A New Era of Efficient Data Communication
In industrial automation, data is the lifeblood of operational awareness and system performance. Whether you’re monitoring field equipment, managing energy usage, or running a large-scale SCADA network, efficient communication is essential.
One of the most powerful technologies enabling this efficiency is MQTT (Message Queuing Telemetry Transport), a lightweight protocol ideal for real-time communication across distributed systems. ControlByWeb 400 Series devices support MQTT natively, offering a simple and scalable solution for integrators and end users looking to enhance connectivity without complexity.
What is MQTT?
MQTT is a publish-subscribe communication protocol specifically designed for lightweight, low-bandwidth communication. Rather than requiring a direct connection between every device, MQTT enables devices to publish data as topics to a broker, which other devices or services can then subscribe to.
Key Benefits:
- Scalability: Makes growing systems easy to expand.
- MQTT easily handles large numbers of devices and data streams, making it well-suited for expanding systems and multi-site deployments.
- Supported by Most Systems: Allows for seamless integration into existing systems.
- MQTT is widely supported by SCADA software, cloud platforms, open-source dashboards, and IoT development tools.
- Efficient: Perfect for cellular and satellite applications.
- Older communication methods require polling the device periodically to get the latest status. MQTT brokers handle pushing the status changes as they occur and can push them to multiple subscribers. This saves data usage as only status changes are transmitted when they occur.
- Optimized: Works well in low-power and limited-resource environments.
- CBW devices can be via a 9-28VDC power supply or over ethernet.
- Real-time: Ideal for responsive systems and alerting.
- Notifications and emergency stops will be triggered as they happen instead of waiting for a periodic polling interval.
Common Use Cases:
Step-by-Step Implementation Guide
Here’s a simplified path to start publishing real-time data using MQTT from a ControlByWeb device:
- Access Device UI: Open the CBW device’s web interface through your browser.
- Navigate to MQTT Settings: Located in the General Settings tab.
- Input Broker Info: Add MQTT broker IP/domain, port (usually 1883 or 8883 for secure), and any required authentication credentials.
- Set Topics: Define MQTT topics and specify data payloads (JSON, raw, etc.) for each channel.
- Test & Validate: Use an MQTT test tool, client, or SCADA integration to confirm message receipt and publishing behavior.
You can find additional information on MQTT in the CBW Integration manual found here.
Integration with SCADA Systems
ControlByWeb’s MQTT support makes it easy to bring device-level data into larger industrial control systems.
Seamless SCADA Integration Includes:
- Mapping topics to SCADA tags for real-time visualization
- Using MQTT payloads to trigger alarms or events in SCADA
- Improved scalability over traditional polling protocols like Modbus
Popular SCADA platforms like Ignition, Inductive Automation, and others support MQTT natively or through modules, making integration straightforward and robust.
An Example of MQTT and ControlByWeb
The following example walks through a ControlByWeb device using MQTT in a manufacturing plant.
A manufacturing plant wants to implement predictive maintenance and real-time alerting on its critical rotating equipment, such as motors and pumps, across multiple production lines. The goal is to monitor vibration levels, motor temperature, and runtime hours to anticipate failures and minimize unplanned downtime.
Hardware Used
- ControlByWeb X-400 with X-12s modules for analog and digital I/O
- Industrial sensors:
- Vibration sensors (4-20 mA output)
- RTDs or thermocouples via signal conditioners
- Run-time counters via digital inputs
- An MQTT broker (industrial edge computer or PLC with MQTT broker support)
MQTT Integration Workflow
- Data Acquisition:
- The X-400 reads sensor data at defined intervals.
- Analog inputs are used for temperature and vibration sensors.
- Digital inputs track equipment on/off cycles and operational hours.
- Data Publishing via MQTT:
- A local edge device polls the X-400 using Modbus TCP or HTTP API.
- The X-400 publishes sensor readings and input changes via MQTT to a centralized broker (on-prem or cloud-based, e.g., HiveMQ or Azure IoT Hub).
- System Integration:
- A SCADA system, MES, or custom dashboard subscribes to relevant topics for visualization and logging.
- Rules engines like Node-RED or Ignition process the data and trigger alarms or work orders if thresholds are breached (e.g., excessive vibration).
Use Case Features
- Thresholds and alarm states configured directly on the ControlByWeb device for local fail-safe alerts.
- MQTT ensures lightweight, low-latency communication over factory LAN or remote cellular networks.
- Enables remote diagnostics by maintenance teams without needing to VPN into site networks.
Benefits
- Proactive maintenance: Catch bearing failures or overheating before catastrophic damage.
- Reduced downtime: Immediate alerts via MQTT allow for quicker response.
- Scalable deployment: Easily repeatable setup across multiple machines or plants.
- Protocol flexibility: ControlByWeb’s Modbus/HTTP/MQTT support means no vendor lock-in.
Popular SCADA platforms like Ignition, Inductive Automation, and others support MQTT natively or through modules, making integration straightforward and robust.
Scalable, Flexible, and Ready for the Future
By supporting MQTT, ControlByWeb gives automation professionals an edge in designing scalable, responsive, and future-ready systems. Whether you’re building a small remote monitoring application or integrating with a cloud-scale IIoT platform, ControlByWeb devices provide the foundation for fast, secure, and scalable communication.
