Search Results (100)

This research study proposes an indoor temperature regulation predictive optimal control system that entails the use of both deep reinforcement learning and the Modbus TCP communication protocol. The designed architecture comprises distributed sub-parts, namely, distributed room-level units as well as a centralized main-part AI controller for maximizing efficient HVAC management in single-family residences as well as small-sized buildings. The system utilizes an LSTM model for forecasting temperature trends as well as an optimized control action using an envisaged DQN with predicted states, sensors, as well as user preferences. InfluxDB is utilized for gathering real-time environmental data such as temperature and humidity, as well as consumed power, and storing it. The AI controller processes these data to infer control commands for energy efficiency as well as thermal comfort. Experimentation on an NVIDIA Jetson Orin Nano as well as on a Raspberry Pi 4 proved the efficacy of the system, utilizing 8761 data points gathered hourly over 2023 in Cheonan, Korea. An added hysteresis-based mechanism for controlling power was incorporated to limit device wear resulting from repeated switching. Results indicate that the AI-based control system closely maintains target temperature setpoints with negligible deviations, affirming that it is a scalable, cost-efficient solution for intelligent climate management in buildings. Full article

The convergence of Operational Technology (OT) and Information Technology (IT) networks has become increasingly prevalent with the growth of Industrial Internet of Things (IIoT) applications. This shift, while enabling enhanced automation, remote monitoring, and data sharing, also introduces new challenges related to communication latency and cybersecurity. Oftentimes, legacy OT protocols were adapted to the TCP/IP stack without an extensive review of the ramifications to their robustness, performance, or safety objectives. To further accommodate the IT/OT convergence, protocol gateways were introduced to facilitate the migration from serial protocols to TCP/IP protocol stacks within modern IT/OT infrastructure. However, they often introduce additional vulnerabilities by exposing traditionally isolated protocols to external threats. This study investigates the security and reliability implications of migrating serial protocols to TCP/IP stacks and the impact of protocol gateways, utilizing two widely used OT protocols: Modbus TCP and DNP3. Our protocol analysis finds a significant safety-critical vulnerability resulting from this migration, and our subsequent tests clearly demonstrate its presence and impact. A multi-tiered testbed, consisting of both physical and emulated components, is used to evaluate protocol performance and the effects of device-specific implementation flaws. Through this analysis of specifications and behaviors during communication interruptions, we identify critical differences in fault handling and the impact on time-sensitive data delivery. The findings highlight how reliance on lower-level IT protocols can undermine OT system resilience, and they inform the development of mitigation strategies to enhance the robustness of industrial communication networks. Full article

In the Industrial Internet of Things (IIoT) field, the diversity of devices and protocols leads to interconnection challenges. Conventional Modbus Transmission Control Protocol (TCP) to Remote Terminal Unit (RTU) gateways suffer from high overhead and latency of the TCP protocol stack. To enhance real-time communication while ensuring reliability, this study applies Markov chain theory to analyze User Datagram Protocol (UDP) transmission characteristics. An Advanced UDP (AUDP) protocol is proposed by integrating a Cyclic Redundancy Check (CRC) check mechanism, retransmission mechanism, Transaction ID matching mechanism, and exponential backoff mechanism at the UDP application layer. Based on AUDP, a Modbus AUDP-RTU gateway is designed with a lightweight architecture to achieve bidirectional conversion between Modbus AUDP and Modbus RTU. Experimental validation and Markov chain-based modeling demonstrate that the proposed gateway significantly reduces communication latency compared to Modbus TCP-RTU and exhibits higher reliability than Modbus UDP-RTU. Full article

This paper presents a framework that enables programmers to deploy embedded real-time firmware of Internet of Things (IoT) devices more conveniently than using plain C/C++-language programming, by abstracting away from low-level details and the ad hoc management of multiple, diverse network technologies. Moreover, unlike other proposals, the framework is able to accommodate both time and event-driven applications. Experimental results show that for Modbus-CAN communication, the worst-case time overhead of the framework is less than 6% of the total combined processing and communication time. Its memory requirement is less than 5% and 4% of the Flash memory and RAM available on a typical IoT microcontroller. The framework also compares favorably with respect to two other approaches in terms of the sustainable minimum cycle time, memory overhead, and level of programming abstraction when tested on a simple real-time algorithm. Full article

