What Is IIoT? Exploring the Industrial Internet of Things

IIOT

What Is IIoT?

You might have heard of the Internet of Things, but you might not yet be familiar with the Industrial Internet of Things (IIoT). It’s all about how devices used in industrial processes communicate with one another and collect data. It’s an emerging idea in the industrial world, and it’s set to change things even more in the years ahead.

Read on to find out all about the Industrial Internet of Things (IIoT) and what it all means, both now and moving forward.

What is the Industrial Internet of Things (IIoT)?

At its core, the Industrial Internet of Things refers to a wide range of industrial devices, such as machines, sensors, gadgets, networks, and motors, that are connected to each other. The devices contain sensors that are connected to networks that then gather data. They also communicate with one another as data is shared and transferred.

Thanks to recent tech advancements, the sensors used for these devices can be made smaller than ever. This means that now even very small industrial devices of various kinds can be connected, allowing for ever greater levels of monitoring, tracking, and data collection as they communicate with other devices.

The real strength of IIoT comes from how businesses can take that data and analyze it to better understand how their functions are operating and how their business processes are performing. The more data you have, the clearer your understanding of performance industrial processes and performance levels. And that’s one of the key reasons why the Industrial Internet of Things is so valuable.

What Can It Do for Businesses?

So, what does IIoT actually do for businesses? One of its biggest advantages is how it supports smarter decision-making. With a steady flow of real-time data, IIoT helps companies move past guesswork and base their choices on solid, actionable insights.

The level of detail provided in this data can be very high. Businesses and business owners can then understand their processes better than ever before, and in turn, this helps them to make their processes more efficient. As they make decisions, they can be led by the data rather than less tangible estimations that might not offer the same accuracy.

The Industrial Internet of Things also helps when it comes to managing supply chains better and coordinating directly with other businesses. When businesses work together better in a more carefully coordinated way, they can be made even more efficient. And that’s something that benefits both businesses.

Overall, these IIoT applications lead to real savings and a more flexible, efficient way of doing business.

How Does IIoT Differ from IoT?

Although there is some overlap between the two, it’s important to understand the difference. Both use sensors and network connections to help devices communicate and boost performance, but they serve very different purposes and operate on different scales.

IoT usually refers to everyday consumer tech, such as TVs, speakers, and smartwatches, and even home appliances like refrigerators and security systems. In this space, the focus is mostly on convenience and lifestyle improvements for individual users.

IIoT, on the other hand, is all about large-scale industrial environments. It’s more about planning, analysis, and business efficiency. As a result, there’s more analysis and data crunching that goes into IIoT.

A worker checking inventory on a tablet in a warehouse

Which Industries are Beginning to Adopt IIoT?

There are already a lot of companies using and benefiting from IIoT, and there are some industrial niches that are using it more than others. As we’ve mentioned, one of its biggest advantages is improved coordination, which makes it especially valuable for supply chain and logistics companies.

It’s also true that the world of manufacturing is starting to embrace IIoT. When manufacturing companies use the Industrial Internet of Things, it allows them to make projections about the most optimal and efficient timing of machinery servicing and things like that. This might not seem like much, but it can reduce the amount of downtime the company experiences.

But it doesn’t stop there. Businesses in retail, warehousing, and other sectors looking to better manage inventory and reduce waste can also benefit from IIoT. Even public sector organizations, like healthcare departments and transportation agencies, are using it to improve services and boost efficiency. IIoT’s flexibility makes it a powerful asset for just about any industry.

How Well Established is this Technology Right Now?

The Industrial Internet of Things isn’t some far-off idea; it’s already here and growing fast. Many companies are putting IIoT solutions to work, but there’s still a lot of room for growth as more businesses start to see the value of connected industrial strategies.

The Industrial Internet of Things is already being heavily invested in, with hundreds of billions of dollars being poured into it by businesses in a variety of industries and sectors every year. In recent years, those numbers have been growing, suggesting that IIoT is on an upward trajectory in terms of business spending.

There are many different things that businesses are spending this money on at the moment. A lot of the money is being spent on logistics and transportation to make supply chains better integrated with IIoT technology. That’ll make it possible for companies to benefit in the ways discussed above.

The Components Behind IIoT

The Industrial Internet of Things (IIoT) runs on the smooth integration of three main components:

  1. Sensor Technology: Thanks to major advancements, sensors are now smaller, more affordable, and easier to scale. They’re the eyes and ears of IIoT, collecting important data on everything from temperature to machine performance.
  2. Network Technology: A strong, reliable network is a must for keeping connected devices talking to each other. Whether it’s wired connections or wireless protocols, the right network setup keeps information flowing smoothly across an IIoT system.
  3. Analytics Technology: All that data pouring in needs serious processing power. Advanced analytics tools help sort through the noise, turning raw data into clear, actionable insights that businesses can actually use to make smarter decisions and streamline operations.

The exact mix of devices and technologies used in an IIoT setup depends on the industry, specific goals, and business needs. This flexibility of industrial IIoT is what makes it so valuable across so many different sectors.

Security Matters

Security is one of the things that you need to think about if you’re going to start using the Industrial Internet of Things. The devices usually used to create an IIoT setup are not ordinarily intended to be connected with other devices and networks. They certainly can be, but you also have to accept that this brings with it an increased threat and risk level.

