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Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges

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A special issue of Sensors (ISSN 1424-8220). This special issue belongs to the section "Internet of Things".

Deadline for manuscript submissions: closed (31 March 2023) | Viewed by 46092

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Special Issue Editors

Prof. Dr. Salvatore Cavalieri

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Guest Editor

Full Professor, Department of Computer Engineering, University of Catania, Catania, Italy
Interests: smart grid; industrial informatic
Special Issues, Collections and Topics in MDPI journals

Dr. Nunzio Marco Torrisi

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Associate Professor, Center of Mathematics, Computing and Cognition (CMCC), Universidade Federal do ABC (UFABC), Santo André, Brazil
Interests: computing; engineering; energy; manufacturing
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

In the last few years a lot of effort is being put in the context of Industry 4.0 and in particular in Industrial Internet of Things (IIoT). The application of the concepts of Internet of Things in an industrial environment opens a lot of different new application like Smart Factory, Smart Logistics, Smart Lifecycle, among others. The application of smart sensors, for instance, eases the digitalization process demanded by Industry 4.0 providing access to the information and configuration of field devices. Reference Architectures has been defined in this context, like Reference Architecture Model for Industrie 4.0 (RAMI 4.0) or Industrial Internet Reference Architecture (IIRA). In particular, the Asset Administration Shell (AAS) has been proposed in RAMI 4.0 to realize the concept of Digital Twin coming from Internet of Things to represent every asset, and its functionality, in the digital world. The digitalization process of Industry 4.0 and IIoT brings a lot of new scenarios and technologies that can be applied in the manufacturing process like Plug-and-Produce, Condition Monitoring and Predictive Maintenance, Artificial Intelligence, Computer Vision, Fog and Edge Computing, Interoperability and Integration protocols, and so on.

The main objective of this special issue is to collect state-of-the-art contributions on the latest research and development, up-to-date issues, and challenges in IIoT. We invite researchers from academia and industry to submit their high-quality works and research findings. Topics of interest include, but are not limited to:

Emerging sensors in IIoT
IIoT for industrial Condition Monitoring and Predictive Maintenance
Intelligent robots based- IIoT for industrial applications
Human machine interface in IIoT for industrial applications
Smart manufacturing using IIoT
Advances in reference architectures for Industry 4.0 and IIoT
Plug-and-Produce, Artificial Intelligence, Computer Vision, Fog and Edge Computing in Industry 4.0
Interoperability and Integration in IIoT and Industry 4.0
New applications of IIoT in industry
Machine-to-machine communication protocol (OneM2M, OPC UA, DDS, etc.)
Novel Information models, standards mapping and software development techniques for IIoT
Novel network technologies applied for IIoT (TSN, 5G, SDN etc.)
Network management and industrial communication protocol
Digital Twin, Device Models, Automation Models
Novel applications of service-oriented architectures in IIoT (e.g., Microservices, REST, Serverless computing)
Application of Blockchain Technology in the Manufacturing Industry
Algorithms for remote IIoT data collection and filtering.

Prof. Dr. Salvatore Cavalieri

Prof. Dr. Nunzio Marco Torrisi
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Sensors is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

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The sequel Special Issue "Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges (Volume II)" has been announced. We look forward to receiving your submission for the new Special Issue.
https://0-www-mdpi-com.brum.beds.ac.uk/journal/sensors/special_issues/12S3F9T77C
Deadline for manuscript submissions: 25 April 2024.

Related Special Issue

Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges (Volume II) in Sensors (4 articles)

Published Papers (12 papers)

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Research

31 pages, 2122 KiB

Open AccessArticle

Virtual Commissioning of Distributed Systems in the Industrial Internet of Things

by Julia Rosenberger, Andreas Selig, Mirjana Ristic, Michael Bühren and Dieter Schramm

Sensors 2023, 23(7), 3545; https://0-doi-org.brum.beds.ac.uk/10.3390/s23073545 - 28 Mar 2023

