MQTT (Message Queuing Telemetry Transport), an ISO/IEC PRF 20922 standard, is a connectivity protocol innovatively designed for low-bandwidth, high-latency networks. Initially deployed in the oil and gas industry, MQTT, with its basis in publish-subscribe architecture, has since found utility in Industrial Internet of Things (IIoT) and Internet of Things (IoT) applications.
MQTT Top Features
High scalability: MQTT is known to enable scalable, reliable, and efficient machine-to-machine communication.
Flexible Integration: It is highly beneficial for the integration of remote instrumentation and flow controllers at network edges.
Security: MQTT provides security through authentication protocols such as OAuth and TLS1.3, along with supporting Customer Managed Certificates.Sparkplug, an associated specification, builds upon MQTT’s security provisions for mission-critical applications.
Decoupling: MQTT allows for the decoupling of data-producing devices from data-consuming applications.
Languages Support: MQTT is supported by several languages including Python and offers easy implementation with minimal coding.
Protocol Structure
Fixed header, Variable header, and Payload
WSS Support
MQTT can be wrapped in a WSS envelope for receiving data directly into a web browser
Additional Capabilities
MQTT is compatible with security measures like firewalls, VPNs, IPsec to further bolster IoT system protection.
MQTT Disadvantages
The high-security provisions demand advanced levels of technical knowledge.
Dependency on TCP/IP might offer limitations in non-supportive environments.
MQTT Use Cases
Use case 1: Industrial Automation
MQTT enhances industrial automation capabilities with its unique ability to incorporate remote accessibility, and secure, efficient data integration.
Use case 2: Distributed Multisite SCADA
MQTT finds substantial applicability in distributed multisite SCADA, where remote data collection is crucial.
Use case 3: Smart City PoC Design
In smarc city PoC design applications, MQTT works exceedingly well for message transport, thus driving seamless communication in modern urban ecosystems.
PLC
PLCs, or Programmable Logic Controllers, play an integral role in automating processes, particularly in the manufacturing sector. Invented in the 1960s to replace large, cumbersome relay banks, PLCs are smaller, faster, and more powerful.
PLC Top Features
Flexible and easily programmable in relay ladder logic, simplifying the programming experience.
Integrated with advanced systems like ERP, MES, and SCADA, enhancing manufacturing operations’ efficiency.
Key player in the birth of Human-Machine Interface (HMI), fostering interactivity in industrial settings.
Central to the development of ‘Data Highway’ and Modbus, allowing PLCs to share information readily.
Adept at monitoring and recording real-time data, including machine productivity and operating temperature.
Important development
Impact
Introduction of third-party software packages in the 1980s
Significantly reduced the cost of programming devices.
Adherence to IEC 61131-3 Standard
All PLC software is compared against it, facilitating understanding of the programming language.
Integration with advanced systems
Aids in increasing efficiency and performance of manufacturing operations.
PLC Limitations
Difficulty in troubleshooting, requires a skilled workforce.
Initial learning curve may be steep for less experienced users due to complex programming languages.
PLC Use Cases
Use Case 1: Robotic arm in Cars
PLCs find extensive use in controlling the functionality of robotic arms in car assembly lines. Their precise, real-time monitoring capabilities make them indispensable in such high-stakes environments.
Use Case 2: Airport Runway Control
In managing airport runway control systems, PLCs ensures smooth and safe operations. They regulate lights, monitor runway conditions, enhance safety and efficiency.
Use Case 3: Traffic Signal Control
PLCs are capable of controlling complex traffic signal systems, offering a robust and reliable solution to manage traffic flows efficiently across cities.
RTU
The RTU (Remote Terminal Unit) is a microprocessor-controlled electronic device designed to perform interface functions between real-world objects and a distributed control system or SCADA system.
RTU Top Features
Communicates via RS485 or wireless links.
Efficient power utilization with solar-powered options.
Capable to operate under extreme environments or hard-to-reach locations.
Supports IEC 61131-3 programming standard for programmable logic controllers.
Defined communication protocols and can troubleshoot installation issues.
Component
Value
CPU
Included
Input/output cards
For analog input (AI), digital input (DI), digital output (DO/CO) and analog output (AO)
Monitoring
Via analog inputs of different types, such as 0-1 mA, 4–20 mA current loop, 0–10 V., ±2.5 V, ±5.0 V, etc
RTU Downsides
Requires technical expertise for defining communication protocols and troubleshooting installation issues.
Power supply depends on AC for CPU, status wetting voltages, and interfacing cards.
RTU Pricing
RTUs have entry-level to premium models with prices ranging from $500 to over $5,000, depending on capacities, functionalities, and brand reputation.
RTU Use Cases
Use case 1
RTUs are used for pipeline and grid guarding systems.
Use case 2
In oil and gas, electric, water utilities, and refineries, RTUs are used for remote monitoring.
