IIOT-3

Unit III IIoT Architecture

Overview of IIOT components including Sensors, Gateways, Routers, Modem, Cloud
brokers, servers and its integration, WSN.
Architecture of Industrial IoT: Business Model and Reference Architecture of IIOT, Industrial
Internet Architecture Framework (IIAF).
Industrial IoT- Layers: IIoT Sensing, IIoT Processing, IIoT Communication, IIoT Networking

Sensors
A sensor is a device or component that detects changes in the environment and
converts them into signals or data that can be measured and processed.
Sensors act like the “sense organs” of a machine, helping it to perceive the world
around it.
They are widely used in everyday life, from smartphones and cars to industrial
equipment and medical devices.

How Do Sensors Work

1. Sensing: The sensor detects a physical input (e.g., light, temperature, pressure,
motion, etc.).
2. Conversion: It converts the detected input into an electrical signal (analog or digital).
3. Output: The signal is sent to a processor or system for further action or monitoring.

Types of Sensors

1. Temperature Sensors: Measure temperature changes.

Examples: Thermometers, thermostats.
Applications: Air conditioners, refrigerators, weather monitoring.
2. Motion Sensors: Detect movement or acceleration.
Examples: PIR (Passive Infrared) sensors, accelerometers.
Applications: Automatic doors, fitness trackers, vehicle safety systems.
3. Light Sensors: Detect light intensity or changes in brightness.
Examples: LDR (Light Dependent Resistor), photodiodes.
Applications: Automatic streetlights, smartphones' brightness adjustment.
4. Pressure Sensors: Measure force or pressure exerted on a surface.
Examples: Barometers, pressure pads.
Applications: Weather stations, car tire pressure monitoring.
5. Sound Sensors: Detect sound waves and convert them into signals.
Examples: Microphones, ultrasonic sensors.
 Applications: Voice recognition systems, home automation.
6. Gas Sensors: Detect the presence or concentration of gases in the environment.
Examples: Carbon monoxide detectors, methane sensors.
Applications: Industrial safety, air quality monitoring.
7. Proximity Sensors: Detect the presence of nearby objects without physical contact.
Examples: Infrared sensors, ultrasonic sensors.
Applications: Parking sensors in cars, touchless faucets.
8. Humidity Sensors: Measure the amount of moisture in the air.
Examples: Hygrometers.
Applications: Weather stations, greenhouses.

Applications of Sensors

Daily Life: Smartphones (touch, light, and motion sensors), home automation
(temperature and motion sensors).
Healthcare: Glucose monitors, heart rate sensors, and X-ray machines.
Automotive: Parking assistance, airbags (pressure sensors), and fuel monitoring.
Industry: Robots (proximity sensors), assembly lines, and safety systems.
Environment: Pollution monitoring, weather forecasting, and disaster management.

Gateways
A gateway is a device or system that connects two different networks, enabling them to
communicate and share data.
Think of it as a bridge or translator between networks that speak different "languages."
Gateways ensure smooth communication between systems, even if they use different
protocols, architectures, or data formats.
An IIoT gateway is a specialized device that connects different industrial equipment and
systems to the internet.
It collects data from sensors and machines on the factory floor, processes this data
locally, and then sends it to the cloud for further analysis.

Functions of IIoT Gateways

1. Data Collection: Gateways gather data from various sensors and devices, such as
temperature sensors, pressure sensors, and machinery. This data is crucial for
monitoring operations and making informed decisions.
2. Data Processing: Instead of sending all raw data directly to the cloud, gateways
process the data locally. They filter out unnecessary information and perform
preliminary analysis to reduce the amount of data that needs to be transmitted.
3. Protocol Translation: Different devices may use different communication protocols
(the rules for how data is transmitted). Gateways can translate between these
protocols, allowing devices that speak different "languages" to communicate effectively.
 4. Real-Time Monitoring: By processing data at the edge (closer to where it is
generated), gateways enable real-time monitoring and quick responses to changes in
conditions. This is particularly important for critical operations where delays could lead
to issues.
5. Security: IIoT gateways enhance security by acting as a barrier between industrial
networks and the internet. They can include features like firewalls and encryption to
protect sensitive data from cyber threats.
6. Machine-to-Machine Communication: Gateways enable machines to communicate
with each other without human intervention, facilitating automation in industrial
processes.
7. Local Storage: Gateways can store some data locally, which acts as a buffer before
sending it to the cloud. This helps manage bandwidth usage and ensures that important
data is not lost during transmission.

