Data transmission is a particular challenge in heterogeneous IT/OT environments. Containerization and the MQTT protocol enable complex integration tasks to be mastered. The Cedalo MQTT platform offers a robust solution for the transmission of machine data in real time and ensures a stable connection to cloud-based applications. An efficient infrastructure that drives industrial digitalization.
The challenge: Data transmission in a heterogeneous IT/OT environment
Operational technology (OT) in industrial companies is usually very heterogeneous. Due to the high investment costs, it is not uncommon for machine tools and industrial plants to be used for 20 years or more. During this time, however, the machines are constantly being developed further, so that different generations of machines with different hardware and various protocols for data transmission exist side by side, especially in fast-growing companies.
These systems must be integrated for connection to the Industrial IoT. The connection between OT and IT is no easy task and requires a great deal of development effort. The individual software modules must be able to interact with each other and form a data pipeline from the machine to the cloud.
In IT, the principle of “containerization” has become established for similar integration tasks. Individual software modules are installed in separate “containers”, which are configured, started and executed independently of each other. With this technology, companies reduce their dependency on an operating system or a single platform or the time-consuming adaptation of the entire code to the new environment.
Another advantage is that the software solutions are easily scalable and can be effortlessly adapted to performance peaks and fluctuating workloads. In addition, it is easy to move the software or application to other environments so that it can be used across platforms and infrastructures.
Portainer is a leading container and device management platform with more than 4 billion downloads worldwide across all industries. It is the only platform that supports Docker, Docker Swarm, Podman and Kubernetes and is specifically designed to reduce complexity for users.
A successful combination of hardware and software is crucial for simple and secure management of applications and devices that is compatible with both the OT and the IT of a company. Different systems can now work on the basis of such a container environment to collect data from machines and sensors in a heterogeneous production environment and send it on to the cloud. MQTT is often used as the communication protocol here.
The solution: data exchange with the Cedalo MQTT platform
MQTT (Message Queuing Telemetry Transport) is a lightweight protocol specifically designed for communication between devices with limited bandwidth or in high latency environments. It causes only a low network load and works very well even in unstable situations. MQTT is known for its efficiency and reliability in data transmission and is therefore very frequently used in industrial IoT.
The important components of an MQTT solution are an MQTT Broker, which transfers data between devices via the MQTT protocol, and an MQTT Broker Web UI, which enables the management and monitoring of MQTT Broker setups.
The Cedalo MQTT platform is a comprehensive solution consisting of the Pro Edition for Eclipse Mosquitto™ and the Management Center Web UI. The platform is suitable for managing and transmitting real-time data on machine statuses, key production figures and telemetry metrics using the MQTT protocol. It enables the reliable transmission of machine data in real time and at the same time offers seamless logging.
The broker receives messages from sensors, machines or middleware, such as the OPC router from inray, and forwards them to the appropriate recipients – for example to a dashboard from the company 40Factory, or data from machines (such as temperature, pressure, vibrations) from the production level to control systems or predictive maintenance platforms, or consumption and grid stability data from smart meters or other energy devices to central systems in the energy sector, and so on.
The broker is designed for use in large enterprise environments and offers high availability, scalability, robust security and multi-tenancy features. This ensures reliable and stable data transmission. The Management Center makes it easy to manage and monitor the broker via a central web interface. The platform is suitable for use in various application areas that require secure and reliable data communication.
The Cedalo MQTT platform is used in production to collect and analyze machine and sensor data in real time. Sensor data such as temperature, pressure or vibration patterns are recorded by machines and transmitted to central systems via MQTT. In this case, the platform enables real-time monitoring and predictive maintenance, which improves efficiency and reduces downtime.
The Cedalo MQTT platform is also used to process sensor data from various distributed locations in real time. For example, electricity consumption data from smart meters can be collected and aggregated in order to control loads or quickly detect faults. In this case, the platform improves grid stability, enables more efficient energy distribution and fast response times in the event of outages.
The result: a robust infrastructure for data transmission
In summary, the Cedalo MQTT platform is characterized by its scalability, security and management options. It provides a robust infrastructure for the transmission of machine data in real time, which is crucial for the digitalization and automation of industrial processes.
Thanks to the synergies with Portainer enables a simple and standardized installation that facilitates management. In addition, the simple update function and uncomplicated scalability ensure maximum flexibility to manage data streams efficiently and adapt them to changing requirements.
Presentation of a real production process on the SP2024
At Smart Production Solutions 2024 (PLC 2024), Portainer and its partner companies Softing, Inray, Cedalo, 40Factory and Iniationware will be showcasing the simulation of an industrial production process in Hall 5, Stand 350. The visitors themselves can pass through various stations as “piece goods”.
Within the simulation, data is recorded and processed in real time. It shows how IIoT solutions collect, analyze and use machine data. Production data such as machine statuses, energy consumption and production quality are transmitted to the cloud via MQTT and displayed in real time on interactive dashboards.
The setup simulates production, data transfer and the conversion of data from the PLC to MQTT and the display on the MAT dashboard. Cedalo shows how its MQTT platform ensures secure and reliable data transmission between the OPC router and the MAT dashboard.
