MQTT is an ISO standard connectivity protocol designed for low-bandwidth, high latency networks, widely used in IIoT and IoT applications. It enables efficient machine-to-machine communication with modern authentication protocols and security measures.
When exploring alternatives to MQTT, you may consider IoT, OPC, DAS, SCADA, RTU, DCS, BAS, PLC, ICS, MES, ERP.
IoT
The Internet of Things, or IoT, revolutionizes industries across the world by creating a network of devices with embedded sensors, exchanging data over the internet. It leverages AI, machine learning and low-cost sensors, pushing boundaries in manufacturing, transportation, healthcare, logistics, retail, and the public sector.
IoT Top Features
Highly versatile: IoT devices vary significantly in size and functionality, from wearable tech to automated farming equipment.
Microcontroller-based: Most IoT devices incorporate a microcontroller, offering control while enabling external communication.
Revolutionizes industries: IoT fuels smart manufacturing, digital supply chains, connected logistics, and preventive maintenance.
Enhanced security: IoT control centers monitor device behavior and limit access, Boosting security.
Feature
Benefit
Low-cost and High Efficiency
Ideal integration of low-cost computing, big data, cloud tech, and mobile tech allows seamless data sharing-collection with little human input, enhancing process efficiency.
Smart Asset Management
Iot ensures continuous equipment and appliance monitoring, mitigating risks and increasing operational efficiency.
Business Model Creation
IoT enables industries to create new layers of automation, fostering innovation in revenue and business models.
IoT Limitations
Connectivity-dependent: IoT devices require constant internet connectivity to function effectively.
Data security: With an increasing number of connected devices, data security and privacy concerns increase.
Interoperability issues: The vast diversity of devices and protocols may cause compatibility problems.
IoT Use Cases
Use case 1: Smart Manufacturing
IoT transforms the manufacturing industry by enabling constant machine and product quality monitoring. IoT sensors measure production output and ensure machines operate within required tolerances, sending alerts for deviations.
Use case 2: Automobiles
In the automotive industry, IoT paves the way for connected cars, allowing manufacturers to maintain continuous relationships with customers. Cars can be operated remotely, and software updates can be pushed directly to the vehicle.
Use case 3: Healthcare
Healthcare systems also use IoT devices extensively. These wearables monitor human health metrics and improve patient care, ushering in a new era of proactive and personalized medicine.
OPC
Incepted in 1996 by an industrial automation task force, OPC or Open Platform Communications is a global industrial telecommunication standard primarily designed to foster real-time data conversations between control instruments from diverse manufacturers. Formally known as the Object Linking and Embedding for Process Control (OLE), its comprehensive application across sectors led to its renaming in 2011. Today OPC has transcended to include Microsoft’s .NET Framework and XML.
OPC Top Features
Superior real-time data reading and writing capabilities with OPC Data Access (OPC DA).
Access to historical data based on OPC HDA.
Exchange of important alarm and event insights via OPC Alarms and Events.
Utility in diverse sectors including process control, building automation, discrete manufacturing, and M2M.
Feature
Benefit
Scalability
OPC model views every device as an independent object, improving scalability and flexibility.
Security
Secure and reliable data exchange enabled by end-to-end encryption, authentication and auditing.
Integrated MES and ERP Support
OPC UA integrates existing OPC interfaces with XML and Web services technologies.
OPC Limitations
Some OPC specifications are reserved for OPC Foundation members only, restricting accessibility.
Server usage heavily reliant on Microsoft’s OLE technology.
OPC’s DA protocol requires extensive systems for effective extraction and transfer of data.
OPC Use Cases
In Industrial Automation and Process Control
OPC is paramount in enhancing interoperability by securely exchanging crucial operational data within the automation space.
In Discrete Manufacturing
OPC servers provide an effective method for real-time data exchange between process control hardware and various software packages.
In Building Automation
OLC’s UA platform finds extensive utilization in building automation, facilitating the management of data exchange across a wide spectrum of platforms, right from embedded microcontrollers to cloud infrastructure.