Types of IIoT Gateways

1. Ethernet Gateways: These gateways connect devices using wired Ethernet

connections, providing reliable high-speed communication.
2. Wireless Gateways: These use wireless technologies like Wi-Fi, Zigbee, or cellular
networks (4G/5G) for connectivity, making them ideal for environments where wiring is
impractical.
3. Multi-Protocol Gateways: These support various industrial protocols (like Modbus,
PROFIBUS, etc.), allowing them to connect both modern and legacy equipment
seamlessly.

Applications

1. Manufacturing: Connect machines and sensors for real-time monitoring, predictive

maintenance, and automation.
2. Energy & Utilities: Monitor equipment and optimize performance in power plants and
smart grids.
3. Transportation: Aid fleet management by tracking vehicle health, fuel usage, and
driver behavior.
4. Smart Cities: Support infrastructure like traffic management and environmental
monitoring.
5. Healthcare: Link medical devices for patient monitoring and equipment tracking.

Routers
Routers are critical components in the Industrial Internet of Things (IIoT), serving as the
backbone of communication within industrial networks.
They manage the flow of data between devices, sensors, and cloud services, ensuring
that information is transmitted efficiently and securely.
 An IIoT router is a networking device that directs data packets between various IoT
devices and the internet.
Unlike traditional consumer routers, IIoT routers are designed specifically for industrial
applications, providing robust connectivity and enhanced security features suitable for
challenging environments.

Functions of IIoT Routers

1. Data Packet Routing: Routers receive data from connected devices and determine the
best path for this data to travel to its destination, whether that’s another device on the
local network or a cloud server.
2. Connectivity: They connect local networks (like those in factories) to the broader
internet, allowing devices to communicate with external systems and cloud services.
This connectivity can be wired or wireless, depending on the application.
3. Protocol Handling: IIoT routers can support multiple communication protocols (such
as MQTT, CoAP, and HTTP), enabling interoperability between different devices and
systems that may use different methods for data exchange.
4. Network Management: Routers often come with management features that allow
network administrators to monitor traffic, configure settings, and troubleshoot issues
remotely. This capability is essential for maintaining operational efficiency in industrial
settings.
5. Security: Security is a major concern in IIoT environments due to the potential risks of
cyberattacks. IIoT routers typically include advanced security features such as firewalls,
VPN support, and intrusion detection systems to protect sensitive data and devices
from unauthorized access.
6. Data Filtering and Prioritization: Some routers can filter incoming and outgoing data
based on predefined rules, prioritizing critical information while minimizing bandwidth
usage for less important data.

Applications of IIoT Routers

1. Manufacturing: Connecting factory machines, sensors, and control systems for real-
time monitoring and predictive maintenance.
2. Smart Cities: Connecting infrastructure like streetlights, traffic sensors, and
environmental monitors to centralized systems for better city management.
3. Transportation: Tracking and managing fleets of vehicles or shipments, ensuring
goods are transported efficiently and safely.
4. Energy: Monitoring energy consumption in factories, buildings, and power grids to
optimize usage and reduce costs.

Modem
A modem (short for modulator-demodulator) is a device that converts digital data from
computers or sensors into analog signals suitable for transmission over communication
 lines, such as telephone lines or cellular networks.
Conversely, it also converts incoming analog signals back into digital data that devices
can understand. In the context of IIoT, modems are essential for enabling devices to
communicate with cloud services or other devices over long distances.

IIoT Modem Working

1. Data Collection: Industrial machines, sensors, or controllers collect data (e.g.,

temperature, pressure, speed).
2. Data Transmission: The IIoT modem takes this data and transmits it through a
communication network (such as cellular, Wi-Fi, or Ethernet) to a central server or
cloud.
3. Data Reception: On the receiving side, the data can be analyzed, monitored, and
stored for further processing, insights, or real-time actions.

