is possible to receive data from the Profinet controller/master as

well as from the I/O device, a simple “bit toggle generator” is used. The generator
is created as a ladder diagram and can be seen in Figure 5.13. The output from the
generator, Q0.0, is sent using OPC UA to node-red where it is displayed in the web
browser interface.
Figure 5.13: Bit toggle generator: Output, “Q0.0”, oscillates between 0 and 1,
holding each value one second each (0.5 Hz cycle)
37
5. Gateway design
38
6
Conclusion
The focus of this thesis was to evaluate what protocols and platforms are and
will be used for IIoT, and also developing a demonstrator that shows a solution
to an actual IIoT problem. The cornerstone of the problem lies in the difficulty
of updating and replacing nodes in already established systems. The created
demonstrator provides a way to simplify the implementation of new nodes by acting
as an abstraction layer between the system and the new device. The demonstrator
or gateway also provides a way to get information from the factory floor to an
outside network.
The results of this thesis project are a theoretical part with an overview of how
and what the Industrial Internet of Things is and on what future trends are to be
expected, the project also resulted in a practical demonstrator gateway used to
show how to help in the problem of adding or changing new nodes in an already
established system.
The verification of the demonstrator gateway was performed both in separate steps
throughout the project but also as a whole. The Bluetooth alarm device was tested
separately by connecting it to Node-Red and verifying the functionality, and then
tested together with the rest of the system. The Profinet drivers were verified in two
ways. The first by checking the led status indication on the PLC Profinet I/O (slave)
device and the PLC Profinet Controller (Master), the second way of verification was
done as described in section 5.5, by using Wireshark to analyze the traffic going in
and out of the demonstrator gateway.
6.1 Goals vs Results

The thesis had four goals to fulfill, which can be found in section 1.2, where two of
them were regarding a prestudy on network protocols and security concerns with a
gateway connected to the internet. The two practical goals were to first create the
functionality to connect to the Profinet network on one side and then on the other
side be connected to either a cloud platform or to a wireless sensor on the other. The
second practical goal was add an abstraction level between an already established
system and a new node. Regarding the first two goals the theoretical information
can be found in section 3.8 and 3.7. The created demonstrator both has the gateway
functionality to talk to Profinet and to the wireless sensor, and also to act as the
proxy between an established system and a new node. One thing that is not quite up
39
6. Conclusion
to specification is that the gateway should be implemented without any alterations to

the established system, which is not fulfilled. The required modification is that one
must remove the old PLC node in the PLC Profinet Controller (master) and replace
it with the GSD file of the gateway. However, after this initial modification, the node
on the far side of the gateway can be replaced without any further modification of
the PLC software.
6.2 Critical discussion

One major objection to the approach taken in this project is that we initially
believed that the same stack could be used to implement both the master and
slave, which is incorrect. Therefore another stack had to be found in the middle of
the project, and a lot of time was spent later to obtain the software. With better
planning we could have received both stacks simultaneously.
Another objection can be made regarding the master Profinet stack, as it is used
as an executable file rather than from actual source code, which would have been
preferable.
To be able to implement the gateway in an industrial environment it is not only

necessary with more rigorous testing and bug removal, but also to implement the
software in a real-time operating system. Additional testing, besides stability and
durability, would be to test the gateway with more than one PLC I/O (slave) device,
to show that the gateway does have dynamic functionality. The closest thing to
testing with another PLC was to verify that the PLC controller (master) works
both when there is an active PLC I/O (slave) device and when it is deactivated.
6.3 The role of the technology

The implemented demonstrator gateway has a large dynamic scope of uses, as
one of the main priorities was to be able to connect Profinet on one side and an
arbitrary technology on the other side. The proxy service function where Profinet
is connected on two sides has a more narrow use-case, as its intended use is to
make it easier to add PLC devices without having to know what type of hardware
is connected on the opposite side. Hopefully the idea of having personal emergency
switches inside helmets will be a reality and not just the bulky wireless emergency
switches that currently exists.
As for IIoT as a whole the role and use is vast: with connectivity comes more
frequent information updates, more predicable maintenance and a clearer overview
of systems by analyzing them. The benefits will lead to better economy for the
users, but also help create a more climate friendly and sustainable industry.
40
6. Conclusion
6.4 Continued development

A natural continuation of the project would be to create an actual industrial
application with a more rugged hardware, perhaps using a Raspberry Pi 3 compute
module. Also other factors regarding stability with more rigorous testing of the
software and hardware and also regarding security and reducing power consumption
with lowered processor utilization. To create a commercial product it would be
desirable to have both the Profinet stacks as “C” source code from the same vendor
to get a better and cheaper implementation.
Another important continuation of the gateway project would be to implement the