To ensure you don’t end up being hit by some sort of cyber hack or attack, you need to put in place the proper security measures. Basic things like strong password protection are key, but there needs to be a broader security strategy in place that can back you and your systems up.

Research has found that one of the main reasons making businesses hesitant to implement IIoT systems is the security worries that they have. That doesn’t need to be something that prevents businesses who would benefit from the Industrial Internet of Things from using it; it should just mean that extra security planning takes place.

Better Speed and Reliability for IIoT with OAS

The Industrial Internet of Things is a new revolution, but it requires an enormous amount of data to be transferred and stored, and only edge solutions can provide the performance, reliability, and speed required to do this efficiently.

Open Automation Software (OAS) has been so valuable in this type of efficient computing for accessing, logging, and displaying data closer to the source from which it’s generated – as well as for its speed, accuracy, and design philosophy as an open network that is easy to implement and cost-effective – that it is utilized for many high-volume systems, such as in Intel’s manufacturing plants and by the U.S. Navy on its nuclear submarines and aircraft carriers.

OAS and Its Many Applications In IIOT

With the OAS platform, almost every industry can find the best-in-class IIoT solutions for high-speed and reliable data logging and transfer, device management and control, and security across network communications.

Building Automation Systems (BAS) have been developed through the OAS Platform by customers for years, being used in commercial property for lighting, HVAC, safety, and security, and in ways that control building operations in more efficient, cost-productive solutions.

With the OAS Data Historian, time series data and event-based data can be collected over an entire building automation data spectrum to observe and act in predictive maintenance, detect downtime, and asset management for a level of advanced control more proficient than ever before in productivity and cost efficiency.

Open Automation Software offers complete operational visibility and connectivity between assets for businesses in the manufacturing industry. With real-time insights and accurate data, AI and human abilities are more efficiently merged, operational costs can be reduced, and customer/product interaction can be enhanced for enhanced marketing and product development.

IIoT integrated with the OAS platform offers endless possibilities. But its applications extend far beyond smart buildings and manufacturing. This system is being effectively implemented in a wide range of industries, such as in the:

  • Marine industry
  • Mining industry
  • Packaging industry
  • Shipping industry
  • Water industry
  • Chemical industry
  • Recycling and waste management industry
  • Telecommunications industry
  • Construction industry
  • Robotics industry
  • Transportation industry
  • And more

Getting Started with IIoT

If you want to get started with the Industrial Internet of Things, the first thing you’ll need to do is identify your goals and what it is you want to achieve. Every business and every project is unique, so only you can identify the goals and needs that have to be addressed as you implement your first Industrial Internet of Things system.

Some projects will be all about monitoring for efficiency or operational performance, others might be integrated with automation, and others will be about predicting future maintenance needs and minimizing downtime as much as possible. You need to identify the specific technologies that you want to make a part of your Industrial Internet of Things system.

From there, you should learn about how to store and analyze data if that’s something that you plan on being a part of your IIoT setup. It’s something that most businesses will want to do in some form or another. It’s also important to remember that it’s a process and that you can make tweaks and changes in the future.

Ready to put the power of the IoT to work for your business? Open Automation Software offers the secure, reliable, high-performance platform you need to build successful IIoT applications. Explore our platform today and start moving toward a smarter, more efficient future.

What is an IoT Gateway?

What is an IoT Gateway

IoT Gateways – Powering the Industrial Internet of Things

As the Internet of Things (IoT) expands, businesses find themselves faced with the challenge of integrating a multitude of devices and protocols. From modern sensors to legacy equipment, the need for seamless communication and data processing across different technologies is greater than ever.

This is where IoT Gateways come in. They are emerging as an essential component in building a robust IoT and for delivering computational power in edge computing scenarios. Edge computing distributes the load on a system by performing data processing at the data source, or “edge”, rather than relying on a central server for the bulk of the work. This is where an IoT Gateway comes in, such as the OAS Platform.

iot gateway

What is an IoT Gateway?

An IoT Gateway is a solution for enabling IoT communication, usually device-to-device communications or device-to-cloud communications. The gateway is typically a hardware device housing application software that performs essential tasks. At its most basic level, the gateway facilitates the connections between different data sources and destinations.

A simple way to conceive of an IoT Gateway is to compare it to your home or office network router or gateway. Such a gateway facilitates communication between your devices, maintains security, and provides an admin interface where you can perform basic functions.

But a gateway IoT industrial solution does much more. It integrates legacy systems, enforces security protocols, enables edge analytics, and ensures that only relevant, pre-processed data is sent to the cloud. This reduces bandwidth usage, improves response times, and enhances data quality.

What functions does an IoT gateway perform?

Today’s industrial IoT gateways are far more than just simple data pass-throughs. They’re intelligent edge devices that perform a wide range of essential functions that power modern industrial environments.

IoT Gateway feature set

versatile IoT Gateway may perform any of the following:

  • Facilitating communication with legacy or non-internet connected devices
  • Data caching, buffering and streaming
  • Data pre-processing, cleansing, filtering and optimization
  • Some data aggregation
  • Device to Device communications/M2M
  • Networking features and hosting live data
  • Data visualization and basic data analytics via IoT Gateway applications
  • Short term data historian features
  • Security – manage user access and network security features
  • Device configuration management
  • System diagnostics

These capabilities make IoT gateways an indispensable part of modern industrial systems, especially as Industry 4.0 and smart manufacturing become the norm.

