Improved Process Control Using Hybrid Industrial Internet of Things Network Topology

Industrial Internet of Things (IIOT) is currently developing as an important manufacturing paradigm with active contemporary research exploring its trends in enhancing Industry 4.0 on a global scope. Manufacturing encompasses a broad umbrella of technologies with this work focusing specifically on process control implementation through IIOT along Industry 4.0 trends. With the vast amounts and types of data generated by implementing closed-loop sensory systems that communicate with IIOT applications, new automated methods are required to securely manage this data in a robust architecture. The expanding capabilities of Internet of Things technologies increase the demands of customers for intelligent, interconnected devices. Legacy Programmable Logic Controllers (PLCs) remain the industry standard for manufacturing and process control. As original equipment manufacturers (OEMs) produce new technologies to bridge the gap, high-value capabilities previously denied to either technology are now possible. The goal of this paper is to compare and to contrast traditional closed systems and existing Free and Open Source Software (FOSS) along Industrial 4.0 trends, as well as show the expanded capability set possible with their hybridization. Manufacturing data management methods to support this hybridization are explored. A framework/methodology for evaluating existing systems relative to their hybridization is presented with the incorporation of IIOT technologies. A proof of concept demonstration of the hybrid network of technologies shows the real-world value and added capabilities of the system. This case study implements a new process control training bench programmed in Siemens Totally Integrated Automation (TIA) Portal and controlled by a SIMATIC S7-1200 PLC. The bench uses a pressure sensor to obtain data used in the control of the internal fluid level. The methods in which this data may be collected and analyzed to implement intelligent closed-loop feedback through IIOT connectivity are explored. A ROSbot running Robot Operating System (ROS), oversees all ROS operations as the open-system master. Hybridization between the two systems forms when they are linked via a Siemens IOT2000 module which allows the ROSbot to accept nodes sent from MATLAB SIMULINK. To demonstrate the capabilities of this hybrid network, the ROSbot is programmed to interact remotely with the process control bench in a scenario analogous to a water truck filling from a water station. The truck moves to an auxiliary location, dumps the load, then returns to the station for another cycle. The novelty of this research is the synthesis of traditional closed and open systems across IIOT networks, namely through the use of the MATLAB ROS Toolbox. It is concluded that hybridization allows for the simultaneous application of the most advantageous features from each system type, namely the versatility of FOSS applications in addition to the robustness and security of a closed PLC without the trade-offs required in traditional applications and research. Future research includes the integration of WAN and GPS/GLONASS navigation with the eventual application of automated access control of network-identified robots on hybrid networks in residential, commercial, and industrial settings.