Application of PLC using MQTT protocol and

AWS Services
Prachi Salodkar Sarthak Wankhede Praful Mishra
Faculty of Electrical Engineering Student of Electrical Engineering Student of Electrical Engineering
Shri Ramdeobaba College of Shri Ramdeobaba College of Shri Ramdeobaba College of
Engineering and Management Engineering and Management Engineering and Management
Nagpur, India Nagpur, India Nagpur, India
[email protected] [email protected] [email protected]

Abstract—The integration of Programmable Logic adaptability set it apart, though it may require additional security
Controllers (PLCs) with Message Queuing Telemetry measures due to lower native standardization [5].
Transport (MQTT) and Amazon Web Services (AWS)
The application of PLC technology integrated with IoT
presents a transformative approach to modern industrial protocols like MQTT and AWS services offers a powerful solution
automation. This paper discusses the crucial role of PLC for modern industrial automation. This combination enables real-
technology in enhancing operational efficiency within time monitoring, streamlined control, and enhanced efficiency in
automated electrical engineering systems. It highlights MQTT various processes. By utilizing MQTT’s lightweight and reliable
as a lightweight messaging protocol designed for low- communication, coupled with AWS’s scalable cloud platform,
bandwidth and constrained environments, facilitating reliable industries can reduce operational costs, minimize downtime, and
data communication. The paper further explores the seamless boost productivity [6]. The ability to remotely monitor and control
communication flow from machines to PLCs, through MQTT devices through web and mobile interfaces further simplifies the
to AWS, enabling real-time monitoring and control via web management of complex industrial systems, making this integration
and mobile applications. A case study of Enel Green Power critical for advancing automation and maintaining competitiveness
illustrates the practical applications and benefits of this in today’s fast-changing industrial landscape [7].
integration, showcasing significant improvements in The application of PLC technology integrated with IoT
operational uptime and cost efficiency. This combination of protocols like MQTT and AWS services offers a powerful solution
technologies is essential for advancing industrial automation, for modern industrial automation. This combination enables real-
ensuring competitive advantages in rapidly evolving markets. time monitoring, streamlined control, and enhanced efficiency in
various processes. By utilizing MQTT’s lightweight and reliable
Keywords—PLC, MQTT, IIoT, AWS, Automation. communication, coupled with AWS’s scalable cloud platform,
industries can reduce operational costs, minimize downtime, and
I. INTROUCTION boost productivity. The ability to remotely monitor and control
The advancement of automation reflects a nation's progress in devices through web and mobile interfaces further simplifies the
technology, science, and industrial capability. PLC technology management of complex industrial systems, making this integration
plays a crucial role in automating electrical engineering systems, critical for advancing automation and maintaining competitiveness
significantly enhancing operational efficiency and addressing in today’s fast-changing industrial landscape.
various equipment-related challenges [1]. With features such as
user-friendly programming, high reliability, and robust II. CONCEPT OF MQTT AND IT’S APPLICATIONS
functionality, Programmable Logic Controllers (PLCs) have
become indispensable in modern industrial automation [2]. As A. MQTT Protocol
industries worldwide shift towards more automated systems, PLC MQTT is an open standard recognized by both OASIS and ISO
technology continues to be a key factor in optimizing production (ISO/IEC PRF 20922) for client-server communication using a
processes, improving system stability, and enabling efficient, large- publish/subscribe messaging model. It is designed to optimize
scale operations [3]. bandwidth usage and minimize device resource consumption,
making it highly suitable for environments with limited network
Message Queuing Telemetry Transport (MQTT) is a capacity or constrained devices. MQTT operates efficiently over
lightweight messaging protocol designed specifically for low-bandwidth, high-latency, or unreliable networks while ensuring
constrained environments, where low bandwidth and limited power reliable message delivery with minimal power consumption. The
are key concerns. Developed in 1999, MQTT operates on a publish- protocol typically operates over TCP/IP or similar network
subscribe architecture, allowing devices (publishers) to send data to protocols that support ordered, lossless, and bidirectional
a broker, which then distributes it to any devices (subscribers) that communication, utilizing port 8883 for secure SSL/TSL
have registered interest in specific topics. This structure reduces the connections and port 1883 for non-secure connections.
need for constant device-to-device communication, making it
efficient in terms of network resources. MQTT's low overhead MQTT's lightweight nature is one of its key advantages,
ensures faster data transmission and minimal power consumption, requiring minimal network overhead with a fixed 2-byte header,
making it an ideal choice for scenarios where maintaining allowing it to handle large-scale IoT networks where bandwidth is
consistent communication over limited networks is crucial [4]. limited. It offers three levels of Quality of Service (QoS) for
message delivery: QoS 0 (at most once), QoS 1 (at least once), and
It also features adjustable Quality of Service (QoS) levels, QoS 2 (exactly once), each offering varying degrees of reliability
ensuring message reliability even in unstable network conditions. depending on the application requirements. For instance, QoS 0 is
Widely adopted in industrial applications, such as remote suitable for non-critical data like sensor readings, while QoS 2 is
monitoring of power plants or transportation systems, MQTT ideal for applications like financial transactions where message
enables real-time, scalable communication. Compared to other duplication or loss is unacceptable.
protocols like HTTP and AMQP, MQTT’s efficiency and

