Name: data communication based on mqtt in a polymer extrusion process
Uploaded: 2022-07-15T13:00:00
Description: Watch this Scientific Journal Video about Data Communication Based on MQTT in a Polymer Extrusion Process at JoVE.com

This study was supported by the Research Program funded by the SeoulTech (Seoul National University of Science and Technology).

1. Broker installation
NOTE: To monitor and record processing data via the Internet, a computer system that relays the data should be prepared. The system should be accessible from both the publishers and the subscribers as shown in Figure 2. Thus, it needs to have a public IP address that is known prior to any communication. An open MQTT broker called Eclipse Mosquitto is installed on the system13.
<ol>
	<li>Con...

<ol>
	<li>Shafiq, S. I., Szczerbicki, E., Sanin, C. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Proposition+of+the+methodology+for+Data+Acquisition,+Analysis+and+Visualization+in+support+of+Industry+4.0.">Proposition of the methodology for Data Acquisition, Analysis and Visualization in support of Industry 4.0.</a> Procedia Computer Science. 159, 1976-1985 (2019).</li><li>Dilda, V., et al. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Manufacturing:+Analytics+unleashes+productivity+and+profitability.">Manufacturing: Analytics unleashes productivity and profitability.</a> McKinsey &amp; Company. , (2017).</li><li>Ismail, A., Truong, H. L., Kastner, W. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Manufacturing+process+data+analysis+pipelines:+A+requirements+analysis+and+survey.">Manufacturing process data analysis pipelines: A requirements analysis and survey.</a> Journal of Big Data. 6, 1 (2019).</li><li>Nwanya, S. C., Udofia, J. I., Ajayi, O. O. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Optimization+of+machine+downtime+in+the+plastic+manufacturing.">Optimization of machine downtime in the plastic manufacturing.</a> Cogent Engineering. 4 (1), 1335444 (2017).</li><li>Zhou, T., Song, Z., Sundmacher, K. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Big+data+creates+new+opportunities+for+materials+research:+A+review+on+methods+and+applications+of+machine+learning+for+materials+design.">Big data creates new opportunities for materials research: A review on methods and applications of machine learning for materials design.</a> Engineering. 5 (6), 1017-1026 (2019).</li><li>Rousopoulou, V., Nizamis, A., Thanasis, V., Ioannidis, D., Tzovaras, D. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Predictive+maintenance+for+injection+molding+machines+enabled+by+cognitive+analytics+for+Industry+4.0.">Predictive maintenance for injection molding machines enabled by cognitive analytics for Industry 4.0.</a> Frontiers in Artificial Intelligence. 3, 578152 (2020).</li><li>Mamo, F. T., Sikora, A., Rathfelder, C. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Legacy+to+Industry+4.0:+A+Profibus+Sniffer.">Legacy to Industry 4.0: A Profibus Sniffer.</a> Journal of Physics: Conference Series. 870, 012002 (2017).</li><li>Figueroa-Lorenzo, S., A&#241;orga, J., Arrizabalaga, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=A+role-based+access+control+model+in+Modbus+SCADA+systems.+A+centralized+model+approach.">A role-based access control model in Modbus SCADA systems. A centralized model approach.</a> Sensors. 19 (20), 4455 (2019).</li><li>Schleipen, M., Gilani, S. -. S., Bischoff, T., Pfrommer, J. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=OPC+UA+&amp;+Industrie+4.0+-+Enabling+technology+with+high+diversity+and+variability.">OPC UA &amp; Industrie 4.0 - Enabling technology with high diversity and variability.</a> Procedia CIRP. 57, 315-320 (2016).</li><li>Ni&#539;ulescu, I. -. V., Korodi, A. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Supervisory+control+and+data+Acquisition+approach+in+node-RED:+Application+and+discussions.">Supervisory control and data Acquisition approach in node-RED: Application and discussions.</a> IoT. 1, 76-91 (2020).</li><li>Perez-Lopez, E. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=SCADA+systems+in+the+industrial+automation.">SCADA systems in the industrial automation.</a> Tecnolog&#237;a en Marcha. 28 (4), 3-14 (2015).</li><li>Andersen, D. L., Ashbrook, C. S. A., Karlborg, N. B. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Significance+of+big+data+analytics+and+the+internet+of+things+(IoT)+aspects+in+industrial+development,+governance+and+sustainability.">Significance of big data analytics and the internet of things (IoT) aspects in industrial development, governance and sustainability.</a> International Journal of Intelligent Networks. 1, 107-111 (2020).</li><li>Kashyap, M., Sharma, V., Gupta, N. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Taking+MQTT+and+NodeMcu+to+IOT:+Communication+in+Internet+of+Things.">Taking MQTT and NodeMcu to IOT: Communication in Internet of Things.</a> Procedia Computer Science. 132, 1611-1618 (2018).</li><li>. Mythbusting the MES. Systema Available from: <a target="_blank" href="https://www.systema.com/blog/mythbusting-the-mes">https://www.systema.com/blog/mythbusting-the-mes</a> (2021)</li><li>Yeh, C. -. S., Chen, S. -. L., Li, I. -. C. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Implementation+of+MQTT+protocol+based+network+architecture+for+smart+factory.">Implementation of MQTT protocol based network architecture for smart factory.</a> Proceedings of the Institution of Mechanical Engineers, Part B: Journal of Engineering Manufacture. 235 (13), 2132-2142 (2021).</li><li>Parian, C., Guldimann, T., Bhatia, S. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Fooling+the+master:+Exploiting+weaknesses+in+the+Modbus+protocol.">Fooling the master: Exploiting weaknesses in the Modbus protocol.</a> Procedia Computer Science. 171, 2453-2458 (2020).</li><li>Mishra, B., Kertesz, A. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=The+use+of+MQTT+in+M2M+and+IoT+systems:+A+survey.">The use of MQTT in M2M and IoT systems: A survey.</a> IEEE Access. 8, 201071-201086 (2020).</li><li>. pyodbc 4.0.34 Available from: <a target="_blank" href="https://pypi.org/project/pyodbc/">https://pypi.org/project/pyodbc/</a> (2021)</li><li>Ayer, V., Miguez, S., Toby, B. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=Why+scientists+should+learn+to+program+in+Python.">Why scientists should learn to program in Python.</a> Powder Diffraction. 29 (2), 48-64 (2014).</li><li>Boyes, H., Hallaq, B., Cunningham, J., Watson, T. <a target="_blank" href="http://www.ncbi.nlm.nih.gov/entrez/query.fcgi?db=PubMed&cmd=Search&doptcmdl=Citation&defaultField=Title+Word&term=The+industrial+internet+of+things+(IIoT):+An+analysis+framework.">The industrial internet of things (IIoT): An analysis framework.</a> Computers in Industry. 101, 1-12 (2018).</li></ol>

