SlideShare a Scribd company logo
• Technology explorer
• B.S. E.E. UTA ‘12
• Automation in manufacturing since graduation
• Diverse experience
• Industries - Aerospace, defense, telecom
• Companies – Garages to aircraft hangars
• Departments – R&D, production, sustainment
• Hobbyist
• Deep learning – Mostly GAN’s
• IoT – Edge data to AI cloud endpoint
• Home automation – Cost analysis/reduction
• Olympus Controls is an automation solutions provider, not an integrator
• We’re the first one our customer calls when they realize they have a
problem
• Engineering oriented and root cause focused
• Driven by the need to solve complex, ambiguous problems
• These 21st century problems require 21st century solutions
• Practical experience with newest technologies
• Analysis – Factory Tour
• We analyze current operations to identify
areas of both immediate and long-term
potential impact
• Planning – Automation Roadmap
• We phase our automation deployments to
align with core objectives by utilizing an
automation roadmap
• Deployment – Onsite Installation
• We collaborate with internal engineering
resources and outside firms to deploy our
technology into your processes quickly and
effectively
• Improvement – Remote Monitoring
• As a growth-oriented company we
understand processes can always be
improved and provide insights into the
health and productivity of our systems
What? Why?
Who? How?
When?
• No previous experience with databases relational or otherwise
• InfluxDB provided:
• Easy data collection (existing MQTT broker)
• Visualization with time ranges
• Cloud access
• Understandable query language with Flux
• Relational is great for tracking assets, but not rates / trends
• SQL being used internal for accounting and inventory
• Influx over others:
• Full-stack data to visualization on one platform
• Low cost of entry
• Scalability
• In Manufacturing: IIoT = Predictability = Uptime = $$$
• Machine state
• Running – Actively handling packages
• Waiting – Robot active but no parts available
• Halted – Robot inactive but powered on
• Faulted – Robot faulted but powered on
• Down – Robot power off
• Production Data
• Daily package counter
• Hourly rate
• Robot health
• Joints
• Current (where we’re focusing today)
• Temperature
• Fully automated end-of-line palletizing solution powered by Universal
Robots’ UR10e
• New turnkey system from Robotiq
• Olympus Controls merged OPTO 22’s groov RIO edge gateway with Telit’s
DeviceWISE edge software platform
• Modbus TCP is supported so the unit is compatible with Universal Robots
LAN (ethernet)
Modbus TCP
Broker
WAN (internet)
MQTT
Factory
Cloud
Factory
• 6 joints (motors) on every arm
• Each joint motor’s current and temperature are continuously monitored
• Values are stored in Modbus TCP registers
• Modbus is a common industrial protocol dating back to the 1970’s
• Many industrial networked devices can use Modbus TCP (over ethernet)
• Telit’s deviceWISE gateways incorporate most common industrial
protocols which allow them to connect to virtually any industrial
device
• JSON message is published to a topic on a public MQTT Broker
• http://www.mqtt-dashboard.com/
• Subscribe - /dwgateway/JointStatus
Modbus TCP Registers are combined
into a JSON message
• Telegraf can use multiple protocols to
use various data sources in the same
database
• MQTT Consumer was used to subscribe
to the “/dwgateway/JointStatus” topic
• JSON_v2 parser was used to create the
database entry
• Telegraf runs detached in Docker
Compose
Robot is cycling primarily shoulder/elbow joints until error
Robot is running, then idle, then Emergency Stop is pressed
• Add production metrics and machine state
• Release all data into MQTT Broker
• Custom dashboards depending on job
• Integrate multiple machines into same bucket
How Olympus Controls Automates Predictive Maintenance with Telit, MQTT and InfluxDB

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How Olympus Controls Automates Predictive Maintenance with Telit, MQTT and InfluxDB

  • 1.
  • 2. • Technology explorer • B.S. E.E. UTA ‘12 • Automation in manufacturing since graduation • Diverse experience • Industries - Aerospace, defense, telecom • Companies – Garages to aircraft hangars • Departments – R&D, production, sustainment • Hobbyist • Deep learning – Mostly GAN’s • IoT – Edge data to AI cloud endpoint • Home automation – Cost analysis/reduction
  • 3. • Olympus Controls is an automation solutions provider, not an integrator • We’re the first one our customer calls when they realize they have a problem • Engineering oriented and root cause focused • Driven by the need to solve complex, ambiguous problems • These 21st century problems require 21st century solutions • Practical experience with newest technologies
  • 4. • Analysis – Factory Tour • We analyze current operations to identify areas of both immediate and long-term potential impact • Planning – Automation Roadmap • We phase our automation deployments to align with core objectives by utilizing an automation roadmap • Deployment – Onsite Installation • We collaborate with internal engineering resources and outside firms to deploy our technology into your processes quickly and effectively • Improvement – Remote Monitoring • As a growth-oriented company we understand processes can always be improved and provide insights into the health and productivity of our systems What? Why? Who? How? When?
  • 5. • No previous experience with databases relational or otherwise • InfluxDB provided: • Easy data collection (existing MQTT broker) • Visualization with time ranges • Cloud access • Understandable query language with Flux • Relational is great for tracking assets, but not rates / trends • SQL being used internal for accounting and inventory • Influx over others: • Full-stack data to visualization on one platform • Low cost of entry • Scalability
  • 6. • In Manufacturing: IIoT = Predictability = Uptime = $$$ • Machine state • Running – Actively handling packages • Waiting – Robot active but no parts available • Halted – Robot inactive but powered on • Faulted – Robot faulted but powered on • Down – Robot power off • Production Data • Daily package counter • Hourly rate • Robot health • Joints • Current (where we’re focusing today) • Temperature
  • 7. • Fully automated end-of-line palletizing solution powered by Universal Robots’ UR10e • New turnkey system from Robotiq
  • 8. • Olympus Controls merged OPTO 22’s groov RIO edge gateway with Telit’s DeviceWISE edge software platform • Modbus TCP is supported so the unit is compatible with Universal Robots
  • 9. LAN (ethernet) Modbus TCP Broker WAN (internet) MQTT Factory Cloud Factory
  • 10. • 6 joints (motors) on every arm • Each joint motor’s current and temperature are continuously monitored • Values are stored in Modbus TCP registers • Modbus is a common industrial protocol dating back to the 1970’s • Many industrial networked devices can use Modbus TCP (over ethernet)
  • 11. • Telit’s deviceWISE gateways incorporate most common industrial protocols which allow them to connect to virtually any industrial device • JSON message is published to a topic on a public MQTT Broker • http://www.mqtt-dashboard.com/ • Subscribe - /dwgateway/JointStatus Modbus TCP Registers are combined into a JSON message
  • 12. • Telegraf can use multiple protocols to use various data sources in the same database • MQTT Consumer was used to subscribe to the “/dwgateway/JointStatus” topic • JSON_v2 parser was used to create the database entry • Telegraf runs detached in Docker Compose
  • 13.
  • 14. Robot is cycling primarily shoulder/elbow joints until error
  • 15. Robot is running, then idle, then Emergency Stop is pressed
  • 16. • Add production metrics and machine state • Release all data into MQTT Broker • Custom dashboards depending on job • Integrate multiple machines into same bucket