979-8-3315-2861-4/24/$31.00 ©2024 IEEE

 MQTT consists of three main components: publishers (clients  Reduced network bandwidth requirements through an efficient
that send messages), brokers (servers that manage the flow of push mechanism.
messages), and subscribers (clients that receive messages). Clients
can simultaneously act as both publishers and subscribers, and they  Reconnect functionality to restore connections after termination.
use application messages, which consist of payloads, QoS levels,  Automatic re-sending of messages that were pending during
properties, and topic names, to communicate with each other disconnection.
through the broker. The broker plays a vital role in managing client
connections, processing subscriptions, and distributing messages  Notification mechanism for clients in case of unforeseen
based on topics, while maintaining low latency and efficient disconnections.
message routing. Its ability to scale to handle numerous devices,  User-friendly and easy to implement with a small set of
combined with low power consumption and reliable data commands.
transmission, makes MQTT a popular choice in IoT ecosystems,
smart devices, and industrial automation [8].  Quality Assurance (QoS) levels to provide varying degrees of
message delivery reliability.
B. Communication with Publisher/Subscriber Model
When an MQTT client connects to the MQTT broker, it can  Optional encryption of messages using SSL/TLS for enhanced
send messages using the "PUBLISH" packet. Each message must security.
include a topic, which is part of the "Variable Header," while the  Authentication of publishers and subscribers using username
actual message content is found in the "payload." The "PUBLISH" and password credentials.
packet contains a fixed header that defines its structure, including
bits for the packet type, flags for duplication (DUP), quality of
service (QoS) level, and a retain flag. The QoS settings determine
how the message is delivered: QoS 0 means the message is sent III. AWS SERVICES AND IT’S APPLICATION WITH PLC
once without acknowledgment, QoS 1 ensures it is delivered at least Cloud computing, particularly through Amazon Web Services
once with an acknowledgment from the broker via a "PUBACK" (AWS), offers a flexible infrastructure that supports various service
packet, and QoS 2 guarantees that the message is delivered exactly models such as Infrastructure as a Service (IaaS), Platform as a
once through a more complex handshake process involving Service (PaaS), and Software as a Service (SaaS). AWS enables
"PUBREC," "PUBREL," and "PUBCOMP" packets. The variable organizations to access resources on-demand, ensuring cost
header of the "PUBLISH" packet includes the topic name and efficiency and scalability while addressing security concerns related
packet ID, while the payload carries the actual message text. to data privacy and access. Its robust platform provides essential
features like confidentiality, integrity, and availability, which are
On the subscriber side, the MQTT client uses the
critical for modern industrial applications.
"SUBSCRIBE" packet to express interest in specific topics. The
"SUBSCRIBE" packet also contains a fixed header that identifies The integration of AWS with Message Queuing Telemetry
its structure, including a reserved field and a packet type identifier. Transport (MQTT) and Programmable Logic Controllers (PLCs)
The variable header includes a packet ID, and the payload specifies showcases a powerful solution for industrial automation. By
the topics the client wants to subscribe to, along with the requested leveraging AWS’s cloud services alongside MQTT’s lightweight
QoS level for each topic. The broker acknowledges the subscription messaging capabilities, industries can facilitate real-time data
request with a "SUBACK" packet, which indicates the success of communication between PLCs and cloud applications. This
the subscription and the maximum QoS level allowed. If a client combination allows for seamless remote monitoring and control of