possibility for more protocols to be used and not only Profinet. It would be diffi-
cult to implement protocols that require special hardware. However, protocols that
can be implemented purely in software, such as POWERLINK, could be a desired
addition.
41
6. Conclusion
42
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www.stonel.com/en/protocols/profibus (visited on Mar. 2017).
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overview/ (visited on Mar. 2017).
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http://cds.linear.com/docs/en/product-selector-card/2PB_RS485fe.
pdf.
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pl/index.php?option=com_docman&task=doc_view&gid=28 (visited on
Mar. 2017).
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technologies/profinet-io/ (visited on Mar. 2017).
[73] Max Felser, Paolo Ferrariand, and Alessandra Flammini. INDUSTRIAL
COMMUNICATIONS SYSTEMS. CRC Press, 2011.
[74] Harald Kleines et al. “Performance Aspects of PROFINET IO”. In: (2008).
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on Phoenix Contact Platform”. In: (2011).
[76] Zhihong Lin and Stephanie Pearson. An inside look at industrial Ethernet
communication protocols. Tech. rep. Texas Instruments, 2013.
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en/us/td/docs/ios- xml/ios/atm/configuration/15- mt/atm- 15- mt-
book/atm-vlan-prty-tag.html (visited on Mar. 2017).
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td/docs/switches/lan/cisco_ie3000/software/release/15- 0_2_se/
configuration/guide/scg_ie3000/swprofinet.pdf (visited on Mar. 2017).
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Mar. 2017).
[80] Wireshark Profinet. 2017. url: https : / / wiki . wireshark . org / PROFINET
[81] Bradley Mitchell. What Is a PAN (Personal Area Network)? 2016. url:
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Mar. 2017).
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//searchmobilecomputing.techtarget.com/definition/personal-area-
network (visited on Mar. 2017).
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[84] Andrew Butterfield and Gerard Ekembe Ngondi. A Dictinary of Computer
Science. Oxford University Press, 2016.
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In: IEEE (2016).
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48
A
Appendix 1 Node-Red setup
By running the following command, Node-Red will be updated to the latest release
and started:
$ update−n o d e j s −and−nodered
$ node−red−s t a r t
To add the graph and bar of the signal strength, the dashboard user interface “node-
red-dashboard” was used. Which can be found at:
h t t p s : / / g i t h u b . com/ node−r ed / node−red−dashboard
or by writing the following command in a terminal:
$ cd ~ / . node−r ed
$ npm i node−red−dashboard
The flow or configuration of Node-Red can be seen in Figure A.1. The flow can
be divided into two different sections, one for the Bluetooth personal emergency
stop alarm and the other regarding Profinet devices. Both sections are subscrib-
ing to their respective MQTT topics, IoT/signal_strength, IoT/Alarm, IoT/sig-
nal_connected, IoT/profinet_value and IoT/red_button. The signal strength is
sent to both a chart and gauge, to give a graphical representation, whereas the rest
are sent to non-editable text boxes.
I
A. Appendix 1 Node-Red setup
Figure A.1: Configuration layout of Node-Red
II
B
Appendix 2 Redis
Instructions for redis installation and setup:
$ sudo apt−g e t i n s t a l l r e d i s −s e r v e r
You will then be prompted to give the superuser password to install, an-
other way to to get “Redis Server” installed on your machine is by visiting
https://redis.io/download and downloading the latest stable release. The following
command can be used to start running the server:
$ r e d i s −s e r v e r
To install Redis to be able to run directly through a terminal one can either down-
load the script file from: https://github.com/crypt1d/redi.sh or use the following
command in a new terminal window:
$ sudo apt−g e t i n s t a l l r e d i s −t o o l s
Once the server is running and “redis-tools” have been installed data can be read
and written to the server through the command line. See example below
$ r e d i s − c l i SET t e s t v a r i a b l e 1
OK
$ r e d i s − c l i GET t e s t v a r i a b l e
"1"
To get access to the server from the Profinet Slave program, the recommended C
client/library “hiredis” was used, which can be accessed at:
h t t p s : / / g i t h u b . com/ r e d i s / h i r e d i s
Other C libraries can be found at:
h t t p s : / / r e d i s . i o / c l i e n t s#c
III
B. Appendix 2 Redis
IV
C
Appendix 3 MQTT
The message broker “Mosquitto” was used in the Gateway to implement the MQTT
protocol. Mosquitto can be found at:
h t t p s : / / m o s q u i t t o . or g /
Or installed and started through the command terminal with the following com-
mands:
$ sudo apt−g e t i n s t a l l m o s q u i t t o
$ mosquitto
From the Bluetooth scripts it is possible to send MQTT messages, to activate and
deactivate the alarm with the following commands:
$ mosquitto_pub −t ’ IoT /Alarm ’ −m ’ Alarm D e a c t i v a t e d ’
$ mosquitto_pub −t ’ IoT /Alarm ’ −m ’ Alarm On’
The next part is to get the Bluetooth signal strength updated twice every second,
and the following is a shorted version of how it is done in the Bluetooth script:
s _ s t r=$ ( echo $cmdout | sed −e ’ s /RSSI return v a l u e : //g ’ )
mosquitto_pub −t ’ IoT / s i g n a l _ s t r e n g t h ’ −m $ s _ s t r
V
C. Appendix 3 MQTT
VI
D
Appendix 4 Raspberry Pi bridge
setup
i f c o n f i g eth0 0 . 0 . 0 . 0
i f c o n f i g eth1 0 . 0 . 0 . 0
b r c t l addbr b r i d g e 0
b r c t l a d d i f b r i d g e 0 eth0
b r c t l a d d i f b r i d g e 0 eth1
i f c o n f i g b r i d g e 0 up
VII
D. Appendix 4 Raspberry Pi bridge setup
VIII
E
Appendix 5 Codesys network port
fix
To prevent Codesys from using all available addresses on the local machine for port
34964 a LD_PRELOAD library is used to intercept the bind() system call. Which
makes it possible to force it to be bound to a specific address. A “C” program for
this can be found at:
h t tp : / /www. ryde . n e t / code /bind . c . t x t
The program can be compiled with:

g c c − n o s t a r t f i l e s −f p i c −s h a r e d bind . c −o bind . so − l d l
−D_GNU_SOURCE
To then run Codesys application with the bound address run the following command,
note that you change 192.168.0.5 to whatever address is desired:
sudo BIND_ADDR=" 1 9 2 . 1 6 8 . 0 . 5 " LD_PRELOAD=/u s r / l i b /bind . so
/ e t c / i n i t . d/ c o d e s y s c o n t r o l
Credit for this solution goes to “Stack Exchange Unix & Linux” user “larsks”
https://unix.stackexchange.com/a/356353/224690
IX
Leveraging AI for Industrial IoT
Chetan Gupta, Ph.D.

Chief Data Scientist, Big Data Lab,
Hitachi America Ltd.
Date: Sept. 19th, 2017
AI
Level Set
Machine
Learning
Data & Outcomes
Artificial
Intelligence
Data
Sensor Data
Human Generated Data
Enterprise Data
Tags, Sensors, Video, etc.
Social Media, etc.
Transactions, logs, etc.
Volume/Speed of data
Heterogeneity of Data
Outcome
Prescriptive/ Autonomous
Recommendation
Predictive
Descriptive/ Self Driving Car, etc.
Movie
Recognition Recommendation, etc.
Clinical Decision
Support, etc.
Fraud Detection, etc.
Complexity
Data Requirement
AI/ML Algorithms
Deep
Learning
“Traditional”
Machine Learning
CNN, RNN, LSTM, etc.