Cited by 1 | Viewed by 1699

Abstract

With the convergence of information technology (IT) and operational technology (OT) in Industry 4.0, edge computing is increasingly relevant in the context of the Industrial Internet of Things (IIoT). While the use of simulation is already the state of the art in almost every engineering discipline, e.g., dynamic systems, plant engineering, and logistics, it is less common for edge computing. This work discusses different use cases concerning edge computing in IIoT that can profit from the use of OT simulation methods. In addition to enabling machine learning, the focus of this work is on the virtual commissioning of data stream processing systems. To evaluate the proposed approach, an exemplary application of the middleware layer, i.e., a multi-agent reinforcement learning system for intelligent edge resource allocation, is combined with a physical simulation model of an industrial plant. It confirms the feasibility of the proposed use of simulation for virtual commissioning of an industrial edge computing system using Hardware-in-the-Loop. In summary, edge computing in IIoT is highlighted as a new application area for existing simulation methods from the OT perspective. The benefits in IIoT are exemplified by various use cases for the logic or middleware layer using physical simulation of the target environment. The relevance for real-life IIoT systems is confirmed by an experimental evaluation, and limitations are pointed out. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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20 pages, 4432 KiB

Open AccessArticle

The Edge Application of Machine Learning Techniques for Fault Diagnosis in Electrical Machines

by Javier de las Morenas, Francisco Moya-Fernández and Julio Alberto López-Gómez

Sensors 2023, 23(5), 2649; https://0-doi-org.brum.beds.ac.uk/10.3390/s23052649 - 28 Feb 2023

Cited by 9 | Viewed by 2205

Abstract

The advent of digitization has brought about new technologies that enable advanced condition monitoring and fault diagnosis under the Industry 4.0 paradigm. While vibration signal analysis is a commonly used method for fault detection in literature, it often involves the use of expensive equipment in difficult-to-reach locations. This paper presents a solution for fault diagnosis of electrical machines by utilizing machine learning techniques on the edge, classifying information coming from motor current signature analysis (MCSA) for broken rotor bar detection. The paper covers the process of feature extraction, classification, and model training and testing for three different machine learning methods using a public dataset to then export the results to diagnose a different machine. An edge computing approach is adopted for the data acquisition, signal processing and model implementation on an affordable platform, the Arduino. This makes it accessible for small and medium-sized companies, albeit with the limitations of a resource-constrained platform. The proposed solution has been tested on electrical machines in the Mining and Industrial Engineering School of Almadén (UCLM) with positive results. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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27 pages, 5305 KiB

Open AccessArticle

Proposal of Mapping Digital Twins Definition Language to Open Platform Communications Unified Architecture

by Salvatore Cavalieri and Salvatore Gambadoro

Sensors 2023, 23(4), 2349; https://0-doi-org.brum.beds.ac.uk/10.3390/s23042349 - 20 Feb 2023

Cited by 7 | Viewed by 1883

Abstract

The concept of Digital Twin is of fundamental importance to meet the main requirements of Industry 4.0. Among the standards currently available to realize Digital Twins there is the Digital Twins Definition Language. Digital Twin requires exchange of data with the real system it models and with other applications that use the digital replica of the system. In the context of Industry 4.0, a reference standard for an interoperable exchange of information between applications, is Open Platform Communications Unified Architecture. The authors believe that interoperability between Digital Twins and Open Platform Communications Unified Architectures communication standard should be enabled. For this reason, the main goal of this paper is to allow a Digital Twin based on the Digital Twins Definition Language to exchange data with any applications compliant to the Open Platform Communications Unified Architecture. A proposal about the mapping from Digital Twins Definition Language to the Open Platform Communications Unified Architecture will be presented. In order to verify the feasibility of the proposal, an implementation has been made by the authors, and its description will be introduced in the paper. Furthermore, the main results of the validation process accomplished on the basis of this implementation will be given. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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19 pages, 5460 KiB

Open AccessArticle

An Interoperable Digital Twin with the IEEE 1451 Standards

by Helbert da Rocha, João Pereira, Reza Abrishambaf and Antonio Espirito Santo

Sensors 2022, 22(19), 7590; https://0-doi-org.brum.beds.ac.uk/10.3390/s22197590 - 07 Oct 2022

