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HRS-Connect
Opensource IIoT-Monitoring
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
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 :-)
05.11.2019 OSMC 2019 4 / 40
How does a HRS work?
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
05.11.2019 OSMC 2019 6 / 40
H2 infrastructure in Germany
HRS in Nuremberg
HRS in Fürth
05.11.2019 OSMC 2019 7 / 40
HRS-Connect – the system
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)
05.11.2019 OSMC 2019 9 / 40
HRS-Connect
preprocessing &
transmission via
MQTT (TLS)
sensors data
from HRS PLC
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)
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)
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
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, ...)
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
05.11.2019 OSMC 2019 15 / 40
Example: compressor
05.11.2019 OSMC 2019 16 / 40
Refueling logs – archive
05.11.2019 OSMC 2019 17 / 40
Refueling logs – detail
05.11.2019 OSMC 2019 18 / 40
Custom (P&ID) diagrams
https://grafana.com/grafana/plugins/pierosavi-imageit-panel
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)
05.11.2019 OSMC 2019 20 / 40
Monitoring with Icinga2
05.11.2019 OSMC 2019 21 / 40
Monitoring with Icinga2 – fieldbus gateways
All checks for RevPi platform will be released on GitHub shortly!
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
05.11.2019 OSMC 2019 23 / 40
We dashboards❤️
05.11.2019 OSMC 2019 24 / 40
Monitoring with Icinga2 – dashboards
Is the agent
running?
05.11.2019 OSMC 2019 25 / 40
Monitoring with Icinga2 – dashboards
PLC connected via
fieldbus?
05.11.2019 OSMC 2019 26 / 40
Monitoring with Icinga2 – dashboards
Key metrics and
customer
availability
05.11.2019 OSMC 2019 27 / 40
Monitoring with Icinga2 – dashboards
Current
maintenance and
other downtimes
05.11.2019 OSMC 2019 28 / 40
Monitoring with Icinga2 – dashboards
05.11.2019 OSMC 2019 29 / 40
Monitoring with Icinga2 – mobile devices
05.11.2019 OSMC 2019 30 / 40
Monitoring with Icinga2 – mobile devices
05.11.2019 OSMC 2019 31 / 40
Monitoring with Icinga2 – Integrations
05.11.2019 OSMC 2019 32 / 40
Provisioning & Deployment
05.11.2019 OSMC 2019 33 / 40
Provisioning - Hardware
●
„provisioning desk“
●
Simultaneously deployment
2x9 RevPi
●
Flexible connection sets for
different hardware
configuration
●
Unit testing
05.11.2019 OSMC 2019 34 / 40
Provisioning - Ansible
●
Infrastructure as Code
●
Dynamic inventory with
PostgreSQL CMDB
●
Plug & play in case of hardware
replacement
05.11.2019 OSMC 2019 35 / 40
Provisioning - Ansible
●
Custom facts
– RevPi type
– Module specs and status
●
Coming soon @ GitHub
 nbuchwitz
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
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
05.11.2019 OSMC 2019 38 / 40
Opensource keeps the world spinning!
offical armhf packages
(Sponsoring)
05.11.2019 OSMC 2019 39 / 40
Questions?
 @NicolaiBuchwitz  nbuchwitz
05.11.2019 OSMC 2019 40 / 40
Thanks!

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

  • 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. 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. 05.11.2019 OSMC 2019 4 / 40 How does a HRS work?
  • 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. 05.11.2019 OSMC 2019 6 / 40 H2 infrastructure in Germany HRS in Nuremberg HRS in Fürth
  • 7. 05.11.2019 OSMC 2019 7 / 40 HRS-Connect – the system
  • 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. 05.11.2019 OSMC 2019 9 / 40 HRS-Connect preprocessing & transmission via MQTT (TLS) sensors data from HRS PLC
  • 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. 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. 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. 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. 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. 05.11.2019 OSMC 2019 15 / 40 Example: compressor
  • 16. 05.11.2019 OSMC 2019 16 / 40 Refueling logs – archive
  • 17. 05.11.2019 OSMC 2019 17 / 40 Refueling logs – detail
  • 18. 05.11.2019 OSMC 2019 18 / 40 Custom (P&ID) diagrams https://grafana.com/grafana/plugins/pierosavi-imageit-panel
  • 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. 05.11.2019 OSMC 2019 20 / 40 Monitoring with Icinga2
  • 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. 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. 05.11.2019 OSMC 2019 23 / 40 We dashboards❤️
  • 24. 05.11.2019 OSMC 2019 24 / 40 Monitoring with Icinga2 – dashboards Is the agent running?
  • 25. 05.11.2019 OSMC 2019 25 / 40 Monitoring with Icinga2 – dashboards PLC connected via fieldbus?
  • 26. 05.11.2019 OSMC 2019 26 / 40 Monitoring with Icinga2 – dashboards Key metrics and customer availability
  • 27. 05.11.2019 OSMC 2019 27 / 40 Monitoring with Icinga2 – dashboards Current maintenance and other downtimes
  • 28. 05.11.2019 OSMC 2019 28 / 40 Monitoring with Icinga2 – dashboards
  • 29. 05.11.2019 OSMC 2019 29 / 40 Monitoring with Icinga2 – mobile devices
  • 30. 05.11.2019 OSMC 2019 30 / 40 Monitoring with Icinga2 – mobile devices
  • 31. 05.11.2019 OSMC 2019 31 / 40 Monitoring with Icinga2 – Integrations
  • 32. 05.11.2019 OSMC 2019 32 / 40 Provisioning & Deployment
  • 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. 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. 05.11.2019 OSMC 2019 35 / 40 Provisioning - Ansible ● Custom facts – RevPi type – Module specs and status ● Coming soon @ GitHub  nbuchwitz
  • 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. 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. 05.11.2019 OSMC 2019 38 / 40 Opensource keeps the world spinning! offical armhf packages (Sponsoring)
  • 39. 05.11.2019 OSMC 2019 39 / 40 Questions?  @NicolaiBuchwitz  nbuchwitz
  • 40. 05.11.2019 OSMC 2019 40 / 40 Thanks!