Rule Based AI SVMs, Random
Forests, etc.
Expert Systems, etc.
Compute
Accuracy
Example – Fraud Detection
Rule Based,
Credit Card
Anomaly Flag Credit Card Fraud
Transactions
Detection
Transactional Data, Descriptive

Example – Churn Prediction
Activity, Classification Predict the probability of

Behavioral Data Techniques losing a customer
Transaction/Social Media Data, Predictive

Example – Product Recommendation
Social Media Collaborative Recommend ads,

Data Filtering products, movies, etc.
Social Media Data, Prescriptive

Example – Autonomous Vehicles
Video, Lidar, etc. Deep Neural Self Driving Cars

Nets
Sensor Data, Autonomous

Impact
Products & Services Personalization of Services, Automation in Products
Sales Up Sell, Cross Sell, Customer Retention
Marketing Micro campaigns, Targeted Advertising
Customer Support Fielding Service/Support Calls
Human Resource Talent Acquisition & Retention
Operational ….
Industrial IoT
Industrial Analytics
Semiconductor
Manufacturing
• Increase Asset Availability
Resources
Healthcare
Chemicals
Financial
Railways
Mobility
Natural
BEMS
• Increase Asset Utilization
• Improve Product Quality Customer
• Increase Safety & Reliability of

Operations End-to-end Automation & Optimization
Operations Optimization
Solution
• Reduce Operations and Quality Enhancement
Cores
Maintenance Cost Predictive Maintenance
• Enhanced Operational Control & Safety Improvement
Planning Lumada
IIoT Problem Taxonomy
Analytics Maintenance Operations Quality

1. Equipment Monitoring 1. Operations Monitoring 1. Quality Monitoring
2. Performance Analytics 2. Characterize Process 2. Testing Process
3. Maintenance Analytics 3. Operator Behavior Monitoring & Evaluation
Descriptive 4. Equipment Failure Root 4. Operation Failure Root 3. Detect Quality Loss
Cause Analysis Cause Analysis 4. Defect Root Cause
Analysis
1. Predict Failures 1. Predict Activity Time 1. Early Defect Detection
2. Estimate RUL 2. Predict Production KPI(s) 2. Yield Quality Predict.
Predictive 3. Predict Failure Impact 3. Demand Forecasting
4. Supply Chain Disruption
1. Reduce Failure Cost 1. Failure Rate Reduction 1. Process Parameter

2. Reduce Failure Rate 2. Fuel/Energy Reduction Recommendation for
3. Repair Recommendation 3. Equipment Scheduling Quality Improvement
Prescriptive 4. Optimize Maintenance and Dynamic Dispatch 2. Improve Testing
4. Operations
Recommendation
Example – Maintenance Effectiveness Estimation
Determine the effectiveness of each maintenance activity, vendor, practice,

etc. to improve maintenance operations
Overhaul Overhaul Chemical Cleaning Overhaul
Sensor Data, Descriptive

Maintenance
Example – Operator Profiling
Characterize the efficiency, safety of operator behavior to improve operations
Sensor Feature Operator Behavior

Mill extraction Machine Profiling
Learning
Data
Video Model
Operator
KPI
Sensor Data/Video Data, Descriptive

Operations
Example – Quality Test Failure Prediction
Predict failures earlier in process
Sensor Data, Predictive

Quality
Example – Repair Recommendation
Recommend the correct repair to reduce repair mistakes and cost of repairs
Symptom
(Free text)
NLP Recommendations
Machine
Learning
Data
Log Model Historical
repair data
Sensor/Maintenance Data, Prescriptive

Maintenance
Example – Mining Operations
Improve OEE for mining operations with automated dispatching
Operational/Simulation Data, Autonomous

Operations
Next Stage of Industrial AI
Prescriptive analytics
OT×AI × AI Driven Control
Value of Insights = Business Impact
Total Operation
Optimization & Automation
Recommendation of best action
Prescriptive Operating
Maintenance Scheduling
Envelope
Analytics Recommendation Recommendation
Recommendation
A view of the future

Predictive Failure Activity Time Batch Quality
Analytics Prediction Prediction Prediction
Insights on the present

Descriptive Performance Operations Quality
Analytics Monitoring Monitoring Monitoring
Predictive Operations Quality

Maintenance Optimization Improvement
Individual Fleets End-to-end

Scope of Control
Next Stage of Industrial AI
AI Driven Recommend actions to achieve multi-

objective optimization with machine
Control learning, AI, and simulation
Up to
85%
Connected Industries
Geographically distributed production systems
Material Equipment Process Product
Supply Chain
& Logistics
Next Steps and Conclusions
Complexity of Automation
Control Operations Strategy

(secs – mins) (mins – days) (days – months)
Enterprise AI/ML
Number of sub-components
Complexity of Automation
Cost Tradeoffs
Failure Prediction: Performance Degradation Detection:

Accuracy-Gain tradeoff Accuracy-Latency tradeoff
$300,000 $100,000
$
Failure Degradation Cost
$250,000
Cost $80,000
$200,000 $
$60,000
Detection Error
Cost
$150,000 False Cost

Alarm
Cost $40,000
$100,000
Total Cost
Total $20,000
$50,000
Cost
$0 $0
In Conclusion
“…I am very optimistic about the eventual

outcome of the work on machine solution of
intellectual problems. Within our lifetime
machines may surpass us in general
intelligence….”
– Marvin Minsky, 1967
It’s difficult to make predictions especially about the future

