Tobias Braun [Herrenknecht AG] | Going Underground with InfluxDB | InfluxDays NA 2021

Going Underground
with InfluxDB
Tobias Braun – Software Architect
Herrenknecht AG, Germany

© 2021 InfluxData Inc. All Rights Reserved.
Overview
- Herrenknecht AG and the presenter
- Building an IIoT platform for Herrenknecht AG
- Focus on handling of sensor data
- InfluxDB as central time series storage
- Migration to InfluxDB Enterprise
- Current status of the product

Herrenknecht AG
- Founded 1977 in Germany
- World market leader for tunnel
boring machines
- For tunnels from 0.1m to 19m
- Traffic, utility and mining
- Vertical and horizontal
- All geologies, even under water
- Major share of global market
- ~ 5,300 employees
- Revenue 2020: 1,007 mio. €

Tobias Braun
Software Architect, Herrenknecht AG
Build an IIoT platform with insight into live and historic data for all tunnel
boring machines delivered by Herrenknecht AG.
Small agile team of 4 developers. Frontend development is supported by an
external partner. We have to compromise and gradually improve what we
build.
E-Mail: braun.tob@herrenknecht.com
Software Architect at Herrenknecht for 2 ½ years
- More than 20 years of experience in highly available, distributed systems
- Worked for:
1&1 IONOS – Web Hosting Core
Burda GmbH – E-Commerce
Trumpf Werkzeugmaschinen GmbH – IIoT platform for a machine tool manufacturer

Building an IIoT platform for
Herrenknecht AG

Tunnel diameter and amount of data correlate
1985
HERA
5.95 m
1996
Sydney
10.70 m
1997
Hamburg
14.20 m
2006
Madrid
15.20 m
2006
Shanghai
15.43 m
2010
Sparvo
15.62 m
2016
Santa Lucia
15.87 m
2013
Hongkong
17.6 m
Concept
St. Petersburg
19.25 m

Current, correct data is vital for TBM operator

Building an IIoT platform for Herrenknecht AG
• Has to support >2000 TBM, several hundred are working simultaneously
• Up to 5000 sensors on a single machine
• Some sensors with sample rates <= 100ms
• Limited bandwidth to the job-site
• Machines can be offline for days, weeks, even months
• Historic data from 40 years and in different formats (SQL, DBase, even CSV)
has to be made available

Building an IIoT platform for Herrenknecht AG
• Can be developed and maintained by a small team
• Start with the basics: Make sure data is recorded consistently
• Development first for TBM, cloud as a second step
• Data storage for the next 10-15 years
• Robust, flexible architecture

InfluxDB as central time
series storage

Why we chose InfluxDB
• Open Source with commercial „Enterprise Edition“
• Windows-Service available (was relevant „back-then“)
• Very space efficient storage
• Query language similar to SQL with powerful aggregations
• Stored in simple, flat files

Where is sensor data stored?
• On-site
• Control room of the TBM is equipped with
ruggedized industrial PCs
• Windows operating system with limited
computing power and SSD
• Data cleansing and storage in InfluxDB OSS
• Cloud
• InfluxDB Enterprise running on Microsoft
Azure

How is data stored?
• Basically one big measurement
• Every sensor is a „float“ field
• Only few tags are used
• Low tag cardinality
• Only write values when there
was a significant change
-> 1-5 GB / month & machine

Simple architecture for InfluxDB in the cloud
• When entering the cloud, we used a quick and pragmatic
approach based on Kubernetes
• One InfluxDB OSS container per TBM
• No clustering of InfluxDB itself
• Azure File Storage (equivalent to Windows share)

Advantages of this approach
• Architecture almost identical to the environment on the TBM,
therefore minimal development effort
• Isolated impact zones
• Cheap pay-per-use storage
• File-based backup is included with Azure File Storage
• InfluxDB OSS – no licensing cost

How is data transferred to the cloud?
• Historic data is converted to InfluxDB format in batches
• Live Data:
• Data cleansing is already done on the machine
• So we simply mirror all the data from the machine to the cloud
• We built a custom synchronization, based on a REST API
• Result: Data is identical on the TBM and in the cloud

Migration to InfluxDB
Enterprise

First issues with the pragmatic approach
• Scaled well to ~100 InfluxDB containers,
• But with >> 100 containers,
• the overall system became unreliable
• … and response times for even simple queries exploded
• … and the infrastructure became prohibitively expensive
• Azure File Storage „forgot“ to unlock files in rare cases
• with hundreds of containers, even rare cases tend to happen
regularly

Decision to migrate to InfluxDB Enterprise
• 750 GB of data in 200 databases
• At most a couple of minutes of downtime for each TBM
• Small team with limited capacity, migration had to be automated
• Executed successfully in Q1/2020, took less than two weeks
• No read-downtime, write-downtime of less than 60 minutes per TBM

Results after the migration
• Reduced TCO of Influx databases by 1/3
• Extensive monitoring and stable operation
• Very reliable and reproducable response times for all
queries

Status of the product

Successful rollout to first customers

Status of the product
• Very positive feedback from customers and internal users
• Team can concentrate on feature development, little
DevOps efforts
• InfluxDB OSS on every TBM
• InfluxDB Enterprise in the cloud just works, unnoticable in
the background

Questions?
braun.tob@herrenknecht.com

Thank You

Tobias Braun [Herrenknecht AG] | Going Underground with InfluxDB | InfluxDays NA 2021

Tobias Braun [Herrenknecht AG] | Going Underground with InfluxDB | InfluxDays NA 2021

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