Use case 3
RTUs play a crucial role in automobile manufacturing and food processing industries.
SCADA
SCADA, or Supervisory Control and Data Acquisition, is a robust computer application designed to consolidate the monitoring and control of plant equipment at a supervisory level. An innovative solution, SCADA simplifies complex industrial processing, enabling seamless tracking and rectification of issues while gauging extensive trends over time.
SCADA Top Features
Centralized Monitoring: Efficient control of a complete network from a singular station.
Automation: Automates intricate industrial processes while detecting and addressing issues proactively.
Interconnectivity: Incorporation of edge computing, artificial intelligence, and machine learning scaling its capabilities to future needs.
Diverse Industry Application: Suitable for a multitude of industries, such as energy, oil and gas refining, transportation, and telecom.
Central components
Remote Terminal Units (RTU), sensors, control relays, SCADA master units, communication channels.
Secondary components
Signal hardware, networks, Human-Machine Interface (HMI), controllers, communication, database, software, and actuators.
Data collection
Discrete sensors for digital information, analog sensors for live environmental conditions.
SCADA Limitations
PLC Cost: Programmable Logic Controllers (PLCs) can result in long-term costs despite providing efficient and secure monitoring.
Cybersecurity concerns: Because of integrated and connected systems, potential cybersecurity threats can emerge.
Legacy system limitations: Older SCADA systems lack scalability, interoperability, and support options.
SCADA Use Cases
Use case 1: Industrial Plants
SCADA proves crucial in industrial plants, automating intricate processes while proactively addressing discrepancies to ensure an optimized control on the entire network.
Use case 2: Energy Sector
In the energy sector, SCADA’s centralized monitoring and control capabilities enable efficient operations and real-time decision-making capabilities.
Use case 3: Transportation
With its high-end automation and integration capabilities, SCADA plays a major role in modernizing transportation systems, streamlining operations and improving security measures.
DCS
DCS, or Distributed Control System, is an automated system designed for comprehensive control across numerous elements. Known for substantial application versatility, DCS finds utility across diverse industries.
DCS Top Features
Decentralized control principle enabling individual control, reporting, and monitoring components in process plants.
Customizable via set configuration tools for database management, control logic, graphics, and system security.
Enhances reliability and reduces installation costs through centralized operator supervisory control.
Prevents full-scale system failure with a design that mitigates single processor failure effects.
Advanced Usage
Industry Acceptance
Advanced process control aid in larger facilities
DCS market forecasted to reach $23.2 billion by 2026
Handles substantial I/O points
Major brands include Siemens, Yokogawa, ABB, Honeywell, Rockwell Automation, Schneider Electric, Emerson
DCS Limitations
Not suited for real-time actions like PLC.
Requires considerable configuration and initial setup.
Comprehensive features may overwhelm small businesses.
DCS Use Cases
Use case 1: Power Generation
DCS accurately manages power generation processes, enhancing efficiency and ensuring stable operations.
Use case 2: Pharmaceuticals and Biotech
In this fast-evolving sector, DCS aids in bringing about precision, safety, and optimal control.
Use case 3: Infrastructure
From controlling water treatment processes to managing widespread infrastructure, DCS brings about streamlined operations.
ICS
At the forefront of the tech and ecological revolution lies the Industrial Control System (ICS). Described by many as a technological ecosystem, ICS brings together elements of IT and Operational Technology (OT), encompassing a broad range of devices, systems and controls integral for industrial process operation and automation.
ICS Top Features
Integrates elements of IT & OT, including PLC, RTU, Control Loop, HMI, Control Server, SCADA Server, IED, and Data Historian
Utilizes well-established protocols such as PROFIBUS, DNP3, Modbus, and OPC
Common types include SCADA and DCS, serving different control needs
Incorporates modern tech trends like cloud computing, big data analytics, and IoT
Feature
Benefit
SCADA Systems
Allows long-distance process monitoring and control
DCS
Provides localized, centralised control, reducing the impact of faults
IT/OT Convergence
Enhances supply chain visibility and integration
ICS Limitations
Emerging IT/OT convergence, while beneficial, may also increase cybersecurity risks
ICS is potentially susceptible to targeted cyber attacks
Recent events, like the Stuxnet and BlackEnergy attacks, underline this inherent vulnerability and the need for effective protection protocols
ICS Use Cases
Manufacturing
The use of ICS in manufacturing allows for a high degree of automated control and synchronization, improving efficiency and reducing waste.
Transportation
ICS also plays a key role in transportation management systems, maximizing route efficiency and fuel conservation, a fundamental step in reducing carbon footprints.
Water treatment
In water treatment facilities, ICS helps maintain optimal process conditions, minimizing energy consumption, and contributing to global water conservation efforts.