Cited by 10 | Viewed by 2563

Abstract

The shop floor or factory floor is the area inside a factory where manufacturing production is executed. The digitalisation of this area has been increasing in the last few years, introducing the Digital Twin (DT) and the Industry 4.0 concepts. A DT is the digital representation of a real object or an entire system. A DT includes a high diversity of components from different vendors that need to interact with each other efficiently. In most cases, the development of standards and protocols does not consider the need to operate with other standards and protocols, causing interoperability issues. Transducers (sensors and actuators) use the communication layer to exchange information with digital contra parts, and for this reason, the communication layer is one of the most relevant aspects of development. This paper covers DT development, going from the physical to the visualisation layer. The reference architecture models, standards, and protocols focus on interoperability to reach a syntactic level of communication between the IEEE 1451 and the IEC 61499 standards. A semantic communication layer connects transducer devices to the digital representation, achieving a semantic level of interoperability. This communication layer adds semantics to the communication process, allowing the development of an interoperable DT based on the IEEE 1451 standards. The DT presented reaches the syntactic and semantic levels of interoperability, allowing the monitoring and visualisation of a prototype system. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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17 pages, 2405 KiB

Open AccessArticle

Integration of IoT Technologies into the Smart Grid

by Salvatore Cavalieri, Giulio Cantali and Andrea Susinna

Sensors 2022, 22(7), 2475; https://0-doi-org.brum.beds.ac.uk/10.3390/s22072475 - 23 Mar 2022

Cited by 9 | Viewed by 2512

Abstract

This paper presents a novel solution in the field of the integration of the Smart Grid and the Internet of Things. The definition of a web platform able to offer a RESTful interface to IEC 61850 Servers to a generic user is proposed. The web platform enables the mapping of information maintained by an IEC 61850 Server into MQTT messages. Suitable mechanisms to introduce interoperable exchange of information were defined. The paper presents the main features offered by the proposed platform. The originality of the proposal is highlighted by comparing it with the current literature. A prototype was realized, and the software implementation choices are described and the main results of its evaluation are presented. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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20 pages, 1822 KiB

Open AccessArticle

Third Party Certification of Agri-Food Supply Chain Using Smart Contracts and Blockchain Tokens

by Ricardo Borges dos Santos, Nunzio Marco Torrisi and Rodrigo Palucci Pantoni

Sensors 2021, 21(16), 5307; https://0-doi-org.brum.beds.ac.uk/10.3390/s21165307 - 06 Aug 2021

Cited by 39 | Viewed by 7050

Abstract

Every consumer’s buying decision at the supermarket influences food brands to make first party claims of sustainability and socially responsible farming methods on their agro-product labels. Fine wines are often subject to counterfeit along the supply chain to the consumer. This paper presents a method for efficient unrestricted publicity to third party certification (TPC) of plant agricultural products, starting at harvest, using smart contracts and blockchain tokens. The method is capable of providing economic incentives to the actors along the supply chain. A proof-of-concept using a modified Ethereum IGR token set of smart contracts using the ERC-1155 standard NFTs was deployed on the Rinkeby test net and evaluated. The main findings include (a) allowing immediate access to TPC by the public for any desired authority by using token smart contracts. (b) Food safety can be enhanced through TPC visible to consumers through mobile application and blockchain technology, thus reducing counterfeiting and green washing. (c) The framework is structured and maintained because participants obtain economic incentives thus leveraging it´s practical usage. In summary, this implementation of TPC broadcasting through tokens can improve transparency and sustainable conscientious consumer behaviour, thus enabling a more trustworthy supply chain transparency. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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25 pages, 9122 KiB

Open AccessArticle

An Analytics Environment Architecture for Industrial Cyber-Physical Systems Big Data Solutions

by Eduardo A. Hinojosa-Palafox, Oscar M. Rodríguez-Elías, José A. Hoyo-Montaño, Jesús H. Pacheco-Ramírez and José M. Nieto-Jalil

Sensors 2021, 21(13), 4282; https://0-doi-org.brum.beds.ac.uk/10.3390/s21134282 - 23 Jun 2021

