Introduction
In industrial automation, integrating PLC systems with cloud-based platforms opens up opportunities for real-time monitoring, remote control, and enhanced data analysis. Control Works has developed a solution that allows users to interact with B&R PLCs from AWS, specifically using MQTT. In this case study, we’ll explore how this system works, enabling users to monitor data from B&R PLCs and send commands via a cloud dashboard without an additional hardware. The example we’ll dive into demonstrates a round-trip time of less than 5 seconds between triggering commands and seeing state changes.
Section 1: Technology Stack Used in the Solution
The seamless integration of B&R PLCs with AWS is powered by a variety of technologies. Here’s a breakdown of the technology stack used in the solution:
B&R Side:
- B&R Compact-S PLC: A compact and cost-effective PLC from B&R’s offering. It handles all industrial automation tasks and is ideal for small to medium-scale operations.
- Standard X20 Input and Output I/O Modules: These I/O cards are used to interface the B&R PLC with physical devices, such as sensors and actuators, for monitoring and control.
- paho.mqtt.c-ar: An MQTT client library based on the Eclipse Paho project. It’s used by the B&R PLC’s Automation Runtime (AR) for MQTT communication, allowing the PLC to send and receive messages via MQTT topics.
AWS Side:
- AWS IoT Core: Utilized for MQTT communication between the B&R PLCs and AWS services. It enables secure, low-latency communication between devices and the cloud.
- Amazon Timestream: A time-series database service used to store data and commands. This service allows efficient storage, retrieval, and analysis of time-series data from the B&R PLCs.
- Amazon Managed Grafana: A visualization tool used to create dashboards. It is used for monitoring and controlling B&R PLCs by displaying real-time data from the PLCs.
- AWS Lambda: Used to execute functions in response to events, such as when a command is sent from the Grafana dashboard. It publishes data to the MQTT topic for communication with the B&R PLCs.
- Amazon CloudWatch: This service is used for triggering AWS Lambda functions based on specific events, such as changes in the state of a device or data arriving from the PLC. In addition, CloudWatch is utilized to monitor AWS spending, sending alerts if your budget is exceeded. This ensures peace of mind, especially since cloud services can quickly lead to unexpected costs if not closely monitored.
Section 2: The Control Works Solution in Action: Case Study of Triggering an Output
Control Works has implemented a solution that bridges the gap between B&R PLCs and AWS, enabling users to monitor data, send commands, and receive real-time feedback. Here’s how the process works in practice:
- Monitoring Data: Data from the input module is sent to AWS in real time using AWS IoT Core. This data is stored in Amazon Timestream and visualized on an Amazon Managed Grafana dashboard.
- Sending Commands: Users can trigger commands from the Grafana dashboard. When a user interacts with the dashboard, AWS Lambda publishes the command to the appropriate MQTT topic for the B&R PLC to receive.
- Real-Time Feedback: Once the command is received by the B&R PLC, it activates the corresponding output. The output is physically connected to the input, which allows us to get a full understanding of the time it takes from issuing a command to the status being updated.
The entire round-trip process, from command initiation to state change feedback, takes less than 5 seconds—highlighting the efficiency and responsiveness of the system. This fast feedback loop makes it ideal for applications where real-time control and monitoring are critical.
Section 3: Reliable and Secure Connection to AWS
The connection between the B&R PLCs and AWS has proven to be both reliable and secure. By following AWS best practices, including the use of certificates and private keys, the system ensures that data transmission is protected and tamper-proof. These security measures provide peace of mind, knowing that communication between the PLCs and AWS remains secure and that sensitive information is safeguarded at all times.
Section 4: Key Benefits of AWS and Grafana Integration with B&R PLCs
Control Works’ solution offers several benefits:
- Real-Time Control and Monitoring: The system allows operators to remotely monitor and control devices with minimal latency, making it suitable for critical applications where quick responses are essential.
- Scalability: With AWS, this solution is scalable, meaning it can be adapted for both small and large operations with ease.
- Data Visualization: Grafana’s powerful visualization tools provide clear, actionable insights into PLC system performance and status.
- Enhanced Decision-Making: The fast feedback loop and accessibility of real-time data enable quicker and more informed decision-making, driving operational efficiency.
Conclusion
By leveraging AWS and Amazon Managed Grafana, Control Works has created a solution that simplifies the process of monitoring and controlling B&R PLCs. With real-time data visualization and quick command execution (less than 5 seconds for round-trip processing), this solution transforms industrial automation by improving control, reducing downtime, and enabling faster decision-making. The integration of AWS with B&R PLCs is a powerful example of how cloud technology can revolutionize industrial operations.
Control Works is happy to help guide your team into this new and exciting technology that can enable limitless possibilities.
