NX-ERA unleashes the power of IIot with MQTT Interface

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NX-ERA unleashes the power of IIot with MQTT
Interface
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What is IIoT? The industrial internet of things
(IIoT) sometimes called Industry 4.0  is
radically changing how businesses, especially
industrial companies, operate.   Lets begin with
a short IIoT definition The Industrial Internet
of Things (IIoT) refers to the vast number of
machines and devices or things a business
uses that are now connected to the Internet.
Protecting this critical operational data, secure
IIoT forms a closed, private Internet network
where the devices can communicate and share data
with other people, systems, and things. This data
can be used to improve existing work practices
and business processes as well as creating
entirely new ways of doing things.
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Benefits of IIoT
As IIoT devices become smaller, cheaper and
smarter, they can be applied almost everywhere.
The data they create can be turned into
actionable insight that delivers incredible
business benefits including
Improved operational efficiency Industrial IoT
software allows you to create environments of
connected assets that bring a wide range of
operational efficiency benefits. Sensors located
in production systems, assembly lines, warehouses
and vehicles produce data that helps managers
monitor exactly how an asset is performing and
address issues before they arise.   Increased
productivity Industrial IoT solutions provide
real-time information on the performance of
equipment and people to help streamline and
improve business processes and workflows.
Cost reduction Deploying IIoT offers large cost
saving benefits for organizations. For example,
industrial IoT devices can save dramatically on
energy bills by as much as 70 on lighting and
30 on air-conditioning, according to some
estimates.   Enhanced customer experience By
placing industrial IoT sensors within products,
manufacturers are able to capture and analyze
data on how customers actually use their products
enabling them to improve future product
upgrades and releases.   Reduce waste Inventory
management is one of the most important benefits
of IIoT software. By attaching IIoT devices to
products, warehouses and vehicles you can make
the entire supply chain process more effective,
reducing the need for excess inventory and the
potential for stock-outs.
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Challenges of IIoT
Many organizations have been attracted by the
benefits of industrial internet of things but
realizing those benefits is not straightforward.
There are many industrial IoT challenges to
overcome before an organization can institute a
successful IIoT program. These include Industria
l IoT Security Security is one the biggest
challenges for IIoT adoption. Many devices are
collecting extremely sensitive data but, in many
cases, the devices have been designed with little
thought to security. Industrial IoT security must
ensure that the identity of every person, system
and thing on the network is properly managed and
detected.
Data Privacy As more and more devices are
connected to the Internet, concerns surrounding
how personal and sensitive data are captured,
transmitted and stored also grow. The value of
IIoT lies in the ability to access, integrate,
and analyze this data while maintaining data
privacy. Industrial IoT Standards Standards lie
at the heart of the development and adoption of
IIoT. Today, there are many IIoT standards but
little standardization. For example, IIoT devices
use a variety of methods to connect and share
data, including LTE, LP-WAN, wi-fi, Bluetooth,
satellite and even Ethernet when connected
directly to a network.
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Challenges of IIoT
Data Management Handling the volume and velocity
of data being created by industrial IoT devices
is a significant challenge for every
organization. All this IIoT data must be
collected, stored and analyzed before it can be
turned into actionable insight that can drive
improved decision-making. Deployment
Models According to PTC, 62 of IIoT deployments
are on-premise, while 38 are in the cloud. The
vast amounts of IIoT data being created places
greater pressure on delivering flexible and
scalable capacity. For industrial IoT, a cloud
deployment offers performance and security gains
over on-premise solutions. Hybrid industrial IoT
cloud deployment splitting processing between
internal systems and the cloud is a
fast-growing deployment model for many businesses.
Range of IIoT Devices IIoT has many different
components and there are many different types of
industrial IoT devices. Typically, industrial IoT
device examples include sensors, actuators, tags,
beacons and receivers. When creating an IIoT
network, all these devices have to be effectively
and securely integrated to derive the full value
of your IIoT investments.
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IIoT Protocol
Of the many different protocols Message Queue
Telemetry Transport (MQTT) complements all the
necessities of IoT. With a view to meet the
Industry 4.0 demands, Messung now offers NX-ERA,
the complete industrial automation solution to
connect your business to IoT universe. All of our
NX-ERA products now support MQTT. When updating
the firmware of the PLC to the latest version and
using MasterTool IEC XE version 3.20, all the
NX-ERA PLCs could make your business closer to
Industry 4.0.
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Why MQTT?