Thank You
White Paper
Big Data Analytics Pilot, Internet of Things
Manufacturing
Optimizing Manufacturing
with the Internet of Things
Intel manufacturing advances operational efficiencies and
boosts the bottom line with an IoT and big data analytics pilot
Introduction
Intel proves IoT success The volume, variety, and velocity of data1 being produced in manufacturing is
growing exponentially, creating opportunities for those diligently analyzing this
by using big data analytics data to gain a competitive edge, respond to changing market dynamics, and
to bring cost savings, increase manufacturing margins, productivity, and efficiency. Equipment across
the factory floor is generating thousands of different data types, such as unit
predictive maintenance, production data at multiple levels, equipment operation data, process data, and
and higher product yields human operator data, which can be stored to be made available for analysis.
to its own manufacturing Although large manufacturers designs for manufacturability, thereby
processes. have been using statistical process improving supply chain management
control and statistical data analysis and introducing the use of customized
to optimize production for years, the manufacturing services to shorten time
extreme composition of today’s data to market for products customized
provide opportunities to deploy new for smart consumers across various
approaches, infrastructure, and tools. geographies.
Manufacturing industries are ready to
This paper outlines an Internet of
embrace the use of big data, supported
Things (IoT) pilot in one of Intel’s
by higher compute performance, open
manufacturing facilities to show how
standards, the availability of industry
data analytics applied to factory
know-how, and the vast availability
equipment and sensors can bring
of highly skilled, data statisticians
operational efficiencies and cost
fueled by academics. With access
savings to manufacturing processes.
to new manufacturing intelligence,
With industry collaboration from
manufacturers will improve quality,
Cloudera, Dell, Mitsubishi Electric,
increase manufacturing throughput,
and Revolution Analytics, this IoT big
have better insights into root cause
data analytics project is forecasted to
of manufacturing issues, and reduce
save millions of dollars annually along
machine failure and downtime.
with additional return on investment
With these new business values and
business value.
technology capabilities, manufacturers
will be able to change business models
and practices in order to optimize
Optimizing Manufacturing with the Internet of Things
Challenge: How to extract data from manufacturing execution and enforce hierarchies of records and
value from all of the data in systems and enterprise systems. On fields within the data. In manufacturing,
manufacturing? the other hand, unstructured data the power of big data technology stems
such as images, text, machine log from the ability to merge and correlate
Big data is characterized by huge files, human-operator-generated shift these data set types to create business
data sets with varied data types, reports, and manufacturing social value through newfound insights. The
which can be classified as structured, collaboration platform texts may be other value proposition of big data
semi-structured, or unstructured, as in a raw format that requires decoding technology is it allows manufacturers to
shown in Table 1. Structured data fits before data values can be extracted. aggregate and centralize various types
nicely into neatly formatted tables, Semi-structured data is a form of of data in a cost-effective, scalable
making it relatively easy to manage structured data that does not conform manner.
and process. Structured data has the to the formal structure of data models
advantage of being easily entered, In manufacturing, process variability
associated with relational databases
stored, queried, and analyzed. stemming from various factors, like
or other forms of data tables, but
Examples include manufacturing data material, process recipes and methods,
nonetheless contains tags or other
stored in relational databases, and and equipment differences, drives a
markers to separate semantic elements
real business need for manufacturers
to turn to a big data solution based on
MANUFACTURING REAL-TIME, a scalable platform that can grow with
INDUSTRIES SEMI-STRUCTURED UNSTRUCTURED STRUCTURED their businesses and manufacturing
EXAMPLES DATA DATA DATA
requirements. Machine data is strongly
Semiconductor Machine builder Operator shift RDBMS databases correlated to yield, quality, and output,
standards like reports
Electronics NoSQL* thereby providing valuable information
SECS/ GEM, EDA or Machine logs to proactively detect processes that
Solar Enterprise data
custom-based on
Error logs warehouse are getting out of control. However,
Machinery
COM, XML
Texts Files stored in some types of manufacturing generate
Energy
Sensors (vibration, manufacturing PCs massive data files (gigabytes in a few
Vision images
Automobiles pressure, valve, and
Audio/Video
Spreadsheets days per tool type, as shown in Table 2),
acoustics), Relays
Aerospace limiting the ability to store, analyze, and
RFID Manufacturing
Chemical and extract useful information from them
collaboration social
Pharma Direct from PLCs, using conventional methods. Without
platforms
Motor and drives,
Metalworking the use of big data technologies, it is
Direct from motion extremely hard to even visualize the
Food and Beverage
controllers, robotic
Pulp and Paper arm information in large data sets from
Clothings and
various sources.
Manufacturing
Textiles historians (time
Furniture series data
structures)
Table 1. Manufacturing data examples
DATA SIZE
DATA TYPES (per week) EXAMPLES
Machine parameters ~5 GB per machine Used to monitor machine performance:
and error logs dispense height, placement (x, y, z), belt
speed, flow rate, oven temperature, laser
power, etc.
Machine events ~10 GB per machine Used to measure process time: start dispense,
end dispense, start setup, and end setup
Defect images from ~50 MB per unit or Used to identify root cause of failure modes,
vision equipment 750 GB per lot defect commonality, defect mapping
Table 2. Data size examples
2
Addressing the challenge: IoT pilot using big data analytics server and IoT gateway in Intel manufacturing
BIG DATA ANALYTICS
BUSINESS INTELLIGENCE
AND VISUALIZATION
Data Analytics
(Visualization, Monitoring, Statistical)
CORPORATE INTRANETS
VPN
FIREWALL Automation DBs

DATA
INGESTION
Data Distill (ETL)
MANUFACTURING SUBNETS
DATA ACQUISITION
Gateway
Gateway Tools
Data Storage, Retention,

and Management
Private Cloud Infrastructure Testers
Figure 1. Building blocks for end-to-end infrastructure enabling manufacturing intelligence from the factory floor to the datacenter
Figure 1 shows a high-level IoT As an example, the architecture be accessed with other analytical or
manufacturing architecture for small can: clean, extract, transform, and monitoring applications on the network.
to large data sets that constitute data consolidate structured data from Other enhanced capabilities could
acquisition and aggregation of various existing databases and unstructured include running analytics in Hadoop
types of data from the manufacturing data from tool sensors and log files or other types of file systems, or
shop floor and the manufacturing from legacy equipment in a data store running analytics in memory for faster
network, which opens up the platform (i.e., Hadoop*). The data can performance. The results of the analysis
possibilities of visualizing, monitoring, then be visualized and analyzed by can be presented to users via intuitive
and data mining for new business high-level factory applications running visualization capabilities in the business
intelligence. in different virtual machines on the intelligence layer of the network.
same on-premise server as the data
store server. Alternatively, the data can
3
Big data analytics IoT server setup in Intel manufacturing pilot
Revolution R Enterprise*
Intelligence
Business
from Revolution Analytics

