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OSMC 2019 | HRS-Connect – Open Source IoT Monitoring by Nicolai Buchwitz

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The expansion of hydrogen refueling stations in Germany and Europe is progressing rapidly. But how to maintain the overview of all relevant parameters and fault messages? How can the refuelling processes be analysed in realtime in order to improve the systems together with the manufacturers? And how does the data from the system actually get into the monitoring system? This presentation will show how a powerful IoT monitoring solution was developed based on the hardware of the RevPi platform and open source software such as Ansible, Icinga2, InfluxDB and Grafana, which helps to ensure the availability of the hydrogen infrastructure and optimize it further.

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OSMC 2019 | HRS-Connect – Open Source IoT Monitoring by Nicolai Buchwitz

  1. 1. HRS-Connect Opensource IIoT-Monitoring
  2. 2. 05.11.2019 OSMC 2019 2 / 40 Nicolai Buchwitz ● CTO @ ENDA KG, Berlin ● Monitoring solutions for EU, federal agencies and industry ● Opensource developer ● Monitoring & M2M consulting  @NicolaiBuchwitz  nbuchwitz
  3. 3. 05.11.2019 OSMC 2019 3 / 40 HRS Connect – Introduction ● Monitoring of hydrogen refuelling stations (HRS*) in realtime ● Analysis of refuellings and other metrics ● Predictive maintenance ● Maintenance / task scheduler ● HRS availability API and app for customers ● (KPI) Reporting * not the hotel platform :-)
  4. 4. 05.11.2019 OSMC 2019 4 / 40 How does a HRS work?
  5. 5. 05.11.2019 OSMC 2019 5 / 40 H2 infrastructure in Germany ● 4 HRS manufacturers ● Liquid hydrogen (LH2) and compressed gas (GH2) ● 15 manufacturer / modell combinations – … extras like bus extensions ● H2.live app with live information for customers H2.live
  6. 6. 05.11.2019 OSMC 2019 6 / 40 H2 infrastructure in Germany HRS in Nuremberg HRS in Fürth
  7. 7. 05.11.2019 OSMC 2019 7 / 40 HRS-Connect – the system
  8. 8. 05.11.2019 OSMC 2019 8 / 40 Revolution PI – the industrial Swiss Army Knife ● Industrial hardware platform based on raspberry pi 3 compute module ● Lots of extension modules (IO, fieldbus gateways, maker kit, …) ● RT kernel patches ● Access data via process image (piControl kernel driver) ● Open-source hardware specs and source code (GitHub)
  9. 9. 05.11.2019 OSMC 2019 9 / 40 HRS-Connect preprocessing & transmission via MQTT (TLS) sensors data from HRS PLC
  10. 10. 05.11.2019 OSMC 2019 10 / 40 Data collection – hardware ● Dedicated control cabinet (visu box) ● Independent of other HRS infrastructure ● Industrial LTE router with IO ● Self healing (reset relais)
  11. 11. 05.11.2019 OSMC 2019 11 / 40 Data collection – agent on RevPi ● Communication via MQTT (TLS!) ● Telegraf & InfluxDB ● Collection and preprocessing of Ø 200 metrics / HRS @ 100-500ms – Pressure, temperature, ophours, load cycles, alarms, ... ● Recording of aggregated refuelling logs ● Monitoring of fill levels (automatic ordering of supplies)
  12. 12. 05.11.2019 OSMC 2019 12 / 40 ● Replaced Icinga2 agent for metrics ● Python3 & MQTT ● Easy usage with RevPiModIO2 ● Cyclic and event based collection of process data Data collection – RevPiModIO2 & MQTT
  13. 13. 05.11.2019 OSMC 2019 13 / 40 Visualization ● All data is visualized in Grafana ( … and even used by our supervisors!) ● Custom plugins (e.g. trend panel, ...) ● Various datasources – InfluxDB – PostgresSQL (meta data / non volatile metrics like refuelling logs) – Custom datasource with metric specifications (unit, tag name, location, ...)