By following the protocol presented, the processing data can be monitored and recorded without expensive IT solutions such as the MES. The IoT technologies can make it easier to acquire and deliver data from conventional machines. It has been shown that the message-based protocol, MQTT, successfully serves as a platform for data communication for polymer processing lines. Moreover, additional data can be flexibly measured and transmitted together. The additional publishers employed in this work were the Raspberry Pis. No...

In the wave of the 4th industrial revolution, the acquisition and monitoring of various processing data have become important tasks1. In particular, improving the manufacturing process using process data and establishing efficient operation plans will be an important goal of all manufacturing facilities2,3. Downtime can be greatly reduced if an alarm can be sent out of the factory or if predictive maintenance can be performed in time4. Recently, many efforts have been made for data analyses in polymer processes5,6. However, it is not easy to conduct these tasks due to the difficulties in acquiring such data from the existing systems7. The hierarchical structure of the control and instrumentation makes the data acquisition and communication difficult.
First of all, it is not possible to obtain data from different machines with different manufacturing dates. It is difficult to realize communication between different machines since this requires interoperability between different fieldbuses in proprietary formats. In this way, communication methods and data formats are kept private. This helps one easily maintain data security but keeps users dependent on the machine builder for the services and future developments. The recent control computers including human-machine interface (HMI) attached to polymer processing machines are mostly Windows-based these days but are loaded with software created in a proprietary development environment. It is possible to use programmable logic controllers (PLCs) from different companies to communicate with the sensors or actuators, but in many cases, the upper supervisory control and data acquisition (SCADA) system is dependent on the control computers8. This practice has caused numerous protocols, fieldbuses, and control systems to compete in the market. Although this complexity has been alleviated little by little over time, many types of fieldbuses and protocols are still in active use.
On the other hand, communication between control devices and SCADA has been standardized by the Open Platform Communications United Architecture (OPCUA)9. Moreover, communication between SCADA and the Manufacturing Execution System (MES) has also been mainly made through OPCUA. In such a tight hierarchical structure, it is not easy to freely extract data for process monitoring and analysis. Usually, data has to be extracted out of the SCADA or MES10. As mentioned earlier, these systems are vendor-specific, and the data formats are rarely open. As a result, the data extraction requires substantial support from the original information technology/operational technology (IT/OT) solution vendors. This can hinder data acquisition for monitoring and analysis.
In a film extrusion line, the control PC is supervised by a SCADA system11. The SCADA system is operated by a computer program that cannot be easily modified. The computer program might be editable, but the editing is quite expensive and time-consuming. To easily monitor and analyze the processing data, the data should be accessible from any location. To monitor the processing data away from the site, the computer program should be capable of streaming the processing data to the Internet12. Moreover, an open free method reduces the expenses for the data acquisition13. This approach allows data analysis to be performed even in small factories that cannot afford to invest in commercial IT solutions14.
In this study, a message protocol based on the publisher-subscriber model is employed. The Message Queuing Telemetry Transport (MQTT) is an open and standard protocol that enables messaging between multiple data providers and consumers15. Here, we propose a system that acquires, transmits, and monitors data using MQTT for existing manufacturing facilities. The system is tested in a film extrusion line to verify the performance. The data from the original controller are transmitted to an edge device via the Modbus protocol. Then, the data is published to the broker. In the meantime, two Raspberry Pis publish the measured temperatures and illuminance to the same broker. Then, any device on the Internet can subscribe to the data, followed by monitoring and recording it as shown in Figure 1. The protocol in this work shows how the whole procedure can be done.

<table border="1" fo:keep-together.within-page="1" fo:keep-with-next.within-page="always">
	<tbody>
		<tr>
			<td>Edge Device</td>
			<td>Adavantech</td>
			<td>UNO 420</td>
			<td>Intel Atom E3815 Fanless</td>
		</tr>
		<tr>
			<td>Film Extrusion Machine</td>
			<td>EM Korea</td>
			<td>Not Available</td>
			<td>For production of 450 mm film</td>
		</tr>
		<tr>
			<td>Pydroid</td>
			<td>IIEC</td>
			<td>Not Available</td>
			<td>Android Devices</td>
		</tr>
		<tr>
			<td>Python3</td>
			<td>Python Software Foundataion</td>
			<td>Not Available</td>
			<td>Windows, Linux</td>
		</tr>
		<tr>
			<td>Raspberry Pi 4</td>
			<td>CanaKit</td>
			<td>Not Available</td>
			<td>Standard Kit</td>
		</tr>
	</tbody>
</table>

data communication based on mqtt in a polymer extrusion process

This work aims at building a flexible data communication structure for a polymer processing machine by employing a publisher-subscriber based protocol called Message Queuing Telemetry Transport (MQTT), which is operated over TCP/IP. Even when using conventional equipment, processing data can be measured and recorded by various devices anywhere through an Internet communication. A message-based protocol allows flexible communication that overcomes the shortcomings of the existing server-client protocol. Multiple devices can subscribe to the processing data published by source devices. The proposed method facilitates data communication between multiple publishers and subscribers. This work has implemented a system that publishes data from the equipment and additional sensors to a message broker. The subscribers can monitor and store the process data relayed by the broker. The system has been deployed and run for a film extrusion line to demonstrate the effectiveness.