Types of IIoT Modems

1. Cellular IIoT Modems **: Connect industrial equipment to the internet using cellular
networks (4G, 5G, or even 3G).
Applications: Remote locations, fleet management, energy monitoring.
2. Wi-Fi IIoT Modems: Provide wireless internet access over local Wi-Fi networks to
connected devices.
Applications: Factories, warehouses, and connected environments.
3. Ethernet IIoT Modems : Use wired Ethernet connections for stable, high-speed
communication between devices.
Applications: Automation, control systems, and heavy industrial environments.
4. Satellite IIoT Modems: Enable communication in remote locations that do not have
access to cellular or Wi-Fi networks.
Applications: Remote infrastructure, disaster recovery, remote monitoring.

Applications of IIoT Modems

1. Manufacturing: Connecting machines on the factory floor to monitor performance,

detect faults, and optimize production lines.
2. Energy: Monitoring solar panels, wind turbines, or smart grids for performance,
maintenance, and efficiency.
3. Agriculture: Remote monitoring of soil conditions, irrigation systems, and livestock
health using sensors connected via IIoT modems.
4. Transportation and Logistics: Fleet management, tracking of goods, and monitoring
vehicle conditions remotely via IIoT modems.
5. Oil and Gas: Connecting equipment and sensors on offshore rigs or remote pipelines
to monitor safety, performance, and predict maintenance needs.

Cloud brokers
 A cloud broker is a service that connects different cloud services and applications,
allowing them to communicate with each other.
They help manage and streamline data flows, ensuring that information is shared
efficiently and securely across different platforms.
In the context of IIoT, cloud brokers allow the integration of data from various sources—
like sensors, machines, and operational systems—into a unified platform for analysis
and decision-making.
They help organizations leverage multiple cloud services effectively without needing to
manage each service individually.

Functions of Cloud Brokers

Data Integration: They enable seamless communication between various types of

devices and different cloud systems.
Scalability: As IIoT networks grow (with more devices), brokers help scale the
communication by managing large amounts of data.
Data Management: Cloud brokers help organize, filter, and prioritize data before
sending it to the cloud, reducing overload and improving efficiency.
Security: Cloud brokers can provide a layer of security by encrypting data and
managing access control between devices and the cloud.
Protocol Translation: Converts data between different communication protocols (e.g.,
MQTT, CoAP, HTTP, OPC-UA).
Data Aggregation: Collects and combines data from multiple IIoT devices before
sending it to the cloud.
Real-Time Data Processing: Enables real-time data transmission and analysis for
immediate action or monitoring.
Device Management: Can monitor, manage, and configure IIoT devices remotely.

Applications of IIoT Cloud Brokers

1. Manufacturing: Collecting data from sensors in factory machines for real-time

monitoring and predictive maintenance.
2. Smart Agriculture: Connecting soil moisture sensors, weather stations, and irrigation
systems to optimize farming practices.
3. Energy Management: Integrating smart meters, grids, and energy storage systems to
optimize energy usage and reduce costs.
4. Supply Chain Management: Tracking inventory, shipments, and machinery in
warehouses to ensure efficient operations.

Servers and its integration

An IIoT server is a computing system that receives data from various connected
devices, processes it, and stores it for further analysis.
 These servers can be located on-premises or in the cloud (remote servers accessed
via the internet).
The choice between on-premises and cloud servers often depends on factors like data
security, processing needs, and operational requirements.

Functions of IIoT Servers

1. Data Collection: Collects data from IIoT devices (sensors, machines, etc.) in real-time.
This data can be related to temperature, pressure, speed, etc.
2. Data Storage: Stores the incoming data for later analysis, either on local edge servers
or in the cloud. The data may be stored in databases, data lakes, or other storage
systems.
3. Data Processing and Analysis: Analyzes the collected data to extract valuable
insights. For example, a server might analyze vibration data from a motor to predict
when it is likely to fail.
4. Decision Making: IIoT servers can automate certain decisions based on real-time
data. For example, if a sensor detects a temperature reading above the normal range,
the server might automatically shut down the machine to prevent overheating.
5. Integration with Other Systems: IIoT servers often need to integrate with other
industrial systems, such as Enterprise Resource Planning (ERP) systems, Maintenance
Management Systems (MMS), or Supervisory Control and Data Acquisition (SCADA)
systems, to provide a complete view of operations.