By linking with high-performance
Intel® MKL multithreaded
math libraries, Revolution R
Analytics
Enterprise uses the power of

Data
Revolution Analytics DeployR* Web Services

Existing Factory
Applications multiple processors to accelerate
Consolidated into common matrix calculations. In
Virtual Machines addition, Revolution R Enterprise
R Based Manufacturing Analytics Template 1, 2, and 3
ETL
parallel, distributed algorithms

enable statistical analysis of Big
Cloudera Data to scale linearly with multi-
AquaFold*
Data Store and
core servers, high-performance

Management
Batch Interactive Machine

Search
Processing SQL Learning computing clusters, big data
MonetDB* appliances, and Hadoop*.
Metadata Resource Management
Storage
Integration
PostgreSQL*
• Revolution R Enterprise* from
Revolution Analytics is analytics
Red Hat Enterprise Linux* for Virtual Datacenters
software built upon the powerful
OS Virtualization
Dell PowerEdge* VRTX open source R statistics language.

The software provides a seamless,
secure data bridge between analytics
solutions and enterprise software,
thereby solving a key integration
problem faced by businesses
Figure 2. Big data analytics server adopting R-based analytics alongside
existing IT infrastructure. 3
The big data analytics server used last-level (L3) cache, and up to 1.5TB
by Intel manufacturing in its pilot maximum memory capacity, along with • MonetDB*: an open source column-
deployment is shown in Figure 2. communication pathways to move data oriented database management
A compact system from Dell, the more quickly. system designed to provide high
PowerEdge* VRTX, 2 was selected to performance on complex queries
The two M820 servers host analytics against large databases, such as
host the big data and analytics software
and application software, and the combining tables with hundreds
in a private cloud setting as an on-
Hadoop nodes, which run in multiple of columns and multimillion rows.
premise server. The system consists of
virtual machines. Red Hat Enterprise MonetDB has been applied in high-
a Dell PowerEdge VRTX chassis with
Linux* for Virtual Datacenters performance applications for data
twenty-five 900GB hard disks and two
operating system provides a complete mining, online analytical processing
Dell PowerEdge M820 blade servers,
virtualization software solution for (OLAP), geographic information
each equipped with four Intel® Xeon®
servers designed for a scalable and fully systems, and streaming data
processors from the E5-4600 product
virtualized datacenter. processing.4
family on each blade. The Intel Xeon
processor E5-4600 product family Analytics and Application node • PostgreSQL*: a powerful, open
provides a dense, cost-optimized, Figure 3 shows how the software is source object-relational database
four-socket processor solution with allocated to different virtual machines system used for online transaction
up to eight cores, up to 20MB of (VMs). The node hosts five VMs that run processing (OLTP). 5
the various analytics and application
workloads. This includes:
4
• AquaFold*: an application server

used to build and deploy production
Column-store quality database and reporting
database for fast
applications quickly. It includes
Revolution Analytics DeployR* Web Services analytics workloads
capabilities like multiple sources data
RDBMS/row-store
Manufacturing Manufacturing Manufacturing synchronization, cross-database data
Analytics Analytics Analytics database for OLTP
Template 1 Template 2 Template 3 workloads migration, data warehousing extract
transform and load, scheduling
data exports/ imports, and custom
Analytics and Application node
business intelligence dashboards.
Dell M820 (four 8-core processors, 256GB RAM)
Supports communication to various
production databases in the network
CLOUDERA ENTERPRISE* DATA HUB like PostgreSQL, Microsoft SQL*,
Oracle*, and IBM DB2* with ODBC*
MANAGEMENT
BATCH ANALYTIC SEARCH MACHINE STREAM 3RD PARTY and JDBC* connections.6
PROCESSING SQL ENGINE LEARNING PROCESSING APPS
DATA
Hadoop* node
WORKLOAD MANAGEMENT Four virtual machines are provisioned
to run a basic, four-node Cloudera
STORAGE FOR ANY TYPE OF DATA Hadoop cluster, consisting of one head
MANAGEMENT
UNIFIED, ELASTIC, RESILIENT, SECURE node and three worker nodes.

SYSTEM
• Apache Hadoop is an open source

FileSystem Online NoSQL distributed software platform for
scalable distributed computing.
Written in Java, it runs on a cluster of
industry-standard servers configured
Hadoop* Node with direct-attached storage and
Dell M820 (four 8-core processors, 512GB RAM) cost-effectively scales performance
by adding economical nodes to the
HDD: 900GB 10K RPM SAS 6GBps 2.5 cluster.
• Cloudera Enterprise Data Hub*

(CDH) offers a unified platform for
big data by providing one place to
store, process, and analyze all of
their data resulting in an extension
of existing investment value and
enabling fundamental new ways to
derive value from their data. CDH is
100 percent Apache licensed open
source and is unique in offering
unified batch processing, interactive
10 x 900GB ~ 6TB 15 x 900GB ~ 10TB usable
SQL, and interactive search and role-
Figure 3. Software allocations to virtual machines on the big data analytics server based access controls.7
5
collected from sensors or via the of tests required could be reduced,