  14. 14. 05.11.2019 OSMC 2019 14 / 40 Visualization - use cases ● One base dashboard per HRS type ● Events via annotations (e.g. refueling or alarm from PLC) ● Special dashboard (e.g. refuelling logs or KPI reporting) ● „Management dashboard“ @ office
  15. 15. 05.11.2019 OSMC 2019 15 / 40 Example: compressor
  16. 16. 05.11.2019 OSMC 2019 16 / 40 Refueling logs – archive
  17. 17. 05.11.2019 OSMC 2019 17 / 40 Refueling logs – detail
  18. 18. 05.11.2019 OSMC 2019 18 / 40 Custom (P&ID) diagrams https://grafana.com/grafana/plugins/pierosavi-imageit-panel
  19. 19. 05.11.2019 OSMC 2019 19 / 40 Monitoring with Icinga2 ● Monitoring of „usual“ metrics on the RevPi (CPU, memory, disk, temperature, ...) ● RevPi module configuration and errors (e.g. wrong wiring or missing module) ● Pending firmware updates ● Frozen process image or missing fieldbus link ● Notification via Telegram (groups / individual)
  20. 20. 05.11.2019 OSMC 2019 20 / 40 Monitoring with Icinga2
  21. 21. 05.11.2019 OSMC 2019 21 / 40 Monitoring with Icinga2 – fieldbus gateways All checks for RevPi platform will be released on GitHub shortly!
  22. 22. 05.11.2019 OSMC 2019 22 / 40 Monitoring with Icinga2 – the map ● Where is the station? Search for name or address ● Visualization of ongoing maintenance work ● Is there a geographic pattern? Mobile network or power outage https://github.com/nbuchwitz/icingaweb2-module-map
  23. 23. 05.11.2019 OSMC 2019 23 / 40 We dashboards❤️
  24. 24. 05.11.2019 OSMC 2019 24 / 40 Monitoring with Icinga2 – dashboards Is the agent running?
  25. 25. 05.11.2019 OSMC 2019 25 / 40 Monitoring with Icinga2 – dashboards PLC connected via fieldbus?
  26. 26. 05.11.2019 OSMC 2019 26 / 40 Monitoring with Icinga2 – dashboards Key metrics and customer availability
  27. 27. 05.11.2019 OSMC 2019 27 / 40 Monitoring with Icinga2 – dashboards Current maintenance and other downtimes
  28. 28. 05.11.2019 OSMC 2019 28 / 40 Monitoring with Icinga2 – dashboards
  29. 29. 05.11.2019 OSMC 2019 29 / 40 Monitoring with Icinga2 – mobile devices
  30. 30. 05.11.2019 OSMC 2019 30 / 40 Monitoring with Icinga2 – mobile devices
  31. 31. 05.11.2019 OSMC 2019 31 / 40 Monitoring with Icinga2 – Integrations
  32. 32. 05.11.2019 OSMC 2019 32 / 40 Provisioning & Deployment
  33. 33. 05.11.2019 OSMC 2019 33 / 40 Provisioning - Hardware ● „provisioning desk“ ● Simultaneously deployment 2x9 RevPi ● Flexible connection sets for different hardware configuration ● Unit testing
  34. 34. 05.11.2019 OSMC 2019 34 / 40 Provisioning - Ansible ● Infrastructure as Code ● Dynamic inventory with PostgreSQL CMDB ● Plug & play in case of hardware replacement
  35. 35. 05.11.2019 OSMC 2019 35 / 40 Provisioning - Ansible ● Custom facts – RevPi type – Module specs and status ● Coming soon @ GitHub  nbuchwitz
  36. 36. 05.11.2019 OSMC 2019 36 / 40 Provisioning - Ansible low level ● Flashing images via USB ● Automatic configuration of profinet settings ● Firmware updates on gateways ● Ansible module & standalone # update firmware on 10.10.12.98 $ update.py --hostname 10.10.12.98 --firmware mGateProfinetTps1.kfu # configure all attached PN devices $ pnio.py -i enp0s20f0u4u4u1 -m configure --station-name hrs-gw2 --ip-address 10.10.12.98 --netmask 255.255.255.0 --all
  37. 37. 05.11.2019 OSMC 2019 37 / 40 HRS-Connect in numbers 4 vendors 4 vendors 80 HRS 80 HRS 15 HRS types 15 HRS types >3.200 refuellings / month >3.200 refuellings / month ~20.000 metrics / second ~20.000 metrics / second <= 500 ms resolution <= 500 ms resolution
  38. 38. 05.11.2019 OSMC 2019 38 / 40 Opensource keeps the world spinning! offical armhf packages (Sponsoring)
  39. 39. 05.11.2019 OSMC 2019 39 / 40 Questions?  @NicolaiBuchwitz  nbuchwitz
  40. 40. 05.11.2019 OSMC 2019 40 / 40 Thanks!

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