ERP
Evolutionary and pivotal in the integration of business functions, Enterprise Resource Planning (ERP) systems have dynamically shaped businesses for nearly 60 years. Born from Material Requirements Planning (MRP) systems in the 1960s, ERP systems have matured into advanced repositories of information, serving businesses of all scales with unparalleled efficiency.
ERP Top Features
Incredibly comprehensive, enabling the integration of all processes required to run an entity
The advent of Cloud ERP has made it accessible to small businesses, eliminating the need for extensive hardware purchases and facilitating remote access
Profound capacities to leverage Artificial Intelligence and Machine Learning for automation, predictive analytics and foresight
Streams real-time data from IoT devices into actionable insights
Feature
Benefit
Advanced Reporting
Provides granular data for accurate insights and decision-making
Increased Collaboration
Connects global teams efficiently, promoting seamless workflows
Data Security
Offers robust security protocols, safeguarding valuable information
ERP Limitations
Unsuccessful implementation could result in inefficiency or ineffective operations
Requires significant investment both in terms of finances and resources
Complexity of the system may necessitate a specialist team for management and maintenance
ERP Use Cases
Use Case 1 – Large Enterprises
For enterprises like J.D. Edwards or Oracle, ERP systems provide a consolidated reservoir of critical business information, enhancing data-backed decision-making and operational efficiency.
Use Case 2 – Manufacturing Sector
With its roots in Material Requirements Planning (MRP), ERP systems serve as the pulse of the manufacturing industry, offering advanced production scheduling capabilities, streamlining resources, and optimizing inventory.
Use Case 3 – Emerging Businesses
Cloud-based ERPs are game-changers for emerging businesses, ensuring scalability and delivering critical operational capabilities without the burden of significant hardware expenditures or extensive IT staff.
DAS
Pioneering a fresh remedy for poor in-building coverage, the Distributed Antenna System (DAS) establishes a network of small antennas, which function as repeaters. Each antenna connects to a central controller that’s linked to a base station in the wireless carrier network. User-friendly and efficient, DAS offers both voice and data services akin to any cellular network tower, ensuring seamless and effective communication.
DAS Top Features
Smaller antennas functioning as repeaters connected to a central controller
Signal propagation through either leaky feeder cables (Passive DAS) or fiber cables (Active DAS)
Amplification of signals as required for effective transmission
Accommodation of up to 240 analog or digital outputs with 8 bits address bus and 16 addresses for internal use
Easily integrated into third-party network management software
Complete monitoring through AIMOS, offering automated and robust management of faults, configurations, and inventory
Feature
Benefit
Modular structure
Facilitates customization and adapts to a range of spaces and utilities
Shared use by multiple carriers
Helps reduce deployment costs
Automated monitoring via AIMOS
Elevates efficiency by tasks execution at specific/regular intervals
DAS Limitations
Heavy on the pocket due to labor-intensive installation processes
The assumption of costs by the carrier often necessitates their involvement
The need for comprehensive site surveys and RF benchmarking tests for accurate project needs assessment
DAS Pricing
Given the varying parameters like travel distance, building characteristics, and technical demands, the cost of DAS installation fluctuates. Precise cost ranges are provided by DAS integrators after a thorough site survey and RF benchmarking tests, aiming to maintain transparency and accommodate distinctive specifications.
DAS Use Cases
Use case 1: Densely Inhabited Indoor Spaces
Given its robust signal coverage, DAS shines in places like malls, medical centers, and high-rise buildings, where connectivity is paramount.
Use case 2: Carrier Integration
DAS makes an excellent choice for carriers seeking to reduce costs by pooling resources, courtesy of its system architecture that allows shared use by multiple operators.
Use case 3: Advanced Network Management
For organizations with extensive network systems, DAS is a boon. Its compatibility with third-party network management software and automated operations via AIMOS streamline system administration and performance monitoring.
SCADA
Enter the cybernetic world of SCADA (Supervisory Control and Data Acquisition) – an audacious, automated heartbeat of industries including manufacturing, oil and gas refining, water and waste control, amongst others.
SCADA Top Features
Automates and Controls: No more backbreaking monitoring, leave it to SCADA to manage complex industrial processes, identify issues and measure trends over time.