Cited by 13 | Viewed by 3259

Abstract

The architecture design of industrial data analytics system addresses industrial process challenges and the design phase of the industrial Big Data management drivers that consider the novel paradigm in integrating Big Data technologies into industrial cyber-physical systems (iCPS). The goal of this paper is to support the design of analytics Big Data solutions for iCPS for the modeling of data elements, predictive analysis, inference of the key performance indicators, and real-time analytics, through the proposal of an architecture that will support the integration from IIoT environment, communications, and the cloud in the iCPS. An attribute driven design (ADD) approach has been adopted for architectural design gathering requirements from smart production planning, manufacturing process monitoring, and active preventive maintenance, repair, and overhaul (MRO) scenarios. Data management drivers presented consider new Big Data modeling analytics techniques that show data is an invaluable asset in iCPS. An architectural design reference for a Big Data analytics architecture is proposed. The before-mentioned architecture supports the Industrial Internet of Things (IIoT) environment, communications, and the cloud in the iCPS context. A fault diagnosis case study illustrates how the reference architecture is applied to meet the functional and quality requirements for Big Data analytics in iCPS. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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17 pages, 32555 KiB

Open AccessArticle

TSCH and RPL Joining Time Model for Industrial Wireless Sensor Networks

by Jose Vera-Pérez, Javier Silvestre-Blanes and Víctor Sempere-Payá

Sensors 2021, 21(11), 3904; https://0-doi-org.brum.beds.ac.uk/10.3390/s21113904 - 05 Jun 2021

Cited by 5 | Viewed by 4007

Abstract

Wireless sensor networks (WSNs) play a key role in the ecosystem of the Industrial Internet of Things (IIoT) and the definition of today’s Industry 4.0. These WSNs have the ability to sensor large amounts of data, thanks to their easy scalability. WSNs allow the deployment of a large number of self-configuring nodes and the ability to automatically reorganize in case of any change in the topology. This huge sensorization capacity, together with its interoperability with IP-based networks, allows the systems of Industry 4.0 to be equipped with a powerful tool with which to digitalize a huge amount of variables in the different industrial processes. The IEEE 802.15.4e standard, together with the access mechanism to the Time Slotted Channel Hopping medium (TSCH) and the dynamic Routing Protocol for Low-Power and Lossy Networks (RPL), allow deployment of networks with the high levels of robustness and reliability necessary in industrial scenarios. However, these configurations have some disadvantages in the deployment and synchronization phases of the networks, since the time it takes to synchronize the nodes is penalized compared to other solutions in which access to the medium is done randomly and without channel hopping. This article proposes an analytical model to characterize the behavior of this type of network, based on TSCH and RPL during the phases of deployment along with synchronization and connection to the RPL network. Through this model, validated by simulation and real tests, it is possible to parameterize different configurations of a WSN network based on TSCH and RPL. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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18 pages, 5988 KiB

Open AccessArticle

Sensors Data Analysis in Supervisory Control and Data Acquisition (SCADA) Systems to Foresee Failures with an Undetermined Origin

by F. Javier Maseda, Iker López, Itziar Martija, Patxi Alkorta, Aitor J. Garrido and Izaskun Garrido

Sensors 2021, 21(8), 2762; https://0-doi-org.brum.beds.ac.uk/10.3390/s21082762 - 14 Apr 2021

Cited by 15 | Viewed by 3739

Abstract

This paper presents the design and implementation of a supervisory control and data acquisition (SCADA) system for automatic fault detection. The proposed system offers advantages in three areas: the prognostic capacity for preventive and predictive maintenance, improvement in the quality of the machined product and a reduction in breakdown times. The complementary technologies, the Industrial Internet of Things (IIoT) and various machine learning (ML) techniques, are employed with SCADA systems to obtain the objectives. The analysis of different data sources and the replacement of specific digital sensors with analog sensors improve the prognostic capacity for the detection of faults with an undetermined origin. Also presented is an anomaly detection algorithm to foresee failures and to recognize their occurrence even when they do not register as alarms or events. The improvement in machine availability after the implementation of the novel system guarantees the accomplishment of the proposed objectives. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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28 pages, 3214 KiB

Open AccessArticle

Semantic Interoperability between IEC 61850 and oneM2M for IoT-Enabled Smart Grids

by Salvatore Cavalieri

Sensors 2021, 21(7), 2571; https://0-doi-org.brum.beds.ac.uk/10.3390/s21072571 - 06 Apr 2021