In Supervisory Control and Data Acquisition (SCADA) systems, central to industrial automation and control systems, the Front-end Processor (FEP) facilitates seamless communication between field control devices and central management systems. As the Industrial Internet of Things (IIoT) and Industry 4.0 centered on the smart factory paradigm gain traction, conventional FEPs are increasingly showing limitations in various aspects. To address these issues, Data Distribution Service, a real-time communication middleware, and Kubernetes, a container orchestration platform, have garnered attention. However, the effective integration of conventional SCADA protocols, such as DNP3.0, IEC 61850, and Modbus with DDS, remains a key challenge. Therefore, this article proposes a Kubernetes-based real-time FEP for the modernization of SCADA systems. The proposed FEP ensures interoperability through an efficient translation mechanism between traditional SCADA protocols—DNP3.0, IEC 61850, and Modbus—and the Data Distribution Service protocol. In addition, the performance evaluation shows that the FEP achieves high throughput and sub-millisecond latency, confirming its suitability for real-time industrial control applications. This approach overcomes the limitations of conventional FEPs and enables the realization of more flexible and scalable industrial control systems. However, further research is needed to validate the system under large-scale deployment scenarios and enhance security capabilities. Future work will focus on performance evaluation in realistic conditions and the integration of quantum-resistant security mechanisms to strengthen resilience in critical infrastructure environments. Full article

Industrial Control Systems (ICS) have become increasingly vulnerable to cyber threats due to the growing interconnectivity with enterprise networks and the Industrial Internet of Things (IIoT). Among these threats, Address Resolution Protocol (ARP) spoofing presents a critical risk to the integrity and reliability of Modbus TCP/IP communications, particularly in environments utilizing Siemens S7 programmable logic controllers (PLCs). Traditional defense methods often rely on host-based software solutions or cryptographic techniques that may not be practical for legacy or resource-constrained industrial environments. This paper proposes a novel, lightweight hardware device designed to detect and mitigate ARP spoofing attacks in Modbus TCP/IP networks without relying on conventional computer-based infrastructure. An experimental testbed using Siemens S7-1500 and S7-1200 PLCs (Siemens, Munich, Germany) was established to validate the proposed approach. The results demonstrate that the toolkit can effectively detect malicious activity and maintain stable industrial communication under normal and adversarial conditions. Full article

This study develops and implements a scalable system architecture for dynamic data acquisition and knowledge modeling in industrial contexts. The objective is to efficiently process large datasets to support decision-making and process optimization within Industry 4.0. The architecture integrates modern technologies, such as the ibaPDA system for data acquisition, and employs communication standards like Modbus TCP and OPC UA to ensure broad compatibility with diverse equipment. In addition, it leverages native protocols offered by certain controllers, enabling direct data exchange without the need for conversion layers. A developed prototype demonstrates the practical applicability of the architecture, tested in a real industrial environment with a focus on processing speed, data integrity, and system reliability. The results indicate that the architecture not only meets the requirements for dynamic data acquisition but also enhances knowledge modeling. This leads to more efficient process control and opens new perspectives for managing and analyzing big data in production environments. The study emphasizes the importance of an integrated development approach and highlights the need for interdisciplinary collaboration to address operational challenges. Future extensions may include the implementation of Python interfaces and machine learning algorithms for data simulation, enabling more accurate predictive models. These findings provide valuable insights for industry, software development, data science, and academia, helping to tackle the challenges of Industry 4.0 and drive innovation forward. Full article