network when supporting sophisticated resulting in decreased test time.
system control and operations. At the Implemented as a proof of concept, this
A closer look at the core of this controller is a hardware solution avoided test costs of $3 million
Cloudera stack platform based on Intel® architecture in 2012 for one series of Intel® Core™
Cloudera Enterprise Data and the Wind River VxWorks* real-time processors. Extending this solution
Hub* (CDH) delivers the core operating system. to more products, Intel expects to
elements of Hadoop*—scalable realize an additional $30 million in
Mitsubishi Electric developed C language
storage and distributed cost avoidance.9
controllers of MELSEC-Q Series to satisfy
computing—along with the diverse requirements of factory
additional components such as Improved manufacturing monitoring
automation, including excellent reliability, Data-intensive processes also help
a user interface, plus necessary tolerance of harsh environments, and
enterprise capabilities such as Intel detect failures in its manufacturing
long-term availability. These features line, which is a highly automated
security, and integration with a make it a robust and reliable product
broad range of hardware and environment. Intel pulls log files out
that requires little maintenance for IoT of manufacturing tools and testers
software solutions. manufacturing applications. across the entire factory network,
CDH can help businesses In place of ladder logic used in which can be up to 5 Terabytes an
transform and accelerate the conventional programmable logic hour. By capturing and analyzing this
way big data is used. When controllers, the C language controllers information, Intel can determine
combined with datacenter of MELSEC-Q series use the when a specific step in one of its
architecture based on Intel® international standard C languages manufacturing processes starts to
Xeon® processors, Cloudera and (C and C++) for greater programming deviate from normal tolerances.10
Intel provide a comprehensive flexibility. This allows users to take full
approach for industrial and Specific to the current end-to-
advantage of their existing C language end platform pilot deployment
manufacturing businesses software and development.
seeking to analyze data to make discussed here, Intel, in collaboration
factories run more efficiently. CIMSNIPER* is a data acquisition with Mitsubishi Electric, Cloudera,
and processing software package Revolution Analytics, and Dell,
for Mitsubishi Electric C Language successfully pioneered capabilities
Controller of MELSEC-Q series. It that have made tremendous headway
Internet of Things (IoT) Gateway in the use of data mining sciences
can collect process data (including
An Intel® Atom™ processor-based SECS messages) and manufacturing to solve practical manufacturing
gateway by Mitsubishi Electric, called equipment errors without modifications issues, thus saving Intel millions of
the Mitsubishi Electric C Language of existing systems. dollars through cost avoidance and
Controller of MELSEC-Q series*,8 improved decision making. The major
is used to aggregate and securely Big data analytics cases at goal of this project is to extract the
ingest data into the big data analytics Intel manufacturing value propositions of data and data
server. Data ingestion is the process of analytics to obtain better insights
validating, filtering, and reformatting Over the past two years, Intel has in predictive manufacturing and
the data to make it easier for the big developed more than a dozen big reduce manufacturing costs without
data analytics software to work on it. data projects that have bolstered both sacrificing throughput or quality.
operational efficiency and the bottom
The Mitsubishi Electric C language line. Here are a couple of examples: The following details some of
controllers of MELSEC-Q series are the groundbreaking work and
embedded solutions equipped with Reduced product test times discoveries Intel accomplished
numerous features characteristic of Every Intel® chip produced undergoes through the integration of big
intelligent systems, including robust a thorough quality check involving a data analytics and technologies
network connectivity and the high complex series of tests. Intel found that for the IoT in manufacturing.
computational performance needed by using historical information gathered
to process large amounts of data during manufacturing, the number
6
Pilot Results: yield losses by up to 25 percent.12 In Use Case 3: Using image analytics to
Use Case 1: Reducing non-genuine addition, Intel was able to save spare identify good or defect units
production yield loss through the cost by reducing the need to replace Background
monitoring and analysis of machine spare parts before they fail during A machine vision equipment is a module
parametric values and timely preventive maintenance resulting in an that screens units and categorizes them
replacement of parts before they fail estimated 20 percent reduction in spare into good and marginal units. The good
cost. units are sent forward to be processed
Background
Automated Test Equipment (ATE) is a Use Case 2: Reducing yield losses by while the marginal ones are inspected
machine that is designed to perform eliminating and minimizing incorrect and determined by a manufacturing
tests on different devices referred to ball assembly in ball attach equipment specialist to be either good or defective.
as a devices under test (DUT). An ATE This manual process takes time.
Background
uses control systems and automated
The ball attach module is where solder Problem Statement
information technology to rapidly
paste is printed onto the lands on the The manual process to inspect and
perform tests that measure and
substrates. Solder balls are placed categorize marginal units is cumbersome
evaluate a DUT.11 The ATE systems
into the ball attach lands, and the and sometimes takes about 8 hours to
interface with an automated placement
paste holds them in place. The entire successfully segregate a host of true
tool, called a handler, that physically
package goes through a reflow oven, reject units from marginal ones.
places the DUT on a Test Interface Unit
which melts the paste and balls to the
(TIU) so that it can be measured by This is caused by the time it takes
substrate lands.
the equipment. for the units to reach the operator,
Solder balls are vacuumed onto tiny flow to a segregation module, and
Problem Statement holes of the placement head. The head to ultimately be segregated. Image
Defective TIUs will wrongly categorize is inspected for excess or missing analytics enables identification of
good units as bad, which negatively balls. Once the head is aligned to the reject units moments after being
impacts Intel manufacturing operation substrates, the balls are placed in the inspected by the inspection module.
costs. Defective TIUs can cause DUTs solder paste on the substrates. After
to be wrongly categorized, including releasing the balls, the placement head Results and Benefits
the rejection of good units. Intel is inspected for any remaining balls. The marginal images recorded at the
manufacturing’s objective was to Finally, the substrates are inspected by machine vision equipment module
detect TIU defects before they happen a camera vision system for any missing are preprocessed. Each image, which
so they could repair or replace them or shifted balls. is unstructured data, is resized,
before units are wrongly categorized. cropped, converted into grayscale
When a faulty TIU wrongly categorizes Problem Statement before converting each pixel to
good units as bad, the units are Units with missing balls are faulty binary. The next stage of the process
scrapped. Some components were material and a yield loss. There are involves feature selection, where the
replaced with spare parts during numerous scenarios in which balls unstructured image is defined by a set
regular preventive maintenance, even are missing from the units, including of distinct values. These values are
if they were still operating properly inadequate vacuum pressure. then fed into various machine learning
to avoid such problems. algorithms to determine true rejects
Results and Benefits
and marginal rejects.
Results and Benefits Yield By visualizing and correlating sensor
The analytics capability predicted up readings with various machine data The image analytics shortens the
to 90 percent of potential TIU failures and execution system data, Intel was time to save true rejects from a pool
before being triggered by the existing able to reduce yield losses, optimize of marginal units. Image analytics
factory’s online process control system. maintenance cost, and avoid sudden identifies defects roughly 10 times
This helped, in this case, to replace equipment downtime.12 This enabled faster than the manual method.12
defective TIUs before causing over the technicians to proactively fix the
rejection of good units, thus reducing problem, toward the journey of having
a predictive maintenance capability.
7
DATA SOURCES DATA VISUALIZATION