ERP
For nearly six decades, ERP (Enterprise Resource Planning) has been a key instrument for integrating business functions. Evolving from Material Requirements Planning (MRP) systems, ERP software now employs state-of-the-art technology to streamline operations, generate relevant reports and provide real-time data access.
ERP Top Features
Utilization of AI and machine learning to automate manual tasks and forecast future trends
Integration of IoT devices, harnessing crucial real-time data for improved decision making
Inclusion of web-based applications offering remote access to critical business data
Feature
Benefit
Streamlined workflow
Boosted efficiency and productivity
Data reporting capabilities
Enhanced understanding of business aspects
Data security measures
Protected confidential business data
ERP Limitations
High cost of initial implementation
Inefficient ERP systems can lead to stagnant or even ineffective operations
Dedicated IT team required for management and system upgrade
ERP Use Cases
Use Case 1: Large-Scale Enterprises
ERP systems have proved indispensable in large corporations with complex operations. These businesses leverage ERP for inventory tracking, production scheduling and integrating processes across departments.
Use Case 2: Manufacturing Firms
Production-based operations like J.I. Case and Oracle have achieved streamlined workflow and improved efficiency through the advanced scheduling capabilities of ERP systems.
Use Case 3: Small Scale Businesses
Earlier restricted to bigger firms, introduction of Cloud ERP has enabled smaller businesses to access this technology, thus boosting their productivity and operational efficiencies.
MES
Delve into the digital symphony of Manufacturing Execution Systems (MES), a grand conductor of manufacturing processes. It masterfully orchestrates the journey of raw materials into finished goods, all within the computerized realm, offering real-time information for intelligent decision-making.
Top Features of MES
Product lifecycle management: From the moment of inception to final dispatch, MES keeps track of a product’s entire lifecycle.
Resource scheduling and order execution: Optimal utilization and seamless coordination of resources, materials, and personnel, culminating flawless order execution.
Production analysis and downtime management: Enables in-depth understanding of production performances and efficient management of downtime.
Quality Control and Materials Tracking: Ensures highest product quality and keeps an eye on each material involved in the process.
Feature
Explanation
Interoperability
The beauty of MES lies in its robust and flexible integration capabilities, bridging the realm of ERP, SCADA, and PLC.
Analytics
With a system guided by empiricism, MES employs analytics to optimize manufacturing processes, enforcing security, and ensuring compliance.
Automation
Automated workflows, personnel scheduling, equipment assignment, all reside under the MES umbrella, transforming engineering BOM (eBOM) to manufacturing BOM (mBOM), offering real-time updates.
MES Downsides
Despite its vast offerings, MES does have its drawbacks:
Truly, a comprehensive solution, however, the cost of implementation can range extravagantly from $375,000 – $1.2 million.
The complexity of the system may require a steep learning curve for the non-tech savvy workforce.
MES Pricing
Cost of implementing MES can range from hefty $375,000 to grand $1.2 million, largely depending on the unique manufacturing requirements.
MES Use Cases
Industry Compliance
MES shines in regulated industries such as food, beverage or pharmaceuticals that demand “as-built” records. With its ability to maintain real-time tracking and traceability of production processes, MES ensures stringent adherence to industry compliance.
Advanced Data Protection
For industries that prioritize advanced data protection, custom-built MES solutions offer a sanctuary, handling and protecting the treasure troves of sensitive data, while seamlessly integrating with existing IT systems.
Efficiency Enhancement
For establishments gravitating towards a lean workflow, MES, with its relentless focus on waste reduction, inventory control, automation, and real-time analysis, breathes efficiency into operations.
IoT
The term IoT, or Internet of Things, refers to a network of devices equipped with integrated sensors and software that converse data over the internet. Local control is offered through a ‘brain,’ while connectivity enables external communication, revolutionizing various sectors including retail, healthcare, logistics, and manufacturing.
IoT Top Features
Advanced features like machine learning and AI are embedded to provide data-driven insights, enhancing operational efficiency and creating new business models.
Adopted across various sectors such as healthcare, where it supports wearable devices monitoring human health analytics, and automotive sector where it enables connected cars and remote vehicle operations.
IoT devices are notably diverse in size and function, accommodating both remote and co-located applications within larger systems.
IoT capitalizes on ML-based algorithms to detect equipment anomalies, sending alerts to users and instigating automated solutions.
Unique convenience offered through device-to-device communication not only redefines connected cars in the automotive industry but also streamlines home automation, lighting, heating, air conditioning, and security systems.
IoT Application
Beneficial Impact
Smart Manufacturing
Constant monitoring enhances productivity and reduces operational costs.
Connected Logistics
Provides real-time visibility into the supply chain, improving inventory management.
Healthcare
Allows remote patient monitoring and management of wearable devices that monitor human health analytics.