Gradual Migration: The NetGuardian 832A supports a smooth transition over time to IP capable devices at remote sites, ensuring zero disruption to your existing systems.
Universally Used: Globe-trotting is easy-peasy for SCADA. It monitors and governs parameters across a range of sectors, including energy, manufacturing, transportation and much more!
Future-proof: SCADA is not a relic — it is the future in the making. It proposes to incorporate 5G networks, quantum computing and artificial intelligence in its capabilities.
Components
Role
RTU and Sensors
Perform site control and collect digital and live data from equipment and environmental conditions.
HMI (Human-Machine Interface)
Processes data, communicates it to human operators maintaining usability and control.
Communication Infrastructure
Intranet or IP over SONET ensure superfast data transmission and control.
SCADA Downsides
Dreaded Cybersecurity: The more connected you are, the more vulnerable you become. This is true for SCADA and it does face cybersecurity concerns.
Legacy Bane: SCADA systems of yore are a hard nut to crack. Their lack of scalability and interoperability, coupled with limited support options, can be daunting.
SCADA Use Cases
Use case 1: Industrial Automation
Need to monitor, govern and automate complicated industry-specific processes? SCADA is your knight in shining armor. It’s specifically designed to automate complex setups, making your job a breeze!
Use case 2: Environmental Monitoring
Yes, you heard it right. SCADA is a superhero that not only manages industrial processes but also tracks environmental conditions. Its analog sensors gather live values and keep a vigilant eye.
Use case 3: Future Forward Approach
Embrace the future now with SCADA! It stands at the gateway of revolutionary enhancements like 5G networks, quantum computing, artificial intelligence, and machine learning. SCADA – the hall of fame for tomorrow’s tech legends.
RTU
An RTU (Remote Terminal Unit) is a robust, microprocessor-controlled electronic device that facilitates interface functions between real-world objects and a distributed control system or SCADA system. Best illustrated via its deployment in diverse applications such as pipeline and grid protection systems, the RTU excels in challenging locations and precarious environments.
RTU Top Features
Designed specifically to function under extreme conditions.
Communicates via RS485 or wireless links, supporting both wired and wireless connections.
Often solar-powered, laying emphasis on power efficiency.
Equipped with modern features aligning with the IEC 61131-3 programming standard for programmable logic controllers.
Capable of monitoring different types of analog inputs and translating raw data into meaningful units like temperature degrees and quantity.
Inherently equipped for multi-drop schemes with unique addressing for each unit.
Feature
Benefit
Interfacing Cards
Provides facility for analog input (AI), digital input (DI), digital output (DO/CO) and analog output (AO).
Battery and Charger Circuitry
Maintains operation during AC power failure, essential for critical applications.
Autonomous Mode
Allows for physical override switches at the RTU during maintenance.
RTU Limitations
Limited communication protocols available.
Requires technical expertise for setup and troubleshooting.
Power supply requirements, including AC power for various CPU and other cards.
RTU Pricing
RTUs span diverse price categories, from entry-level models priced at around $500 to premium models with a price tag exceeding $5,000. The pricing primarily hinges on capacities, functionalities, and brand reputation.
RTU Use Cases
Use case 1
RTUs are critically important in the oil and gas industry for remote monitoring purposes. Given the volatile and often inaccessible nature of these sites, RTUs lend a reliable solution for real-time asset management and monitoring.
Use case 2
In the electric utility sector, RTUs aid with grid control and diagnostics. They can withstand harsh environments and monitor large areas, enabling efficient resource deployment and reducing downtime.
Use case 3
Food processing units use RTUs to monitor and control refrigeration units, ovens, and other pieces of essential machinery. The ability of the RTUs to operate under extreme conditions and provide actionable data in real time facilitates safe and efficient production.
DCS
Enter the world of DCS (Distributed Control System), a leading automated control system. Operating with a distributed paradigm, it is used in varied industries, from managing to controlling processes. An increase to $23.37 billion by 2025 is anticipated in global DCS revenue at a CAGR of 4.5%.