IoT Gateways and Edge Computing

In edge computing, critical data processing occurs at the data source rather than in a centralized cloud-based location. A versatile IoT Gateway is the essential link in delivering edge computing power to technicians in the field or on the plant floor. IoT Gateways that come equipped with these capabilities are referred to as ’Smart’ Gateways.

The OAS Platform and Universal Data Connector is an example of a next-generation industrial IoT Gateway. It delivers both edge and cloud capabilities to support flexible deployment, seamless data integration, and real-time system responsiveness. From single-site operations to distributed global networks, the OAS Platform offers the scalability and performance needed to support complex IoT infrastructures.

Explore the OAS Product Ecosystem

Overview of IoT software products by Open Automation Software
Distributed Network Architecture implementing Edge Computing to provide accurate and scalable network solution for Industry 4.0 data.
How to publish data to Azure IoT Hub, AWS IoT Gateway, and MQTT Brokers.

What is SCADA?

What is SCADA
What is SCADA?

Supervisory Control and Data Acquisition (SCADA) is a control system architecture that includes various software and hardware elements such as computers, data communications, peripheral devices, and controllers that interface with machinery.

If you’re still wondering, “What is SCADA?” think of it as the digital nervous system for manufacturing plants, utilities, and other complex operations.

SCADA systems let operators manage equipment either on-site or remotely. They gather data from sensors, controllers, and human-machine interfaces (HMIs), giving teams a clear view of what’s happening and helping them respond quickly when needed. Whether you’re overseeing a factory floor or a city’s water system, what is a SCADA system if not a key piece of today’s automation puzzle?

Define SCADA: Core Functions and Architecture

To define SCADA, it helps to start with the basics. At its core, SCADA is all about four main things:

  • Supervising industrial equipment
  • Controlling operations remotely
  • Gathering real-time data
  • Storing and analyzing historical trends

A full SCADA system typically includes these key components:

  • Sensors and Inputs: Pick up real-world data from machines and environments.
  • PLCs and RTUs: Convert and send that data where it needs to go.
  • HMIs: Provide a user-friendly way for people to interact with the system.
  • Data Historians: Keep a detailed record of everything for tracking and analysis.

Each part works together to keep things running smoothly, catch problems early, and help operators make smart decisions fast.

What Does a SCADA System Look Like?

Most SCADA architecture consists of programmable logic computers (PLCs) or remote terminal units (RTUs). These are systems that can communicate with different objects within a factory or manufacturing plant. The information is then sent to computers with SCADA software, which can then process and display the information. This can be used to trigger automated actions or human interventions.

For example, a SCADA system can be configured to alert an operator if multiple sensors are failing or systems are acting outside a defined margin of error. The operator can remotely pause the processes involved and then use the SCADA system data to determine the cause of the issue.

Once the operator has reviewed the data and discovered the issue, they can manually resolve the fault or reboot the system to fix any potential errors. By looking at the log file for that particular faulty component, the operator can get a better understanding of what caused the problem and how it can be fixed in the future. That’s the power of SCADA in action.

By establishing systems like this, manufacturing and industrial plants can drastically improve performance, reduce the loss of product, and make it easier for operators to manage their plants with fewer employees.

Where Does OAS Fit In?

OAS plays a pivotal role in modern SCADA systems by offering:

With OAS, your SCADA architecture becomes smarter, faster, and easier to manage.

The Components of a SCADA System

To gain a better understanding of SCADA, it helps to understand the individual components that make up a system.

Inputs and Sensors

SCADA: Inputs and Sensors

Inputs and sensors are the first component of a SCADA system and are integral to the overall functionality. These inputs and sensors are essentially used to pick up data that is sent to various other components of the SCADA system.

Sensors can generally be anything that needs to be monitored. For instance, sensors can be used to detect pressure within a pipe, monitor temperatures, or even measure the direction of the wind.

Inputs involve anything that humans will touch or interact with. It can mean basic two-state on/off switches, a joystick that controls a robotic arm, or even adjust something more precisely, such as the temperature of another device.

These devices act as the eyes and ears of a SCADA system.

PLCs and RTUs

SCADA: PLC

PLCs and RTUs are used to collect data from inputs and sensors. They can then convert the data into information that is used by the SCADA system. It’s often translated into something much easier for operators to understand.

For example, a computer will only understand a switch as having two states: 0 and 1. PLCs and RTUs can be programmed to understand 0 as “Off” and 1 as “On”. This can then be used to display the state of a machine as on or off to the operator instead of 0 and 1, making it a bit easier to read. This is just a very simple example of how PLCs and RTUs translate data into something much easier to understand.

As another example, a rotating device could have hundreds of states depending on how much it has turned, and its current position could be expressed as a number based on a relative angle.

If that number increases, then it could indicate that the device is being rotated clockwise, and the PLC can be programmed to display this to the operator as “Right” or “Clockwise”, and vice versa as “Left” or “Anti-Clockwise” if the value is decreasing. This could help operators understand if an exhaust fan is currently pushing or pulling air, which would be useful for a ventilation system.

PLCs can also send commands to inputs. This can be automated, such as opening a relief valve if there is too much pressure in a system, or it can be sent manually by the user.