Integration of Servers in IIoT

1. Data Collection: Sensors deployed on machines collect data related to various

parameters (like temperature, pressure, etc.) and send it to gateways.
2. Data Transmission: Gateways aggregate this data and transmit it to the appropriate
server for processing—this could be either an on-premises server or a cloud server.
3. Data Processing and Analysis: Once the server receives the data, it processes it
using analytical tools to derive insights that can improve operational efficiency or
predict maintenance needs.
4. Feedback Loop: The processed information is then sent back to relevant systems or
applications for action—this could involve alerting operators about potential issues or
adjusting machine settings automatically based on real-time insights.
5. User Access: Operators can access this processed information through dashboards or
applications on their computers or mobile devices, allowing them to make informed
decisions quickly.

Benefits of IIoT Server Integration

Real-Time Monitoring: Allows for instant detection of issues, reducing downtime and
increasing productivity.
 Predictive Maintenance: Servers can analyze data to predict equipment failure before
it happens, saving money and reducing unexpected repairs.
Cost Efficiency: Optimizes operations, energy use, and labor costs by providing real-
time insights into machine performance.
Improved Decision Making: Helps management make informed decisions based on
comprehensive data and insights from across the factory or organization.

Challenges

Data Overload: Managing and processing massive amounts of data generated by IIoT
devices can be overwhelming.
Interoperability: IIoT devices and servers often use different communication
standards, making integration challenging.
Security Risks: As IIoT systems are connected to the internet, they are vulnerable to
cyberattacks, making strong security measures necessary.

WSN
Wireless Sensor Networks (WSNs) are crucial components in the Industrial Internet of
Things (IIoT), enabling the monitoring and collection of data from various environments
without the need for physical wiring.
A WSN (Wireless Sensor Network) is a network of small, battery-powered devices
called sensors that are wirelessly connected.
These sensors can detect things like temperature, pressure, humidity, light, or motion
and send this data to a central system for analysis.
In simpler terms, a WSN is like a group of "smart" sensors that communicate wirelessly,
providing real-time information from different places.

How WSNs Work

1. Data Collection: Sensor nodes continuously monitor their surroundings and collect
data based on their programmed parameters.
2. Data Transmission: The collected data is sent wirelessly from the sensor nodes to the
base station.
3. Data Processing: The base station processes this data and may send it to cloud
servers for further analysis or storage.
4. User Access: Users can access this processed information through applications or
dashboards for monitoring and decision-making.

Applications

1. Predictive Maintenance: By monitoring the condition of equipment in real-time, IIoT

can predict when machines are likely to fail, allowing for timely repairs before problems
occur.
 Example: Using vibration sensors to monitor a motor’s health. If vibrations exceed
normal levels, a repair is scheduled before failure.
2. Asset Tracking: IIoT with WSN helps track assets in real-time by using sensors on
machines, tools, or products.
Example: A warehouse uses sensors to track the location of inventory and
optimize its storage.
3. Energy Management: Sensors monitor energy consumption, and IIoT helps optimize
the energy use of factories or offices by providing real-time data.
Example: Using temperature sensors in an HVAC system to adjust heating and
cooling based on real-time needs, saving energy.
4. Quality Control: WSNs can be used to monitor environmental factors (such as
humidity or temperature) that affect product quality.
Example: A food production facility using humidity sensors to ensure products are
stored in the correct conditions.
5. Automation: With the help of sensors, IIoT allows systems to automatically adjust or
control machines based on real-time data, leading to more efficient operations.
Example: A robotic arm in an assembly line automatically adjusting its speed
based on the parts being produced.

Business Model and Reference Architecture of IIOT

1] Business Model

The IIoT Business Model revolves around how companies create, deliver, and capture
value using IIoT technologies. It focuses on transforming traditional industrial practices
into smart, connected systems.

