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Nilden Tutular, Volkan Balikci, Uygar Zubari [Eldor Corporation] | MQTT - Machine Data Collection | InfluxDays NA 2021

Nilden Tutular, Volkan Balikci, Uygar Zubari [Eldor Corporation] | MQTT - Machine Data Collection | InfluxDays NA 2021 MQTT – Machine Data Collection Collecting data from machines triggers our data-driven insights to predict breakdowns. Using Telegraf and Kapacitor for that aim creates magnificent data pipelines to help doing zero-break production.

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MQTT – 

Machine Data
Collection
With TICK-STACK
© 2021  InfluxData Inc. All Rights Reserved.
Who we are?
© 2021  InfluxData Inc. All Rights Reserved.
© 2021  InfluxData Inc. All Rights Reserved.
Our Data Engineering Architecture
© 2021  InfluxData Inc. All Rights Reserved.
© 2021  InfluxData Inc. All Rights Reserved.
Machine Data Collection with MQTT Architecture
The data obtained by the Robot Controller, such as Torque, Temperature & Current, are sent to the PLC
with the EtherCAT industrial communication protocol. This data is then sent to the MQTT Broker on the server
with the MQTT communication protocol. The sent data is instantly listened by the Telegraf through the MQTT
Broker
.

We have worked with many different types and brands of robots. In this presentation we wanted to share the
details of our work with KUKA Industrial Robots. We use OMRON brand as PLC.
© 2021  InfluxData Inc. All Rights Reserved.
© 2021  InfluxData Inc. All Rights Reserved.
Details about Data Collection
KUKA Industrial Robots have 6 axes. Therefore, the data we receive is separated on an axis basis.
 

▶ Each data has two subtypes. Average and Peak Values.
 

The data (Torque, Temperature & Current) received from the Robot is sent to the PLC with the EtherCAT (Industrial Communication Protocol).
 

These data are made meaningful in PLC and transmitted to MQTT Broker in the form of JSON Data Format.
Axis No Torque Temperature Current
for (i=1; i<=6; i++)
Axis Average Value Axis Average Value Axis Average Value
Axis Peak Value Axis Peak Value Axis Peak Value
© 2021  InfluxData Inc. All Rights Reserved.
© 2021  InfluxData Inc. All Rights Reserved.
• On the PLC side, we process and combine the data (Torque, Temperature, Current) we receive from the robot and convert it to JSON format. We publish it to MQTT broker with
MQTT protocol
.

• Omron PLCs are used in our factory. That's why we made this project using Omron PLC’s
.

• In order to use the MQTT Protocol on the PLC side; First of all,
 

• It is necessary to have an Ethernet card on which the Socket Service Functions of the PLC can be used. Because when using MQTT, it has to open a socket according to the
TCP/IP standard and send the data to this socket with a topic
.

• Omron has created a library to PLC, which includes function blocks for MQTT Protocol and JSON Data Standard. ( A function block is a smart function with its own instances
and memories.)
Details about Data Collection

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Nilden Tutular, Volkan Balikci, Uygar Zubari [Eldor Corporation] | MQTT - Machine Data Collection | InfluxDays NA 2021