Alarms and Notifications

SCADA: Alarm Notifications

Alerts are vital in SCADA systems. If a threshold is breached, the system can alert staff, activate fail-safes, or even shut down equipment to prevent damage.

PLCs and RTUs can be programmed to automatically send notifications or raise alarms. For example, if the pressure built up in a tank or pipe is too much, then a notification will be sent to operators, and the PLC will automatically send a command to a defined relief valve to release pressure.

However, if the relief valve cannot be opened and a disaster is imminent, then the system will raise alarms and start processes to help contain the potential damage and prevent accidents from occurring.

Notifications can also be used to get an overall idea of how a system is performing. Operators can set up SCADA notifications to give them a general idea of how the plant is performing at certain times of the day. This will help the operator check if the plant is performing well and will give them an idea of what areas to inspect if needed, or if they can focus on other tasks.

Human-Machine Interface (HMI)

SCADA: HMI

An HMI tends to be a display that can be interacted with using various inputs like a keyboard, mouse, or custom buttons. The information is often displayed as numbers, but it can also be programmed to interpret data graphically as well. It can also be connected to cameras that will display the device or component that the system is monitoring.

For instance, an HMI could display a picture of a tank in a facility that is storing some kind of liquid. The HMI could display graphs showing the current volume within the tank and also contain controls that could be used to empty the tank or prevent it from losing volume.

In short, an HMI is typically used to analyze the information, but it can also be used to make data-driven decisions to optimize the production process and prevent further loss of a product should an error occur.

Historian

The final component of a complete SCADA system would be the data historian.

A historian is responsible for storing and logging all of the data that the SCADA system collects. It also records logs for certain actions that take place within the system, such as activating certain machines or sending commands to inputs from an HMI.

The purpose of the historian is to log everything that happens with the system and also create historical data for certain processes, plants, and systems. Historian systems typically sync with an online system so that operators and even shareholders can access the data from anywhere. However, a historian can also be operated locally by running it from a server PC at the plant. This PC is connected to the SCADA network and records everything that happens within the plant.

The data can be used to create actionable reports by the operator, but it can also be used to create historical data that is given to shareholders to see the process of the plant and its overall effectiveness. Historical data can also be used to identify the cause of an accident that led to a loss of product or an employee injury.

Who Uses SCADA?

SCADA is mainly used by industrial organizations and manufacturing plants that use complicated and intricate machinery to produce a large number of products or perform multiple processing tasks at once. The purpose is to help maintain large and efficient systems by recording data from multiple sensors and devices that can be used to mitigate downtime.

SCADA systems work mainly in these scenarios, but their application can be modified to be used in a number of different industries. At its core, SCADA is just a system to monitor multiple PLCs and RTUs that are being fed with data from sensors and manual inputs. In that sense, SCADA can be applied to a variety of different industries and use cases as long as there is a need to collect, compile, and analyze large sets of data at once.

As of now, SCADA systems are critical in industries such as:

  • Energy and power generation
  • Food and beverage
  • Manufacturing
  • Recycling
  • Oil and gas
  • Transportation
  • Building management
  • Water and wastewater

These are major industries that make full use of SCADA by deploying hundreds or potentially thousands of sensors and manual input devices that provide data to PLCs and RTUs.

From large industrial plants to small-scale operations like supermarket refrigeration, SCADA adapts to virtually any use case that demands monitoring and automation.

Even smart homes can use mini SCADA systems to manage climate control. For example, temperature sensors throughout the home can feed data into a controller that turns HVAC systems on or off to maintain comfort.

As you can see, SCADA systems have multiple applications on both a large industrial scale and a smaller home scale. However, its primary purpose is for use in large industrial and manufacturing operations.

SCADA Compatibility and Industry Standards

A control system architecture is only as useful as the compatibility it offers. While the concept of SCADA is simple to understand, the components used to create one need to work in harmony.

Open Automation Software’s Universal Data Connector is a great example of a SCADA component that is essential for gaining unparalleled access to industrial operations and enterprise data.

The OAS Platform supports data transport from any data source to any destination. It supports a wide variety of PLCs from reputable brands such as Allen Bradley and Siemens, and it can move data between popular cloud-based IoT services such as AWS, Azure, and MQTT brokers and clients.

For a SCADA system to be effective, flexible, and customizable, it needs to support multiple platforms, connectors, and tools. The core of any world-class SCADA system is in the connectivity between the different PLCs, RTUs, and databases. With effective automation solutions, you’ll find it much easier to manage your operations and optimize them as much as possible.

Contact Open Automation Software Today

The OAS Universal Data Connector gives operators complete access to industrial operations and data. Download the OAS Platform today or schedule a live interactive demo. Don’t hesitate to get in touch to learn more about the OAS Platform and how it can transform your SCADA system.

What is MQTT? Definition, Protocol Basics, and Real-World Uses

MQTT-icon

MQTT Definition

MQTT-icon

MQTT, short for Message Queuing Telemetry Transport, is a lightweight messaging protocol that makes it easy for devices to communicate, even when network conditions aren’t ideal. It was originally created by IBM for machine-to-machine (M2M) communication and has since become an open standard that’s widely used in Internet of Things (IoT) applications.

Using a client/broker setup, the MQTT protocol is great for small, low-power devices with limited memory or bandwidth. Its small packet size and low power use make it a smart choice for situations where reliable communication is needed, even over spotty or expensive networks.