Types of Business Models

1. Product-Based Model: The company sells physical or digital products to customers.

Revenue: Earned through the sale of products.
Example: Apple selling iPhones, Samsung selling TVs.
2. Subscription Model: Customers pay a recurring fee to access a product or service.
Revenue: Earned through regular subscription payments.
Example: Netflix, Spotify, Amazon Prime.
3. Advertising-Based Model: The company offers products or services for free and
makes money through advertising.
Revenue: Earned from advertisers who pay to display ads.
Example: Google, Facebook, YouTube.
4. Marketplace Model: The company provides a platform where buyers and sellers can
meet and transact.
Revenue: Earned through transaction fees or commissions on sales.
 Example: eBay, Amazon, Airbnb.
5. On-Demand Model: The company provides services as and when customers need
them.
Revenue: Earned by charging customers per use or service.
Example: Uber, DoorDash, TaskRabbit.

2] Reference Architecture of IIOT

The reference architecture of IIoT outlines how different components interact within an
IIoT ecosystem.
It provides a structured framework that helps organizations understand how to
implement IIoT solutions effectively.

Components of IIoT Reference Architecture

Device Layer: Collects raw data using sensors.

Connectivity Layer: Transmits the data to central systems.
Edge Layer: Processes data locally for faster decisions.
Data Storage Layer: Stores data for long-term analysis.
Data Processing Layer: Analyzes the data and extracts useful insights.
Application Layer: Presents actionable insights to users.
Business Layer: Drives business decisions based on insights.

Industrial Internet Architecture Framework

The Industrial Internet Architecture Framework (IIAF) is a comprehensive blueprint
or framework that guides the design and implementation of systems in the Industrial
Internet of Things (IIoT).
It helps to organize the components of an IIoT system, ensuring that they work together
smoothly to provide better operational efficiency, security, scalability, and data
management in industrial settings.
The IIAF provides a set of standards and guidelines to build and deploy industrial IoT
solutions across different industries, like manufacturing, energy, transportation, and
more.

The Industrial Internet Architecture Framework (IIAF) core components:

1. Perception Layer (Edge Layer): Collects real-time data via sensors and actuators.
Example: Temperature and pressure sensors in a factory.
2. Network Layer: Ensures data transmission from sensors to processing systems via
protocols like Wi-Fi, Ethernet, or 5G. Example: Machine sensors sending data to a
central system.
3. Edge Layer (Edge Computing): Processes data locally to reduce latency and enable
real-time decision-making. Example: Edge device analyzing temperature data to trigger
 alerts.
4. Data Management & Storage Layer: Stores and manages data for retrieval and long-
term use. Example: Cloud storage for operational data.
5. Application Layer: Provides interfaces for users to interact with the IIoT system,
offering insights and reports. Example: Dashboards displaying machine health and
performance.
6. Security Layer: Protects data and systems with encryption, authentication, and
firewalls. Example: Encrypting sensor data before cloud transmission.
7. Integration Layer: Enables communication between legacy systems and IIoT
technologies using APIs and middleware. Example: Integrating IIoT data with ERP
systems.

Benefits of the IIAF

1. Efficient Operation: Helps businesses automate and optimize industrial processes in

real-time.
2. Data-Driven Decisions: Provides actionable insights from vast amounts of data,
leading to improved decision-making.
3. Cost Savings: Predictive maintenance, energy optimization, and waste reduction lower
operational costs.
4. Improved Safety: Continuous monitoring helps detect issues early, improving worker
safety and reducing accidents.
5. Scalability: Supports growth by enabling new devices and applications to be easily
integrated into the system.

Challenges of Implementing IIAF

1. Complexity: Integrating various technologies, data sources, and systems can be

complex.
2. Security Risks: IIoT systems are vulnerable to cyber-attacks, so strong security
measures must be implemented.
3. Data Overload: Managing and analyzing the large volume of data from IIoT devices
can be challenging.
4. Cost of Implementation: Initial setup costs for IIoT systems can be high, especially for
legacy systems.

Industrial IoT- Layers

1] IIoT Sensing
IIoT Sensing refers to the use of various sensors and devices to collect data from the
physical environment.
These sensors are embedded in machinery, equipment, or infrastructure and measure
variables such as temperature, pressure, vibration, humidity, and more.
Key Functions:

Data Collection: Sensors continuously monitor physical parameters from machinery,

environments, or products.
Monitoring Equipment: They track the health and status of industrial assets.