DCS Top Features
DCS boasts of distributed functionality, easing individual control, reporting, and monitoring components in process plants.
A set of configuration tools are utilized by DCS for database management, control logic, graphics, and system security.
With its centralized operator supervisory control, DCS enhances reliability and reduces installation costs.
Its structural design includes an engineering workstation, operating station, process control unit, communication system, and smart devices.
Stability
The DCS structure effectively mitigates single processor failure effects.
Growth
The Distributed Control Systems market is expected to grow to $23.2 billion by 2026, according to MarketsandMarkets Research.
Top Brands
DCS is represented by brands like Siemens, Yokogawa, ABB, Honeywell, Rockwell Automation, Schneider Electric, Emerson.
DCS Downsides
Unlike a Programmable Logic Controller (PLC), which is an ideal controller for real-time actions, DCS may not be the optimal choice for smaller facilities or fewer I/O points.
DCS Use Cases
Use case 1: Power Generation
Within the field of power generation, DCS provides enhanced production efficiency and safety, all while optimizing interaction among numerous controllers.
Use case 2: Oil and Gas Industry
For the oil and gas industry, DCS serves as a vital tool for managing substantial I/O points, offering integration to existing industry architecture.
Use case 3: Pharmaceuticals and Biotech
DCS is influential in the pharmaceutical and biotech industries, where it supports modifications, upgrades, and promotes ease of maintenance throughout the plant life cycle.
BAS
A journey into the world of control systems won’t be complete without the mention of Building Automation Systems (BAS). With roots going as far back as the 1600s, BAS has grown from the innovation of Dutch Cornelius Drebbel to become a significant player in the contemporary tech era.
BAS Top Features
Consistent and advanced temperature control, which dates back to the invention of thermostat concept by schoolteacher Warren Johnson in 1883.
Versatile interoperability with many protocols such as BACnet, Lonworks, Niagara, etc.
Efficient integration with cutting-edge HVAC controls systems such as ABB’s Aspect system.
Feature
Description
Adaptable to Other Systems
Modern BAS can link access control, security systems, fire alarms, and elevators.
Energy-Smart
Green buildings designed to accommodate a BAS for energy, air, and water conservation.
Scalability
Future BAS will likely be scalable, managing a range of building systems efficiently.
BAS Limitations
Improperly configured BAS systems can account for approximately 20% of building energy use. This represents about 8% of total energy use in United States.
Presently, many traditional buildings’ heating, ventilation, AC, lighting systems still operate independently, posing a challenge to full-scale BAS implementations.
BAS Use Cases
Use case 1
BAS is particularly beneficial in the management of large-scale buildings. With its integrated controls, BAS helps in efficient regulation of temperature, lighting, ventilation, and security systems, ensuring optimal building performance.
Use case 2
For green building designs, BAS presents an advantage. It enables effective conservation of energy, air, and water, contributing to the sustainability of these environmentally-friendly structures.
Use case 3
For the modern tech era, the evolution and versatility of BAS offer greater interoperability. Organizations can seamlessly integrate different building systems and protocols, boosting efficiency and productivity.
PLC
A PLC or Programmable Logic Controller is a digitally operating electronic apparatus with a programmable memory. Invented in the 1960s, PLCs automate numerous processes, playing a critical role in varied fields, most notably in manufacturing. Through the decades, these powerful devices have witnessed dramatic enhancements in speed, size, power, and sophistication.
PLC Top Features
Standardization: Facilitated by the introduction of the IEC 61131-3 Standard, making PLC software understanding and comparison easier.
Software Packages: The emergence of third-party software packages in the 1980s drastically reduced the cost of programming these devices.
Interactivity: Birth of Human-Machine Interface (HMI) in response to the demand for interactive PLC software terminals in the 1990s.
Integration: Modern-day PLCs are linked with ERP, MES systems and SCADA, turbocharging manufacturing operations’ efficiency and performance.
Capabilities: Today, due to advancements in memory and processor technology, PLCs maintain core functions, whilst onboarding advanced capabilities.
Feature
Advantage
Ladder Logic
This visual representation of Boolean Logic simplifies comprehension for engineers.