ON EQUIPMENT
Sensors Business Intelligence,

Visualization, Tools
and Apps
VALUE DATA ANALYTICS

Predictive Maintenance,
Reduced MTTR, Revo DeployR WebServices
Improve Cycle Time,
Reduce Cost R Based Manufacturing Analytics Template 1, 2 and 3
DATA FILTERING AND
DATA TRANSPORT
DATA PREPARATION
FTP/
MQTT/
RESTFul Extract Transform Load, Database Extraction Tools, SQL, Phyton, Perl
Scoop
DATA STORAGE/WAREHOUSE
Cloudera Operational Data

CLOUDERA ENTERPRISE* DATA HUB
Hadoop*
MANAGEMENT
(MapReduce BATCH
PROCESSING
ANALYTIC
SQL
SEARCH
ENGINE
MACHINE
LEARNING
STREAM
PROCESSING
3RD PARTY
APPS
DATA
and HDFS)
WORKLOAD MANAGEMENT RDMS/
OLTP
DATA DISTILLATION STORAGE FOR ANY TYPE OF DATA
MANAGEMENT
UNIFIED, ELASTIC, RESILIENT, SECURE

SYSTEM
FileSystem Online NoSQL NoSQL COL/

Phyton, R, Perl, Excel (Hadoop) OLAP
Various Lib
Figure 4. High-level data flow
Data Flow • All incoming factory data is stored - Flume* can receive a stream of
in Hadoop*. The following, non- continuous log data.
Figure 4 shows how data flows from the
exhaustive list shows some of the
previously discussed use cases. • The data specific to these use cases
possibilities that can be achieved
described in the section above are in
• Machine data and sensors data are using readily available capabilities in
the form of Comma-Separated Value
sent by the Intel Atom processor- Hadoop:
(CSV) files or raw images. While the
based gateway to the Big Data
- HTTP: The Big Data Analytics Hadoop ecosystem includes plenty
Analytics Server (BDAS) as they are
Server exposes an authenticated of ways to ingest data (as described
acquired in real time. For instance,
REST HTTP endpoint that supports in the previous point), some of the
machine data from the ball attach
operations into HDFS. machines in the factory have limited
module acquired over machine
network transfer capabilities, which
interface ports and from analog - Apache Sqoop* provides the
required custom engineering to
sensors are streamed at a velocity of connectivity tool for moving data
deliver data into HDFS:
a few MBs per a few seconds. from non-Hadoop data stores—
such as relational databases and
data warehouses—into Hadoop.
8
- FTP: The IOT gateway has an FTP Summary of key learnings

client that periodically connects to and conclusions
the Big Data Analytics Server and
Intel integrated and validated a big Big data analytics and
transfers over the latest acquired
data analytics on-premise server the Internet of Things in
data directly into HDFS. Other
solution with data extracted from manufacturing as an end-to-
streaming protocols like MQTT
Intel’s own manufacturing network end platform is the critical
and REST can be used depending
and from equipment and sensors backbone to enable the vision
on the real time streaming and
through the use of Internet of Things of smart manufacturing.
analytic requirements.
gateway to validate the business value This platform is scalable
- CIFS share (Windows share): of Internet of Things in manufacturing. and available in various
The Big Data Analytics Server The Mitsubishi Electric C language configurations using currently
provides a Windows/CIFS share controllers of MELSEC-Q series available industry-standard
directory that the gateway can were used. The pilot involved close building blocks.
copy files into. collaborations between the factory
engineers, the IT department, and
• The CSV files are directly imported
industry experts from Cloudera, Dell, For Intel, this pilot is forecasted to
into HBase* using Pig, while the raw
Mitsubishi Electric, and Revolution save millions of dollars (USD) annually
images first go though a preprocess
Analytics. The team started leveraging with additional return on investment
using a map-reduce job using
existing machine performance and business values that Intel is still
computer vision techniques to
monitoring data, then proceeded realizing. Benefits include improving
produce a text data representation
to leverage big data analytics and equipment component uptime,
of the image.
modelling to ingest the data to predict minimizing wrong classification of
• Depending on the operational potential excursions and failures. Being good units as bad (hence increasing
requirements, the data is stored able to predict the machine component yield and productivity), enabling
in one of three databases: NoSQL failures allows engineers to repair and predictive maintenance, and reducing
(Hadoop), RDMS/SQL, or Coli/OLAP. prevent the excursion, hence reaping component failures. There are many
tremendous savings from wasting other types of parametric, metrology,
• The databases are accessed and
production units, time to repair, and product, and equipment data—both
processed using various tools,
machine components. structured and unstructured within
including AquaFold, ad hoc reporting,
workflow scheduling, and ETL and An integrated suitcase of various Intel manufacturing environment and
database integration. At the same software building blocks on the Big Data machines—which could be mined
time, the Cloudera Distribution for Analytics Server and IOT gateway were and analyzed to extract new business
Hadoop performs various operations used. This framework can be applied values. Capitalizing on this opportunity
on the data. and implemented for manufacturers will enable further efficiency and
which have not started leveraging on the productivity enhancements to the
• The processed data is further factory and ultimately create a
intelligence contained in manufacturing
analyzed using Revolution competitive advantage.
data. Manufacturers that have already
Analytics tools designed for
been using data to improve their
factory applications.
efficiency can incrementally add to their
• The data is presented to users in easy existing capabilities to evolve their data
to understand dashboards. mining and analytics capability to the
next level.
9
1. Gartner analyst Doug Laney introduced the 3Vs concept in a 2001 MetaGroup research publication, 3D data management: Controlling data volume, variety and velocity.
http://blogs.gartner.com/doug-laney/files/2012/01/ad949-3D-Data-Management-Controlling-Data-Volume-Velocity-and-Variety.pdf.
2. www.dell.com/us/business/p/poweredge-vrtx/pd
3. www.revolutionanalytics.com/revolution-r-enterprise
4. en.wikipedia.org/wiki/MonetDB
5. www.postgresql.org/about
6. www.aquafold.com/
7. www.cloudera.com/content/cloudera/en/products-and-services/cloudera-enterprise.html
8. www.mitsubishielectric.com/fa/products/cnt/plcq/items/index.html
9. Source: “2012-13 Intel IT Annual Report,” www.intel.com/content/www/us/en/it-management/intel-it-best-practices/intel-it-annual-performance-report-2012-13.html.
10. Source: “Intel Cuts Manufacturing Costs With Big Data,” InformationWeek, March 18, 2013, www.informationweek.com/software/information-management/intel-cuts-
manufacturing-costs-with-big-data/d/d-id/1109111.
The TCO or other cost reduction scenarios described in this document are intended to enable you to get a better understanding of how the purchase of a given Intel product, combined
with a number of situation-specific variables, might affect your future cost and savings. Nothing in this document should be interpreted as either a promise of or contract for a given level
of costs.
11. Source: http://www.techopedia.com/definition/2148/automatic-test-equipment-ate
12. Results might vary depending on package size, process, and equipment used in the manufacturing process.
INFORMATION IN THIS DOCUMENT IS PROVIDED IN CONNECTION WITH INTEL® PRODUCTS. NO LICENSE, EXPRESS OR IMPLIED, BY ESTOPPEL OR OTHERWISE,
TO ANY INTELLECTUAL PROPERTY RIGHTS IS GRANTED BY THIS DOCUMENT. EXCEPT AS PROVIDED IN INTEL’S TERMS AND CONDITIONS OF SALE FOR SUCH
PRODUCTS, INTEL ASSUMES NO LIABILITY WHATSOEVER, AND INTEL DISCLAIMS ANY EXPRESS OR IMPLIED WARRANTY, RELATING TO SALE AND/OR USE OF INTEL
PRODUCTS INCLUDING LIABILITY OR WARRANTIES RELATING TO FITNESS FOR A PARTICULAR PURPOSE, MERCHANTABILITY, OR INFRINGEMENT OF ANY PATENT,
COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT. UNLESS OTHERWISE AGREED IN WRITING BY INTEL, THE INTEL PRODUCTS ARE NOT DESIGNED NOR
INTENDED FOR ANY APPLICATION IN WHICH THE FAILURE OF THE INTEL PRODUCT COULD CREATE A SITUATION WHERE PERSONAL INJURY OR DEATH
MAY OCCUR.
Intel may make changes to specifications and product descriptions at any time, without notice. Designers must not rely on the absence or characteristics
of any features or instructions marked “reserved” or “undefined.” Intel reserves these for future definition and shall have no responsibility whatsoever for
conflicts or incompatibilities arising from future changes to them. The information here is subject to change without notice. Do not finalize a design with
this information.
The products described in this document may contain design defects or errors known as errata which may cause the product to deviate from published
specifications. Current characterized errata are available on request. Contact your local Intel sales office or your distributor to obtain the latest specifications
and before placing your product order. Copies of documents which have an order number and are referenced in this document, or other Intel literature, may
be obtained by calling 1-800-548-4725, or by visiting Intel’s Web site at www.intel.com.
Copyright © 2014 Intel Corporation. All rights reserved. Intel, the Intel logo, Intel Atom and Xeon are trademarks of Intel Corporation in the U.S.
and/or other countries.
*Other names and brands may be claimed as the property of others.
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Main Industrial Network