  • 1. MQTT – 
 Machine Data Collection With TICK-STACK
  • 2. © 2021  InfluxData Inc. All Rights Reserved. Who we are?
  • 3. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Our Data Engineering Architecture
  • 4. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Machine Data Collection with MQTT Architecture The data obtained by the Robot Controller, such as Torque, Temperature & Current, are sent to the PLC with the EtherCAT industrial communication protocol. This data is then sent to the MQTT Broker on the server with the MQTT communication protocol. The sent data is instantly listened by the Telegraf through the MQTT Broker . We have worked with many different types and brands of robots. In this presentation we wanted to share the details of our work with KUKA Industrial Robots. We use OMRON brand as PLC.
  • 5. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Details about Data Collection KUKA Industrial Robots have 6 axes. Therefore, the data we receive is separated on an axis basis. ▶ Each data has two subtypes. Average and Peak Values. The data (Torque, Temperature & Current) received from the Robot is sent to the PLC with the EtherCAT (Industrial Communication Protocol). These data are made meaningful in PLC and transmitted to MQTT Broker in the form of JSON Data Format. Axis No Torque Temperature Current for (i=1; i<=6; i++) Axis Average Value Axis Average Value Axis Average Value Axis Peak Value Axis Peak Value Axis Peak Value
  • 6. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. • On the PLC side, we process and combine the data (Torque, Temperature, Current) we receive from the robot and convert it to JSON format. We publish it to MQTT broker with MQTT protocol . • Omron PLCs are used in our factory. That's why we made this project using Omron PLC’s . • In order to use the MQTT Protocol on the PLC side; First of all, • It is necessary to have an Ethernet card on which the Socket Service Functions of the PLC can be used. Because when using MQTT, it has to open a socket according to the TCP/IP standard and send the data to this socket with a topic . • Omron has created a library to PLC, which includes function blocks for MQTT Protocol and JSON Data Standard. ( A function block is a smart function with its own instances and memories.) Details about Data Collection
  • 7. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Mosquitto, Open Source MQTT Broker, is used as MQTT Broker. By the way, to briefly explain the MQTT Broker ; An MQTT broker is a server that receives all messages from the clients and then routes the messages to the appropriate destination clients. PLC and Telegraf are connected to MQTT Broker as MQTT Client. Here, the Broker acts as a server, making it possible to transfer data between clients . This Broker is installed on a Windows operating system computer. With the installation of this program, that computer turns into a MQTT Broker . The Broker's configuration is set to activate 1 port for up to 5 Robots for optimum data usage (Default 1883) . PLC publishes the data from the determined topic to the Broker. Obtains the data by listening to the broker from the same topic in Telegraf.
  • 8. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Predictive Maintenance Architecture Details
  • 9. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Telegraf: High Qualified Server Agent As a deamonset for collecting robot data from Broker(directed from PLC)
  • 10. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. 10 Telegraf: High Qualified Server Agent
  • 11. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. Configuration # Configuration for telegraf agent [agent] interval = "1s" metric_batch_size = 1000 metric_buffer_limit = 10000 collection_jitter = "0s" flush_interval = "5s" flush_jitter = "0s“ precision = "" debug = true # Configuration for sending metrics to InfluxD B [[outputs.influxdb]] urls = ["http://ourdomain:8086"] database = "telegraf“ skip_database_creation = true ## HTTP User-Agent user_agent = "telegraf" [[inputs.mqtt_consumer]] servers = ["tcp://ourIP:1883"] # MQTT QoS, must be 0, 1, or 2 name_override = "rpmOvm1" qos = 0 connection_timeout = "70s" ## Topics to subscribe to topics = [ "SmartFactory0090/RPM" ] #topic_tag="SmartFactory0090/ RPM" persistent_session = false client_id = "" data_format = "json“ #[inputs.mqtt_consumer.tags] # destinationdb ="telegraf" tag_keys=[ "LineName", "ModuleName", "StationName", "RobotName", "RobotType", "EditDate" ] Telegraf as a deamonset for collecting robot data from Broker
  • 12. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. The data we collect EditDate LineName ModuleName RobotID RobotName RobotType StationName host topic -------- -------- ---------- ------- --------- --------- ----------- ---- ----- 2021-10-04T10:41:45.593Z OM1 Unload 2183201 PickMold KR10_R900_2 ST1_Mold ourHost.com.tr SmartFactory0090/RPM 2021-10-04T10:41:30.792Z OM1 Unload 2183205 CellUnload KR10_R1100_SIX X ST6_CellUnl ourHost.com.tr SmartFactory0090/RPM 2021-10-04T10:41:27.693Z OM1 Unload 2183204 Transfer G10_851SR ST4_Transfer ourHost.com.tr SmartFactory0090/RPM Fields Tags
  • 13. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. The next steps We have already configured these two technologies in order to predict our Robot’s breakdown times. We have 1-Click ML Architecture with Kapacitor on Chronograf and still trying to improve our TICK-Stack knowledge for using the same stack in other fields like sensor data.
  • 14. © 2021  InfluxData Inc. All Rights Reserved. © 2021  InfluxData Inc. All Rights Reserved. References • https://www.support-omron.fr/telechargements/documentations/2019-03-28%20-%2009-14-20%20-%201454888610/MQTT_library_revE.pdf • https://www.support-omron.fr/telechargements/documentations/2019-03-28%20-%2009-14-20%20-%201422177077/JSON_library_revE.pdf • https://assets.omron.eu/downloads/manual/en/w501_nx_nj-series_cpu_unit_software_users_manual_en.pdf • https://www.kuka.com/tr-tr/%C3%BCr%C3%BCnler/robot-sistemleri/end%C3%BCstriyel-robot/kr-agilus • https://www.ethercat.org/default.htm • https://www.kuka.com/tr-tr/%C3%BCr%C3%BCnler/robot-sistemleri/robot-kontrol-%C3%BCniteleri/kr-c4
  • 15. © 2021  InfluxData Inc. All Rights Reserved. Questions?
  • 16. © 2021  InfluxData Inc. All Rights Reserved. Thank You
  • 17. © 2021  InfluxData Inc. All Rights Reserved.