What is MQTT used for?

A common application is to use this protocol on hundreds or thousands of remote devices that may have battery or solar power and be utilizing cellular or other limited or expensive communications.

Because of the small packet size, the overall bandwidth usage is low compared to other common protocols. Even with limited connectivity, the client/broker architecture is an excellent choice.

The remote device connects to the broker when possible and publishes its topics. The broker then notifies any client that has subscribed to that topic. This eliminates the need to constantly poll the device for changes, thus reducing the network usage.

Real-World Example: Why MQTT Matters

Let’s use a simple example of a remote site where you want to know if someone entered a building. With a traditional polling system, your app might check the sensor every second, which means the device has to stay alert and connected all the time. That drains power fast and racks up data costs, especially if there’s no wired internet nearby.

MQTT handles this much more efficiently. The device only sends a message to the broker when something actually changes. It’s a lightweight, low-power way to keep data flowing without wasting energy or bandwidth. The MQTT broker then alerts any subscribed clients, so you’re still getting the info you need, just without the constant back-and-forth.

Connecting to MQTT

MQTT-concept

The MQTT protocol is supported across a wide range of platforms, including Windows, Android, iOS, and macOS. You can quickly get started using readily available MQTT client applications that allow you to connect, subscribe, and publish to MQTT brokers within minutes.

In addition, MQTT is compatible with many programming languages, making it easy for developers to integrate MQTT capabilities into their applications.

To learn more about MQTT & other integrated systems, contact your OAS Sales Representative toll-free in the US on 1-800-533-4994 or for international enquiries call 1-303-679-0898.

Open Automation Software as an MQTT Client

Open Automation Software (OAS) functions as a full-featured MQTT client, capable of both publishing data to and subscribing to data from any MQTT broker. This makes it simple to collect, process, and distribute data from remote devices, whether you’re monitoring industrial sensors, PLCs, databases, or web-based inputs.

OAS also enables users to:

  • Visualize real-time and historical data.
  • Set up alarms and notifications via email, SMS, or voice.
  • Share non-MQTT data sources (like Excel, .NET applications, or SQL databases) with MQTT-compatible devices.

In short, OAS acts as a powerful bridge between your existing systems and modern IoT infrastructure.

What is Modbus? A Guide to Industrial Communication

What is Modbus?

In industrial automation, seamless device communication is critical. One of the most trusted tools facilitating this connectivity is Modbus, a protocol that has stood the test of time. But what is Modbus, and why is it still widely used in modern industrial systems?

In this guide, we’ll break down the Modbus communication protocol, how it works, and where it’s commonly applied. Plus, we’ll cover how Open Automation Software makes integration easier than ever.

What is Modbus?

Modbus is a serial communication protocol developed by Modicon in 1979 to enable communication between programmable logic controllers (PLCs). It allows multiple devices connected to the same network to exchange information in a standardized format.

In simple terms, Modbus enables a Modbus Master (usually a central controller or computer) to request data from or send instructions to Modbus Slaves (sensors, actuators, or other peripheral devices). A typical setup includes one Master and up to 247 Slaves, each with a unique address.


A Brief History of Modbus

To understand what the Modbus protocol is all about, it’s helpful to look at its origins. In the late 1960s, Modicon developed the first PLC at General Motors’ request. By the late 1970s, the need for these devices to communicate became apparent. While multiple companies attempted to develop their own solutions, Modicon’s release of the Modbus protocol became a milestone in automation history.

By making Modbus an open standard, Modicon allowed developers worldwide to integrate the protocol into their hardware and software products without licensing fees. This led to its wide adoption across industries, where it remains popular due to its simplicity and reliability.

Common Uses for Modbus

So, what is a Modbus protocol used for in real-world scenarios?

Modbus is an open protocol platform, meaning manufacturers can build their equipment free of charge without needing to pay royalties. It has become a standard communications protocol in the sector, and it is a common means for connecting industrial electronic devices.

Modbus is commonly used in industrial environments to connect instruments such as temperature sensors, flow meters, and human-machine interfaces (HMIs) with control systems. Its primary function is to transmit signals from control devices to centralized controllers or data acquisition systems.

For instance, a Modbus-enabled temperature sensor might collect readings and send them to a PLC, which then makes adjustments or triggers alarms based on that data.

Understanding How Modbus Works

Modbus is generally transmitted over serial lines between devices. The most straightforward setup involves a single serial cable that is connected to serial ports on two devices: a Slave and a Master.

The data will be sent as a series of zeroes and ones called bits. Each bit is sent as a voltage. Zeroes are sent as positive voltages, and ones are sent as negatives. The bits are sent in very high quality. A standard transmission speed is typically 9600 baud (bits per second).

The Modbus Organization, Inc.

Since 2004, The Modbus Organization, a non-profit group of users and developers, has overseen the evolution of Modbus. Their goal is to promote widespread adoption of the protocol by supporting education, development, and interoperability standards.

Modbus components on circuit board

Types of Modbus Protocols

Today, Modbus exists in several variations to support different applications and media types. The three most commonly used are:

Modbus RTU

Modbus RTU is a type of serial Modbus. This transmission mode encodes messages as bytes that are sent one after the other without any spaces between them, though a 3-½-character space inside acts as a delimiter between messages.