Profinet Industrial Internet of Things

Department of Computer Science and Engineering

Profinet Industrial Internet of Things Gateway

Department of Computer Science and Engineering

Master’s Thesis 2017

Henrik Johansson, Gothenburg, June 2017

List of Figures xiii

2 Industrial environment background 7

3 Internet of Things background 11

3.9.1 Open Platform Communications Unified Architecture (OPC

A Appendix 1 Node-Red setup I

B Appendix 2 Redis III

D Appendix 4 Raspberry Pi bridge setup VII

E Appendix 5 Codesys network port fix IX

1.1 Overview of how the gateway can be connected to different systems,

3.1 Publisher/Subscriber type protocol setup . . . . . . . . . . . . . . . . 18

5.1 Overview of how the Gateway is structured internally . . . . . . . . . 27

A.1 Configuration layout of Node-Red . . . . . . . . . . . . . . . . . . . . II

ASCII: American Standard Code for Information Interchange

IDA is a system, created by the company SEVAB, that is designed to cre-

Controller PLC Controller PLC

IDA Gateway PLC

1.2 Goal and Purpose

The overall goals of this thesis project are to:

1.4 Ethical Aspects

Another concern would be regarding implementing a commercial Profinet stack,

1.5 Thesis report outline

This chapter covers information regarding industrial environments, such as hard-

2.1 Programmable Logic Controller (PLC)

2.1.1 PLC programming

2.1.2 Ladder Diagram (LD)

2.2 Industrial safety

be a conventional wireless emergency stop. Another feature of the emergency stop

2.3 Industrial hardware

This chapter covers basic background information regarding Internet of Things

3.1 Internet of Things

3.2 Cloud Computing

a company or organization needs can be changed dynamically, certain months might

3.3 Industrie 4.0

3.4 Industrial Internet of Things

3.5 Industrial Internet Consortium (IIC)

The Industrial Internet Consortium, or IIC for short, is a consortium created by

3.6 Industrial Internet Reference Architecture

The different viewpoints focused on in the Reference documentation are: Business,

3.7 Cloud security concerning outside threats

3.8 Industrial IoT platforms

3.8.4 Echelon IzoT

3.8.8 AllJoyn Framework

connectivity without a cloud service. However, if a cloud service is desired it can

3.9 IoT Protocols for industry

3.9.1 Open Platform Communications Unified Architecture

Publishers Subscribers Clients Clients

Figure 3.1: Publisher/Subscriber Figure 3.2: Client/Server type proto-

3.9.2 Hypertext Transfer Protocol (HTTP)

3.9.3 Message Queue Telemetry Transport (MQTT)

3.9.4 Constrained Application Protocol (CoAP)

3.9.5 Data Distribution Service (DDS)

Figure 3.3: Centralised Publisher/- Figure 3.4: DDS distributed

3.10 Security with SSL/TLS encryption

in C to be executed on UNIX type operating systems, such as GNU/Linux and OS

A network is a structure of interconnected computers or nodes, which communicates

4.1 OSI model

4.2 Industrial networks