Data Highway and Modbus
These rapid developments facilitated information sharing and consequently led to programming terminals.
Size and Cost of Solid-State Memory
Decreasing size and cost of solid-state memory have made PLCs adaptable for applications requiring expensive data acquisition systems.
PLC Limitations
Difficulty in troubleshooting.
Requires a skilled workforce.
PLC Use Cases
Use case 1
PLCs are utilized in manufacturing sectors like the automobile industry for operating robotic arms.
Use case 2
PLCs monitor and control air compressors, making operations safe and efficient.
Use case 3
They also play a crucial role in airport runway control – ensuring accurate and safe traffic coordination.
ICS: The Heavyweight Champ of Industrial Automation
Enter a beast from the realm of process automation and control – the Industrial Control System(ICS). Not your average backyard solution, ICS operates at the intersection of Information Technology (IT) and Operational Technology (OT), bringing an extensive arsenal of tools to the industrial process table.
ICS Top Features
Unified IT & OT variables – The blending of IT and OT breathes life into ICS, providing greater visibility and integration.
Various Control Mechanisms – From Programmable Logic Controllers (PLCs) to Remote Terminal Units (RTUs), and Control Loops to SCADA Servers, choices abound.
Human-Machine Interface (HMI) – Ensures man and machine play nice.
SCADA & DCS – Depending on your battlefront, SCADA allows remote control, while DCS provides local supervisory control.
ICS Components
Purpose
Intelligent Electronic Device (IED)
Your smart soldiers on the field
Data Historian
Your information time-traveler
Control Server
The puppet-master
ICS Disadvantages
Cybersecurity: ICS often presents a juicy target for cybercriminals, largely thanks to IT/OT convergence and adoption of new tech.
Single Point of Failure: A fault in the control loop within a DCS system can impact the overall system, despite its centralized architecture.
ICS Use Cases
Manufacturing
Manufacturers would hail ICS for its real-time control of operations, enhancing both efficiency and quality of products. Its integration of OT and IT facilitates swift decision-making thanks to precise and timely data.
Power Generation
ICS is a knight in shining armor for power facilities. Its distributed control system ensures seamless operation of complex and inter-dependent processes, from steam generation to power dispatch.
Transportation
ICS isn’t just suitable but practically tailor-made for transportation giants, managing the complex, interconnected systems at lightning speed, ensuring safety and punctuality.
MES
Manufacturing Execution Systems (MES) are computerized systems used in manufacturing to enhance productivity. Tracking and documenting the transformation of raw materials into finished goods, MES provides real-time information for improved decision-making, contributing significantly to production output control.
MES Top Features
Resource scheduling – balances inputs and outputs for optimal production.
Order execution and dispatch – streamlines production flow.
Product lifecycle management – monitors products from conception to recycling.
Materials tracking – ensures requisite materials are available and correctly utilized.
Feature
Benefit
Product quality
Enforces quality standards
Downtime management
Minimizes production interruptions
Production analysis
Enables optimization of production processes
MES Limitations
Despite its formidable advantages, MES can pose limitations such as:
High implementation costs – ranging from $375,000 – $1.2 million.
Requirement for skilled labor – trained professionals needed to maximize system potential.
Integration complexities – Case-specific customization required for seamless integration with existing systems.
MES Pricing
The cost of implementing MES typically ranges from $375,000 – $1.2 million, depending on the scale and complexities of the production process.
MES Use Cases
Use case 1: MES in regulated industries
MES shines in regulated industries such as food, beverage, or pharmaceuticals, where it provides an “as-built” record crucial in capturing data, processes, and outcomes.
Use case 2: MES for inventory management
MES allows real-time tracking of work-in-progress inventory levels, ensuring efficient utilization of resources and prevention of stockouts.
Use case 3: MES for Global Market Growth
With the increased use of industrial automation, low deployment costs and the need for regulatory compliance, MES is driving global market growth, projected to generate revenue of $18.06 billion by 2025.
Patrick Daugherty
Content writer @ Aircada. Merging AR expertise with a love for late-night gaming sessions.