For each eight-bit byte: one start bit, eight data bits, one bit for parity, and one stop bit are sent, for a total of 11 bits per byte. Every Modbus RTU message is ended with an accompanying error checksum in what is called a cyclic redundancy check (CRC).

Modbus ASCII

The Modbus ASCII protocol initiates every message with a colon “:” character. An ASCII carriage return/line feed (CR/LF) character ends every message transmission. This provides variability in what is being communicated with more spacing in between the bytes, giving it the ability to transmit through certain modems.

ASCII characters are used to communicate this data. For each eight–bit byte, one start bit, seven data bits, one bit for parity, and one stop bit are sent, for a total of 10 bits. Modbus ASCII messages are ended with an error checksum called a longitudinal redundancy check (LRC).

There are pros and cons to be weighed when using either of these two types – Modbus RTU and Modbus ASCII – as Modbus ASCII is much simpler to read by just looking at the message, but the RTU messages are much smaller, allowing for an enormous amount of data to be communicated in the same amount of time. Modbus RTU is used most commonly.

Modbus TCP

Modbus TCP is different in that it does not require a checksum, but is basically the RTU protocol running on Ethernet and a TCP interface. The TCP port 502 is reserved for Modbus, while the new Modbus/TCP Security uses Port 802.

Much more on this can be found at Modbus.org.

Modbus Protocols and IoT

Despite its age, Modbus remains a cornerstone of industrial control systems. It’s used in PLCs, distributed control systems (DCS), variable frequency drives (VFDs), and more.

With the rise of IoT (Internet of Things) and IIoT (Industrial IoT), Modbus has proven adaptable. It continues to power real-time automation for everything from factory machines to smart thermostats.

Rather than being replaced by newer technologies, Modbus is increasingly integrated into them, providing a bridge between legacy systems and modern IoT platforms.

There are now several software companies providing solutions for Modbus and IoT integration, but only one of them has the experience and reliability to liberate your data with unparalleled connectivity: Open Automation Software.

Open Automation Software Modbus IoT Data Connector

The OAS Modbus IoT Data Connector provides a direct connection to Modbus slave devices and the ability to host data to Modbus masters with the built-in Modbus Driver Interface. The Modbus Driver Interface supports communications over Ethernet and Serial interfaces with Modbus TCP, Modbus RTU, and Modbus ASCII protocols.

With Modbus Automation Software from OAS, businesses will find the easiest process for adding Modbus communications in Real-Time Automation on the market – with one click of a button! Three of the most widely used Modbus Protocols can then be seamlessly implemented – Modbus TCP, Modbus RTU, and Modbus ASCII protocol – onto both Ethernet and Serial Port interfaces with the Modbus Master connection. Modbus TCP over Ethernet and Modbus RTU and ASCII over Serial Ports with the Modbus Slave connection.

After a quick and easy setup, the communication speeds you experience while running multiple Ethernet connections are at the fastest possible, with update rates averaging 15 milliseconds per packet. Data from anywhere, to anywhere, is sent in real-time with direct access to Modbus-compatible devices. A PC and a standard internet connection are all that is required to host live Modbus data. Remote data logging is also made highly secure, and backup devices can be optionally defined with Automated Communications Failover.

The ease of access for Modbus IoT Data Connector isn’t limited to only a few operating systems, either. Supported systems include Windows PC/Server, Windows Embedded, Windows IoT, Linux Server, Virtual Machines (Win/Linux), Raspberry Pi 4, and Docker Containers (Win/Linux).

The OAS Platform: Full Connectivity

Open Automation Software began 28 years ago with the philosophy that user interfaces and database archiving software should be open, far-reaching, and provide easy implementation and cost-effectiveness for consumers. An Open Architecture plan allows unparalleled customization with open accessibility to third-party reporting systems, .NET applications, web interfaces, open standards like OPC UA and MQTT, and even remote Microsoft Excel workbooks.

The nature of the OAS Platform empowers you with flexibility. Purchasing the Universal Data Connector in combination with connectors for devices, databases, applications, IoT services, and more will give you the most powerful and versatile framework for enterprise systems integration. The built-in compatibility with other developer tools and APIs gives you an unlimited number of options for customization and automation.

The full range of products include:

Universal Data Connector
The core of the OAS Platform, the UDC is a Windows based program allowing it to be implemented in several different ways. Enable data connectivity, server-to-server networking, and more.

Data Historian
Log data in open format to MS SQL Server, Oracle, mySQL, PostgreSQL, InfluxDB, MongoDB, SQLite, MariaDB, Access, SQL Azure, Amazon Aurora, Amazon RDS, and CSV files.

Alarm Logging & Notification
Log events to open databases, and send notifications via SMS, email, and voicemail.

Device & Data Connectors
Read and write data to Allen Bradley, Siemens, and Modbus devices, Universal Drivers, OPC, OPC UA, databases, and Excel. Read MTConnect.

IoT Connectors
Connect to cloud-based IoT gateways such as AWS, Azure IoT, and MQTT Brokers.

Visualization Tools
Build custom Visualizations, User Interfaces, HMIs and Dashboards for Windows, web, as well as native iOS and Android devices.

SDKs & APIs
Develop custom automation apps for Windows, web, and mobile devices. Integrate with .NET and REST APIs. Build custom integrated device drivers.