This paper investigates the integration of intrusion detection systems (IDSs) within Digital Twin (DT) architectures to enhance cybersecurity in industrial environments. Using the CICIDS2017, CIC Modbus, and 4SICS 2015 datasets, we evaluate the performance of Random Forest (RF) and Support Vector Machine (SVM) in detecting network intrusions. Results indicate that RF achieves an accuracy of 99.9% for CICIDS2017, with high precision, recall, and low false positives. In contrast, SVM exhibits an accuracy of 94.2% for the same dataset, struggling with high rates of false positives and moderate recall. Similarly, for 4SICS 2015, RF demonstrates an accuracy of 93%, being balanced and reliable for industrial applications, while SVM shows only 88% accuracy, with a low precision of 65% and a high false alarm rate. For the CIC Modbus dataset, RF displays an accuracy of 95% in validation and 93% in testing, highlighting strong detection in ICS networks. However, SVM maintains an accuracy of 88%, with weak separation between benign and malicious traffic, and a higher misclassification rate. Our findings highlight the importance of DT-IDS integration in real-time threat detection and system resilience, paving the way for future research in deep learning-based IDS solutions. Full article

The rising cost of energy and the urgent need for sustainability have driven industries to adopt smarter solutions for monitoring and optimizing resource consumption. In this study, we present an Industrial Internet of Things (IIoT)-based approach for real-time energy and air consumption monitoring in manufacturing, focusing on a legacy Turret Punch Press (TPP) at Mitsubishi Electric Air Conditioning Systems Europe Ltd. (M-ACE). Due to its age and lack of modern monitoring capabilities, the machine was suspected to be inefficient, requiring a retrofitting strategy for improved transparency and optimization. To address these challenges, a structured IIoT-enabled monitoring system was deployed, integrating KEYENCE MP-F series sensors, an energy monitoring module, and Ethernet communication via Modbus TCP/IP. A comprehensive dashboarding system was developed for real-time visualization and analysis of energy consumption trends, identifying inefficiencies and optimizing machine usage. The data-driven approach revealed significant energy savings of up to 56% and uncovered hidden inefficiencies, including a persistent air leak. By implementing a smart shut-off valve triggered by real-time power consumption data, unnecessary air leakage was eliminated, reducing compressed air waste and overall energy costs. The results demonstrate the effectiveness of IIoT-based retrofitting for industrial energy efficiency, showcasing a scalable framework that can be applied across various machines and production environments. This study highlights the importance of data-driven decision-making in smart manufacturing, contributing to both cost reduction and sustainability goals in industrial settings. Full article

Current technological progress in automation and robotics allows human kinematics to be used to control any device. As part of this study, a sensory glove was developed that allows for a delta robot to be controlled using hand movements. The process of controlling an actuator can often be problematic due to its complexity. The proposed system solves this problem using human–machine interactions. The sensory glove allows for easy control of the robot by detecting the rotation of the hand and pressing the control buttons. Conventional buttons have been replaced with SMART materials such as conductive thread and conductive fabric. The ESP32 microcontroller placed on the control glove collects data read from the MPU6050 sensor. It also facilitates wireless communication with the Raspberry Pi microcontroller supporting the Modbus TCP/IP protocol, which controls the robot’s movement. Due to the noise of the data read from the gyroscope, the signals were subjected to a filtering process using basic recursive filters and an advanced algorithm with Kalman filters. Full article

In parallel with the development of data transmission in the telecommunications sector to connect peripheral devices, hardware engineers have defined interfaces for independent communication systems. The basic idea of having standardized interfaces for external devices was quickly extended to control and instrumentation equipment, as the real-time characteristic of distributed systems became a challenge in the field. The proposed Modbus Extension (ModbusE) builds on these new techniques introduced in the UART interface, so that the newly introduced extension retains all the characteristics of the Modbus RTU except for the character bit structure. The validation of the ModbusE protocol allowed the proposal of a new communication message structure, a description of Modbus devices, an acquisition cycle to attain a deterministic temporal response behavior and the definition of an architecture for IIoT integration. In this work, practical research is based on data update times in SMARTConvert software when between 1 and 50 registers are accessed. These registers can, in the most favorable case, be at consecutive addresses and can all be read in a single bus query request, or at addresses 1 to 50, or the registers must be read in separate requests. The contributions of this paper are related to highlighting cases where Modbus modules are incorporated, the addressed registers are not consecutive and the Modbus reads 1 or more holding register records and the ModbusE proposal. As these registers must not be on consecutive addresses, it is necessary to make several requests, defining the function of a Modbus acquisition cycle, adapting the equations to the purpose of the tests carried out, measuring the Modbus communication signals and describing the ModbusE communication concept. Full article