• It is a lightweight message protocol that is
  based on subscription-publishing model and
  requires low bandwidth. E.g. Facebook uses MQTT
  for its messenger product on mobile platform, to
  ensure usage of this application is minimized.
• This model follows/defines two entities in the
  network the broker (also called server) and the
  clients.
• Using our MasterTool programmer, the user will be
  able to transform our PLC into a client, thereby
  allowing from a simple TCP / IP connection to a
  secure connection based on TLS certificates.
• MQTT is a high-level architecture and consists of
  two main parts (Broker Clients)

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Broker

• As can be seen, this protocol does not require
  synchronization between the parties involved, as
  the broker is responsible for ensuring the
  delivery of published messages.
• So, broker helps to sort the information and
  better manage the messages.
• Types of brokers available are Eclipse IoT
  Mosquito, Active MQ, Hive MQ etc.

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Clients

• Clients are any devices (PLC in our case) which
  interact with broker either publishing messages
  or subscribing to a topic.
• Topics are the routes where messages are
  published within a broker.  
• When PLC publishes message to the broker and
  broker forwards this message to subscribers
  avoiding point-to-point connections between
  subscribers and publishers.
• When broker (server) publishes any message, then
  PLC (client) acts as a subscriber.
• MQTT supports TLS (Transport Security Level) for
  secure connection between client server.
  Communication between client and server is
  established via TCP connection or an encrypted
  TLS connection for secure messages.

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Web Service Tools

• Any web service tool could be used as a
  programming platform for intuitive and
  straightforward integration between smart
  devices, PLCs and brokers. Node-Red is an example
  of the web server tool.
• If we write or publish a message from Node-Red,
  this published message will be received by broker
  first. If PLC is subscribed to this message under
  any topic, then it will receive the message from
  the broker.
• Thus, it is possible to communicate with
  different cloud platforms, such as Node-RED,
  where it is possible to create supervision
  diagrams for an entire system, including
  different devices.

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Screen Display on Mobile/Terminal/Tablet through
Cloud Platform/Local Server
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Typical Architecture
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CASE STUDY
Our customer is an Automotive Ancillary
Manufacturing company having a huge installed
base of PLCs (of different make) in their
premises being utilized for varied applications
including Robotic Cells. Customer Requirement
Application Robot Line Welding Machine The
customer wanted his PRODUCTION data and some
critical alarms to be monitored on Web
Visualisation tool and to collect the data
centrally in a local Server. Also to be energy
efficient, the customer wanted to monitor energy
consumed at each stage of the production line.
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Proposed Solution
Since the existing PLC does not support Industry
4.0 compatibility, Messung suggested a cost
effective solution to retrofit the PLC with
latest NX-ERA XPRESS PLC which has integrated
multiple protocol communication including MQTT
OPC UA protocols. To take care of Energy
Management System, energy meters were installed
with Modbus RTU communication facility. The
NX-ERA XPRESS PLC gathered the data from the
energy meters on integrated MODBUS Protocol
(inbuilt RS485 port). Moreover the data was
compiled and sent to the Customer Server. The
application was developed, panel rewired and
monitored within an hour. What's more, this task
was accomplished during the break, so it helped
to reduce machine downtime. The data was taken
on TCP/IP port to the Customer Server on MQTT
with broker running on the same.
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Production Management Solution Monitoring
Data Recording
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Conclusion
Messung NX-ERA PLCs for Industrial Automation
have opened new doors to ever increasing demands
for Internet of Things by introducing MQTT, where
the users can operate, make analysis and even
save on their existing sensors, devices or even
machines. With Messung's smart factory automation
control solutions, users can check, monitor and
even control some of the critical functionalities
of any machine in the plant at their fingertips
on their interactive devices based on operating
systems like MAC OS, Windows, IOS or Androids. As
proven automation experts and leading PLC
supplier in India, Messung has in-depth
understanding of industrial machinery, production
processes and practical implementation of
technology, complemented by a strong team of
experienced engineers with tried and tested
execution methodology. A pioneering industrial
automation control systems supplier and
provider of machine automation control
solutions for four decades, you can trust
Messung's cutting-edge industrial automation
control solutions with IIoT can transform
operations and efficiencies across the shop
floor.
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Thank you

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• 501, 502 503 Lunkad Sky Vista, Viman Nagar,
  Pune, India - 411 014.
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