Networking Features
Provides the most robust, scalable, and reliable distributed networking platform for IIoT solutions.

IIoT Edge Computing vs. Cloud Computing

edge-computing

As enterprise infrastructures evolve and Industrial Internet of Things (IIoT) systems become more distributed, businesses must decide between edge computing vs. cloud computing, or how to best combine the two. Understanding the nuances of cloud computing and edge computing can help you build a more efficient, responsive, and cost-effective IIoT platform.

What is Edge Computing?

In edge computing, critical data processing occurs at the data source rather than in a centralized cloud-based location. Other terms sometimes used to describe edge computing include ‘fog’ computing and grid computing.

The Industrial Internet of Things (IIoT) relies on data from many sensors, controllers, and attached servers, often across multiple, remote locations. Certain data processing tasks are best performed ‘at source’ rather than in the cloud.

What is Cloud Computing?

Cloud computing refers to the delivery of computing services such as servers, storage, databases, networking, software, and analytics over the internet. Instead of processing data locally, businesses send it to centralized data centers in the cloud for handling.

This model allows for scalable computing power, centralized management, and advanced analytics capabilities. In IIoT environments, cloud platforms are well-suited for storing large datasets, running machine learning models, and powering enterprise-wide dashboards.

Why Cloud-Only Architectures Fall Short for Real-Time IIoT Data

When it comes to cloud vs edge computing, it’s important to understand that cloud solutions alone are not always ideal for real-time IIoT applications.

Here’s why:

  • Traditional cloud computing pushes data to a central server and pulls it back down to clients, which introduces latency.
  • For real-time IIoT use cases, this delay can mean unreliable data delivery and lower accuracy.
  • Bandwidth costs escalate as large volumes of data are transferred to the cloud.
  • Network outages or low-quality connections impact performance and availability.

While cloud computing is effective for certain workloads (like document storage or content delivery) it lacks the responsiveness required for time-sensitive industrial applications.

Edge vs Cloud Computing: A Side-by-Side Comparison

Understanding the different strengths of edge and cloud computing helps clarify when to use each architecture.

Edge Computing Capabilities

  • Basic data visualization
  • Basic data analytics and short-term data historian features
  • Data caching, buffering, and streaming
  • Data pre-processing, cleansing, filtering, and optimization
  • Some data aggregation
  • Device to Device communications/M2M

Cloud Computing Capabilities

  • Complex analytics
  • Big Data mining
  • Sources of business logic
  • Machine learning rules
  • Advanced visualizations
  • Long term data storage/warehousing

Real-World Example: Edge Computing in Action

Imagine a field technician servicing a remote wind turbine. With edge computing, they can instantly access key diagnostic data, even in areas with limited cellular connectivity. The turbine’s local IIoT gateway provides the required compute power on-site.

More in-depth analysis and historical trend reports, however, are handled later via the cloud computing platform. This hybrid approach ensures speed at the edge and analytical power in the cloud.

The Business Case for Edge Computing

The business case for edge computing is driven by cost savings in computing power and bandwidth as well as its ability to provide faster and more accurate access to automation data at its source.

For many IIoT applications, edge computing is the reliable and cost-effective way to ensure data quality, freshness, accuracy, and speed of delivery. Other factors, such as the quantities of data transferred and bandwidth costs, will determine the ultimate mix of cloud and edge services.

 

Cloud Computing vs. Edge Computing: Which Is Right for You?

Edge computing and cloud computing are complementary architectures that come together to create powerful IIoT platforms. One does not replace the other.

The best IIoT solution for your business will likely be a mix of the two architectures. Deciding which computing tasks should happen in the cloud or at the edge requires careful analysis of your business needs. Software providers like Open Automation Software are ideally placed to provide the software infrastructure for creating a world-class IIoT solution, as well as providing advice on how to best design your edge computing platform.

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IIoT Sparkplug B

Open Automation Software’s latest update now includes a new interface for Sparkplug B Edge of Network Nodes and Host Applications.

Sparkplug B IIoT

The OAS IIoT platform has recently added support for Sparkplug B as an Edge Network Node and a Host Application. Sparkplug B is an industry-standard that enables common topic and payload definitions for MQTT data transport.

As an Edge of Network (EoN) Node for Sparkplug B, OAS can offer bi-directional communications to all tags in the OAS Engine using any combination of Sparkplug B identifiers. This is achieved using four new properties to define the hosting Group ID, Edge Node ID, Device ID, and Metric name in each OAS tag.

This interface supports all data sources of OAS, including Allen Bradley ControlLogix, CompactLogix, GuardLogix, Micro800 MicroLogix, SLC 500, PLC-5 PLCs, Siemens S7 controllers, Modbus TCP, RTU, and ASCII masters and slaves, OPC UA clients and servers, OPC DA clients and servers, MTConnect, custom MQTT payloads, .NET interfaces, REST API, and databases.

In addition, OAS provides a Sparkplug B Host Application interface to control and consume data from the EoN Node to receive and extract NDATA and DDATA automatically to tag values and write data to EoN Node Metric values through NCMD and DCMD Sparkplug B commands. OAS tags can also be created automatically based on the NBIRTH and DBIRTH data received from an EoN Node.

You can connect to any third-party MQTT Broker that supports MQTT V3.11 or V5.0, including HiveMQ, Mosquitto, or OAS built-in MQTT Broker. OAS supports Sparkplug B versions 2.2 and 3.0.