It has been found that the data shown in the HMI and measured by the Raspberry Pis were monitored and recorded in the subscribers as shown in Figure 5. As presented in the video, the processing data are logged into the database.
<img alt="Figure 1" class="xfigimg" src="/files/ftp_upload/63717/63717fig01.jpg" /> 
Figure 1: Outline of the data transmission using the MQTT protocol.<...

Watch this Scientific Journal Video about Data Communication Based on MQTT in a Polymer Extrusion Process at JoVE.com

Data Communication Based on MQTT in a Polymer Extrusion Process

This work proposes a flexible method for data communication between a film extrusion system and monitoring devices based on a message protocol called Message Queuing Telemetry Transport (MQTT).

This work aims at building a flexible data communication structure for a polymer processing machine by employing a publisher-subscriber based protocol ...

Research

JoVE Journal

Engineering

Micropunching Lithography for Generating Micro- and Submicron-patterns on Polymer Substrates

Conducting polymers have attracted great attention since the discovery of high conductivity in doped polyacetylene in 19771. They offer the advantages of ...

Fabrication Process of Silicone-based Dielectric Elastomer Actuators

This contribution demonstrates the fabrication process of dielectric elastomer transducers (DETs). DETs are stretchable capacitors consisting of an ...

Adsorption Device Based on a Langatate Crystal Microbalance for High Temperature High Pressure Gas Adsorption in Zeolite H-ZSM-5

We present a high-temperature and high-pressure gas adsorption measurement device based on a high-frequency oscillating microbalance (5 MHz langatate ...

Morphology Control for Fully Printable Organic&#8211;Inorganic Bulk-heterojunction Solar Cells Based on a Ti-alkoxide and Semiconducting Polymer

Morphology Control for Fully Printable OrganicÃƒÆ’Ã‚Â¢ÃƒÂ¢Ã¢â‚¬Å¡Ã‚Â¬ÃƒÂ¢Ã¢â€šÂ¬Ã…â€œInorganic Bulk-heterojunction Solar Cells Based on a Ti-alkoxide and Semiconducting Polymer

The photoactive layer of a typical organic thin-film bulk-heterojunction (BHJ) solar cell commonly uses fullerene derivatives as the electron-accepting ...

Challenges in Rheological Characterization of Highly Concentrated Suspensions &#8212; A Case Study for Screen-printing Silver Pastes

Challenges in Rheological Characterization of Highly Concentrated Suspensions ÃƒÆ’Ã‚Â¢ÃƒÂ¢Ã¢â‚¬Å¡Ã‚Â¬ÃƒÂ¢Ã¢â€šÂ¬Ã‚Â A Case Study for Screen-printing Silver Pastes

A comprehensive rheological characterization of highly concentrated suspensions or pastes is mandatory for a targeted product development meeting the ...

Fabrication of Polymer Microspheres for Optical Resonator and Laser Applications

This paper describes three methods of preparing fluorescent microspheres comprising &#960;-conjugated or non-conjugated polymers: vapor diffusion, ...

Production and Characterization of Vacuum Deposited Organic Light Emitting Diodes

A method for producing simple and efficient thermally-activated delayed fluorescence organic light-emitting diodes (OLEDs) based on guest-host or exciplex ...

Predicting Catalyst Extrudate Breakage Based on the Modulus of Rupture

The mechanical strength of extruded catalysts and their natural or forced breakage by either collision against a surface or by a compressive load in a ...

A Polymer-based Piezoelectric Vibration Energy Harvester with a 3D Meshed-Core Structure

In this study, we fabricated a flexible 3D mesh structure with periodic voids by using a 3D lithography method and applying it to a vibration energy ...

O-cresol Concentration Online Measurement Based On Near Infrared Spectroscopy Via Partial Least Square Regression

Unlike macroscopic process variables, near-infrared spectroscopy provides process information at the molecular level and can significantly improve the ...