This study presents a methodology for the development of modern Supervisory Control and Data Acquisition (SCADA) systems aimed at improving the operation and management of concentrated solar power (CSP) plants, leveraging the tools provided by industrial digitization. This approach is exemplified by its application to the CESA-I central tower heliostat field at the Plataforma Solar de Almería (PSA), one of the oldest CSP facilities in the world. The goal was to upgrade the control and monitoring capabilities of the heliostat field by integrating modern technologies such as OPC (Open Platform Communications)) Unified Architecture (UA), a Wi-Fi mesh communication network, and a custom Python-based gateway for interfacing with legacy MODBUS systems. Performance tests demonstrated stable, scalable communication, efficient real-time control, and seamless integration of new developments (smart heliostat) into the existing infrastructure. The SCADA system also introduced a user-friendly Python-based interface developed with PySide6, significantly enhancing operational efficiency and reducing task complexity for system operators. The results show that this low-cost methodology based on open-source software provides a flexible and robust SCADA architecture, suitable for future CSP applications, with potential for further optimization through the incorporation of artificial intelligence (AI) and machine learning. Full article

In this paper, we introduce the Secured Real-Time Machine Communication Protocol (SRMCP), a novel industrial communication protocol designed to address the increasing demand for security and performance in Industry 4.0 environments. SRMCP integrates post-quantum cryptographic techniques, including the Kyber Key Encapsulation Mechanism (Kyber-KEM) and AES-GCM encryption, to ensure robust protection against both current and future cryptographic threats. We also present an innovative “Port Hopping” mechanism inspired by frequency hopping, enhancing security by distributing communication across multiple channels. Comparative performance analysis was conducted with widely-used protocols such as ModBus and the OPC UA, focusing on key metrics such as connection, reading, and writing times across local and remote networks. Results demonstrate that SRMCP outperforms ModBus in reading and writing operations while offering enhanced security, although it has a higher connection time due to its dual-layer encryption. The OPC UA, while secure, lags significantly in performance, making it less suitable for real-time applications. The findings suggest that SRMCP is a viable solution for secure and efficient machine communication in modern industrial settings, particularly where quantum-safe security is a concern. Full article

This survey paper explores the cybersecurity certification requirements defined by the SunSpec Alliance for Distributed Energy Resource (DER) devices, focusing on aspects such as software updates, device communications, authentication mechanisms, device security, logging, and test procedures. The SunSpec cybersecurity standards mandate support for remote and automated software updates, secure communication protocols, stringent authentication practices, and robust logging mechanisms to ensure operational integrity. Furthermore, the paper discusses the implementation of the SAE J3072 standard using the IEEE 2030.5 protocol, emphasizing the secure interactions between electric vehicle supply equipment (EVSE) and plug-in electric vehicles (PEVs) for functionalities like vehicle-to-grid (V2G) capabilities. This research also examines the SunSpec Modbus standard, which enhances the interoperability among DER system components, facilitating compliance with grid interconnection standards. This paper also analyzes the existing SunSpec Device Information Models, which standardize data exchange formats for DER systems across communication interfaces. Finally, this paper concludes with a detailed discussion of the energy storage cybersecurity specification and the blockchain cybersecurity requirements as proposed by SunSpec Alliance. Full article

The general evolution of fieldbus systems has been variously affected by both computer electrical engineering and science. First, the main contribution undoubtedly originated from network IT systems, when the Open Systems Interconnection model was presented. This reference model with seven layers was and remains the foundation for the development of numerous advanced communication protocols. In this paper, the conducted research resulted in a major contribution; specifically, it describes the mathematical model for the Modbus protocol and defines the acquisition cycle model that corresponds to incompletely defined protocols in order to provide a timestamp and achieve temporal consistency for proposed Modbus Extension. The derived technical contribution of the authors is to exemplify the functionality of a typical industrial protocol that can be decomposed to improve the performance of data acquisition systems. Research results in this area have significant implications for innovations in industrial automation networking because of increasing distributed installations and Industrial Internet of Things (IIoT) applications. Full article