For step-by-step instructions for setting up Sparkplug B communications, watch the video below:

Supported Data Sources

  • Allen Bradley
  • Modbus
  • Siemens S7
  • OPC UA
  • OPC DA
  • MTConnect
  • Kafka
  • Excel
  • AWS IoT
  • MQTT
  • Rest API
  • .NET API
  • Databases
  • Other IoT Endpoints

Refer to “Getting Started with Sparkplug B EoN Node” for a step-by-step guide on using OAS as a Sparkplug B Edge of Network Node. Similarly, “Getting Started with Sparkplug B Host Application” provides detailed instructions on using OAS as a Sparkplug B Host Application.

You can also utilize the OAS Data Route feature to enable server-to-server data transport and additional protocol translation, including Sparkplug B EoN Node to EoN Node data transfer.

Advanced Network Communications for Open Automation Software

Advanced Networking

OAS v17 … Stronger, Lighter, Faster

Open Automation Software has optimized it’s encryption methodology in Version 17 and in a nutshell it is stronger, lighter and faster!  Data encryption may not be an exciting topic for everyone but fortunately for our users, the developers at OAS get really excited about it! 

Security needs to be built in, not bolted on.  Open Automation Software has spent a good part of this year re-writing it’s entire encryption algorithm from the bottom up.  Every aspect of the software includes this change and has been meticulously tested.  The results exceeded our own expectations.

  • Packet sizes are 3-9 times smaller depending on the type of data being transported, resulting in increased speed.

  • The time to encode a packet is now up 2 to 8 times faster while decoding can be up to 10 times faster than previous versions of OAS.

  • Additional encryption methods implement a unique seed value for each client connection to encrypt the user credentials, removing clear text for the username and eliminating the possibility of sniffing user credentials.

  • Client and server packet handshake with a 64-bit unique identifier. 

  • Live Data Cloud networking is now 6 to 18 times faster as previous versions, almost as fast the updated basic networking.

Version 17 of OAS also includes pre-configured security groups and mandatory use of security features. 

A Closer Look at OAS V17 Security Hardening

OAS V17

Security has always been a top priority at Open Automation Software and we are continually reviewing and enhancing our security practices to stay current with the latest technology. Version 17 of the software has included some next-level enhancements to ensure that we are THE platform you will want to trust your SCADA system to.

Secure software relies both on the developer and the end user. Security must be built into the software foundation and the end user must use the security features provided. OAS has always provided that secure foundation and Version 17 has upped the game and also made end user utilization of security features a priority.

Pre-Configured Security Groups

The software now loads with a pre-configured Admin Security Group.  Upon installation, users are prompted to create an admin user and access is prohibited until that admin user has been created.  Security is now only configurable by an authenticated user with assigned access to this feature.  The Default security group, for unauthenticated users, is now locked down allowing only limited functionality.  OAS has always allowed the creation of multiple Security Groups where administrators can secure any feature, even down to the individual tags and tag groups.  This remains and continues to allows end users to customize security to meet their needs. 

User Credential Encryption

User Credential Encryption

Version 17 of OAS has widened encryption strategies to include database authentication, user credentials and all configuration calls.  V17 implements a new encryption methodology that allows it to provide extended encryption utilizing AES encryption while increasing the speed of data transfer.

Secure Client Server Handshaking

Secure Client Server Handshaking

Each client server transaction now includes a unique 64-bit identifier allowing OAS to securely transport your data.

Data Packet Encryption

New Data Packet Encryption

In addition to broadening the scope of encryption, V17 of OAS had entirely reworked its encryption process.  Data packets are now 3-9 times smaller allowing for much faster transfer speed.  This new method provides superior security and gets it done faster!

Security Update for Open Automation Software

Open Automation Software has Released OAS Version 17 with Security Enhancements.

Open Automation Software has been updated to notify users to setup security on the OAS Engine if the default security has not been updated to protect against unauthorized access. OAS version 17 also includes ironclad protection from packet spoofing, faster byte stream compression, updated encryption, and new client server handshaking for packet validation.

All OAS client interfaces have been updated to include this new transport including all .NET assemblies, OAS Configure application, Excel Connector, and service to service communications for Windows and Linux.

To secure older versions of OAS, follow the instructions here: Getting Started – Security

Secure Client Server Handshaking
Each data packet now includes an ironclad transport that cannot be reproduced externally, both the client and the server will reject the packet if replicated from a sniffed packet. Each packet from client to server is unique and must pass an algorithm verification from previous transport for validation.

User Credentials Encryption
The data within the byte stream no longer shows the username as clear visible text. An updated encryption method implements a unique seed value for each client connection to encrypt the user credentials.

New Data Packet Encryption
The data within the packet is encrypted with a different method that prevents all data within the packet from being extracted with sniffing the network connection.

Security Access
The default installation now automatically adds an Admin security group to make it very easy to assign an administrator user. Users are also prompted to disable the Default security group after the administrator user is created. Security Groups and Users configuration can no longer be accessed with the default credentials after an Admin user is created. Users are now prompted to setup security when connecting to the service. REST API calls for configuration access is no longer permitted under the default security with a blank username and password.
View the Getting Started – Security guide to setup security for all versions of OAS to protect against unauthorized access to configurations, live data, and historical data.