IoT Limitations
As IoT becomes pervasive, there are growing concerns about data security and privacy.
Integration with existing IT systems can be complex and costly.
With a variety of devices and protocols in the IoT ecosystem, interoperability can be a challenge.
IoT Use Cases
Use case 1: Smart Home Products
IoT has been instrumental in creating Smart Home Products for consumer markets, encompassing home automation, wearable tech and appliances with remote capabilities.
Use case 2: Transport Logistics
In the Transport and Logistics sector, IoT enhances efficiency and safety by allowing fleet management teams to reroute based on weather, vehicle and driver availability.
Use case 3: Healthcare
Within the Healthcare sector, IoT improves patient care by enabling remote patient monitoring, health analytics, and device automation.
BAS
Developed in the mid 1980s, Building Automation Systems (BAS) have revolutionized HVAC controls systems. BAS stemmed from the innovative concept of the modern thermostat first introduced by Warren Johnson in 1883.
BAS Top Features
Integrates multiple protocols with the Niagara controls framework
Allows interoperability with any BACnet device through ABB’s Aspect system
Links with access control, security systems, fire alarm systems, and elevators in modern BAS
Offers efficiency and conservation of energy, air, and water
Feature
Description
ABB’s Integra
A Niagara-based controls line, offering high levels of interoperability
Analogue Electronic Controllers
Paved the way for DDC devices, laying the foundation for modern BAS
Demand for Higher Interoperability
Drove the development of open protocols like BACnet, which is now widely adopted
BAS Limitations
Improper configurations can result in unnecessary energy use, accounting for nearly 20% of building energy consumption
Lacks full integration in traditional buildings: heating, ventilation, AC, and lighting systems often operate independently
BAS Use Cases
Use Case 1 – Green Buildings
For green buildings, BAS ensures energy, air, and water conservation while maintaining climate within specified parameters. The system is designed to use light based on room occupancy and monitor performance and device failures, providing malfunction alarms when necessary.
Use Case 2 – High-Rise Commercial Buildings
BAS is well-poised for high-rise commercial buildings, where it can be used for access control, security systems, fire alarm systems, and elevators. This enhances security and emergency responses, ensuring a safe and comfortable environment for all occupants.
Use Case 3 – Future Construction
As the future of construction veers towards energy efficiency and automation, BAS is likely to see increased adoption. Its scalable, energy-smart features, including the management of heating, lighting, security, and ventilation systems, meet the requirements of future buildings, making it a predominant system choice moving forward.
DAS
The ingenious antidote to poor in-building coverage is here – the DAS, short for Distributed Antenna System. Acting like network-chameleon, DAS readily fits into your existing architecture with a network of small antennas functioning as repeaters. These antennas are puppeteers called upon by your existing infrastructure, controlled by a central controller directly linked to the wireless carrier network’s base station.
Best Features of DAS
Strong signal distribution through a passive DAS system capturing signals via antennas on the roof, transmitting via leaky feeder cables.
For more power, an active DAS passes the signal via roof antennas through fiber cables, amplifying the signals as needed.
Provides voice and data services akin to any cellular network tower, completely transparent to mobile devices.
Full modularity, being able to interface any experiment to your computer for data recording/processing.
Powerful monitoring via AIMOS (a comprehensive DAS management platform).
Feature
Benefits
Handles Up to 240 Inputs
Provides ample capacity with up to 240 distinct analog or digital inputs. It’s power on a platter.
Unique Synchronization
Every data frame start is identified with a synchronization word, ensuring smooth and effective data flows.
Automated AIMOS Operations
From alarm polling, RF frequency allocation, to software updates, AIMOS can handle almost everything at specific/regular intervals.
Downsides of DAS
DAS installation processes can be labor-intense and costly.
Carrier involvement is usually necessary and costs are often borne by the carrier.
Requires comprehensive site surveys and RF benchmarking tests for accurate project needs assessment.
DAS Pricing
While the exact cost of a DAS deployment may vary based on building characteristics, tech demands and more, it’s noteworthy that the pricing includes licenses for AIMOS. CommScope offers various licensing methods for AIMOS, making flexibility a watchword. However, the actual cost ranges remain transparent only after comprehensive site surveys and RF benchmarking tests are performed.
DAS Use Cases
High-Rise Buildings
Looking for uninterrupted, solid signal strength in skyscrapers? DAS delivers, becoming the ideal solution for high-rise buildings.
Malls
Easy to deploy in densely populated indoor spaces, DAS ensures you’re not left signal-less when shopping, reducing coverage blackspots in your favorite mall.
Hospitals
Day-to-day functions in medical centers and hospitals would immensely benefit from robust, clear signal coverage, another domain where DAS shines.
Hannah Stewart
Content writer @ Aircada, tech enthusiast, metaverse explorer, and coffee addict. Weaving stories in digital realms.