Cited by 12 | Viewed by 3289

Abstract

In the era of Industry 4.0, pervasive adoption of communication technologies based on the Internet of Things represents a very strong requirement in several domains. In the smart grid domain, there is the need to overcome one of the main limitations of the current electric grid, allowing the use of heterogeneous devices capable of measuring, monitoring and exchanging information about grid components. For this reason, current literature often presents research activities about enabling internet of things (IoT) in smart grids; in particular, several proposals aim to realize interworking between IoT and smart grid communication standards, allowing exchange of information between IoT devices and the electrical grid components. Semantic interoperability should be achieved in an interworking solution in order to provide a common meaning of the data exchanged by heterogeneous devices, even if they belong to different domains. Until now, semantic interoperability remains an open challenge in the smart grid field. The paper aims to propose a novel solution of interworking between two of the most used communication systems in smart grids and IoT domains, i.e., IEC 61850 and oneM2M, respectively. A semantic interoperability solution is also proposed to be used in the interworking scheme here presented. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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20 pages, 5812 KiB

Open AccessArticle

Automated Design and Integration of Asset Administration Shells in Components of Industry 4.0

by Jakub Arm, Tomas Benesl, Petr Marcon, Zdenek Bradac, Tizian Schröder, Alexander Belyaev, Thomas Werner, Vlastimil Braun, Pavel Kamensky, Frantisek Zezulka, Christian Diedrich and Premysl Dohnal

Sensors 2021, 21(6), 2004; https://0-doi-org.brum.beds.ac.uk/10.3390/s21062004 - 12 Mar 2021

Cited by 38 | Viewed by 5785

Abstract

One of the central concepts in the principles of Industry 4.0 relates to the methodology for designing and implementing the digital shell of the manufacturing process components. This concept, the Asset Administration Shell (AAS), embodies a systematically formed, standardized data envelope of a concrete component within Industry 4.0. The paper discusses the AAS in terms of its structure, its components, the sub-models that form a substantial part of the shell’s content, and its communication protocols (Open Platform Communication—Unified Architecture (OPC UA) and MQTT) or SW interfaces enabling vertical and horizontal communication to involve other components and levels of management systems. Using a case study of a virtual assembly line that integrates AASs into the technological process, the authors present a comprehensive analysis centered on forming AASs for individual components. In the given context, the manual AAS creation mode exploiting framework-based automated generation, which forms the AAS via a configuration wizard, is assessed. Another outcome consists of the activation of a virtual assembly line connected to real AASs, a step that allows us verify the properties of the distributed manufacturing management. Moreover, a discrete event system was modeled for the case study, enabling the effective application of the Industry 4.0 solution. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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20 pages, 1447 KiB

Open AccessArticle

A Model for Predictive Maintenance Based on Asset Administration Shell

by Salvatore Cavalieri and Marco Giuseppe Salafia

Sensors 2020, 20(21), 6028; https://0-doi-org.brum.beds.ac.uk/10.3390/s20216028 - 23 Oct 2020

Cited by 43 | Viewed by 5680

Abstract

Maintenance is one of the most important aspects in industrial and production environments. Predictive maintenance is an approach that aims to schedule maintenance tasks based on historical data in order to avoid machine failures and reduce the costs due to unnecessary maintenance actions. Approaches for the implementation of a maintenance solution often differ depending on the kind of data to be analyzed and on the techniques and models adopted for the failure forecasts and for maintenance decision-making. Nowadays, Industry 4.0 introduces a flexible and adaptable manufacturing concept to satisfy a market requiring an increasing demand for customization. The adoption of vendor-specific solutions for predictive maintenance and the heterogeneity of technologies adopted in the brownfield for the condition monitoring of machinery reduce the flexibility and interoperability required by Industry 4.0. In this paper a novel approach for the definition of a generic and technology-independent model for predictive maintenance is presented. Such model leverages on the concept of the Reference Architecture Model for Industry (RAMI) 4.0 Asset Administration Shell, as a means to achieve interoperability between different devices and to implement generic functionalities for predictive maintenance. Full article

(This article belongs to the Special Issue Industrial Internet of Things in the Industry 4.0: New Researches, Applications and Challenges)

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