Types of Sensors:

Temperature Sensors: Measure heat levels to ensure equipment operates within safe
limits.
Humidity Sensors: Monitor moisture levels to prevent condensation that could
damage equipment or affect product quality.
Vibration Sensors: Detect irregular vibrations in machines, which can indicate
potential failures and allow for predictive maintenance.
Pressure Sensors: Monitor gas or liquid pressure in systems to ensure they operate
safely and efficiently.

Importance :

Accuracy: Ensures real-time, accurate data collection from critical industrial

equipment.
Early Detection: Sensors help in detecting problems early, allowing for predictive
maintenance.

2] IIoT Processing
IIoT Processing refers to the data processing and analysis that happens after the
sensors collect data.
The data collected is sent to processing units (either at the edge or in the cloud) where
it is analyzed to derive meaningful insights.

Key Functions :

Data Filtering: Raw data is processed to eliminate noise and only the relevant data is
sent for analysis.
Real-Time Analysis: Processes data in real-time to identify patterns, anomalies, or
trends.
Decision Making: Based on the processed data, automated systems or humans can
make decisions to improve operations.

Importance :

Speed: Allows fast decision-making and immediate actions based on the insights.
Predictive Analytics: Helps predict failures and optimize processes to reduce
downtime and maintenance costs.
3] IIoT Communication
IIoT Communication refers to the methods and technologies used to transfer data
between devices, sensors, and systems across the IIoT network.
Efficient and reliable communication ensures that data flows smoothly from sensors to
processing units and then to the end-users.

Key Functions:

Data Transmission: Ensures that data from sensors is transferred to the processing
system (edge or cloud).
Real-Time Communication: Facilitates the flow of data in real-time so that instant
actions can be taken based on analysis.

Types of Communication:

Wired Communication: Uses cables or physical connections (e.g., Ethernet, industrial

networks) to transmit data.
Example: Using Ethernet cables to connect sensors on a factory floor to a central
computer for processing.
Wireless Communication: Uses wireless networks for communication, offering more
flexibility in deployment and scalability.
Wi-Fi: Common for short-range communication in local networks.
LoRaWAN (Long Range Wide Area Network): Used for long-range, low-power
data transmission, ideal for outdoor or remote sensor deployments.
5G: High-speed communication suitable for real-time data transfer in industries
like manufacturing or autonomous vehicles.

Importance:

Flexibility: Wireless communication allows IIoT systems to be deployed without the

constraints of physical wiring.
Scalability: Wireless systems can easily scale by adding more sensors and devices to
the network.

4] IIoT Networking
IIoT Networking refers to the network infrastructure that supports the communication
between devices, sensors, and systems in an IIoT environment.
It ensures that data is transmitted across devices, cloud systems, and user interfaces
reliably and securely.

Key Functions:
 Data Routing: Ensures that data is routed to the correct location, whether it’s an edge
device, a central server, or the cloud.
Connectivity: Ensures reliable communication between devices over local, wide-area,
or cloud networks.
Network Security: Protects the data being transmitted between devices and systems,
ensuring integrity and confidentiality.

Types of Networking:

Local Area Network (LAN): Used for connecting devices within a local area, like a
factory floor.
Example: Ethernet or Wi-Fi networks within a factory.
Wide Area Network (WAN): Used to connect devices over a large geographic area,
such as between different factories or remote sensors.
Example: Using 4G or 5G networks to send data from remote oil rigs to a central
processing center.
Private Networks: Dedicated, secure networks used by industrial facilities to ensure
high reliability and security for sensitive data.
Example: Using a private cellular network for secure communication between
factory sensors and the control system.

Importance :

Reliability: Ensures consistent data transfer, even in challenging environments.

Security: Protects the data from external threats and unauthorized access.
Scalability: Supports the growing number of devices and sensors in an IIoT
ecosystem.

How They Work Together

Sensing: Collects real-time data from machines and environments using sensors.
Processing: The collected data is analyzed locally (edge) or centrally (cloud) to derive
actionable insights.
Communication: The processed data is transmitted over communication networks,
ensuring data moves efficiently.
Networking: The network infrastructure ensures that all devices, sensors, and
processing systems can communicate with each other securely and reliably.