wants to unsubscribe from topics, it sends an "UNSUBSCRIBE" industrial processes, enhancing operational efficiency. With AWS,
packet, and the broker responds with an "UNSUBACK" packet to organizations can easily scale their resources, ensuring that they can
confirm the unsubscription. This efficient model allows clients to meet dynamic demands while maintaining high levels of data
easily manage their subscriptions while relying on the broker to security. This synergy empowers companies to innovate and
handle message distribution and acknowledgment processes [9]. A improve their automation frameworks, ultimately leading to
simple representation of connection between publisher and increased productivity and competitiveness in the market.
subscriber using MQTT broker is given below in figure 1.
When a machine is connected to a PLC, the PLC serves as the
central control unit, gathering real-time data from the machine's
sensors and actuators. This data, which may include performance
metrics, operational status, and fault information, is then processed
and prepared for transmission. Using the MQTT protocol, the PLC
sends this data to a cloud-based MQTT broker. MQTT’s publish-
subscribe model ensures efficient, low-latency communication,
even in resource-constrained environments. Once the data is sent to
the broker, it is routed to AWS cloud services, where it is stored,
processed, and analyzed.
AWS plays a critical role in managing and scaling this data
flow, offering the computational resources and storage needed to
handle vast amounts of information in real-time. From AWS, the
processed data can be accessed through web or mobile applications
on phones, computers, or other devices. This enables users to
monitor and control industrial processes remotely, making
adjustments or diagnosing issues from anywhere in the world. This
seamless flow of information—from the machine to the PLC,
through MQTT, into AWS, and then to user devices—creates a
robust and scalable system that enhances efficiency, ensures
Figure 1: Communication between Publisher and Subscribers using MQTT continuous monitoring, and simplifies maintenance. Below is given
broker.
how we send data from a device to PLC to AWS through MQTT
protocol and then to application users in figure 2.
C. Features of MQTT
 Lightweight protocol with minimal transport overhead.
 Figure 2: Data being sent from a machine to PLC then sent to AWS cloud using MQTT broker

the Ignition system. This allowed operators to remotely

A. Applications monitor and control the cleaning process of protective barriers
at water inlets, ensuring efficient plant operations.
Enel Green Power, a global leader in renewable energy, Results:
operates numerous hydroelectric plants across Europe. Like many
others, their older plants were running on legacy SCADA systems,  Increased Uptime: Predictive maintenance led to fewer
which made predictive maintenance and real-time performance unplanned outages, significantly improving plant availability.
optimization difficult. In an effort to modernize their facilities, Enel The plant’s downtime was reduced by 30%.
Green Power upgraded their control system with Ignition,
incorporating predictive maintenance and advanced monitoring  Cost Savings: By detecting equipment issues earlier and
features [10]. scheduling maintenance more effectively, Enel Green Power
reduced repair costs by 20%.
 Better Data Utilization: Ignition’s unified platform enabled the
Challenges: aggregation of all operational data. Operators could now
monitor critical parameters and KPIs from a single interface,
The company faced several key issues: improving decision-making speed and accuracy.
 Remote Operations: With Ignition’s mobile app, plant operators
 Outdated SCADA: Their older SCADA systems provided could now manage and control the plant from anywhere,
limited functionality, lacked flexibility, and required on-site reducing the need for onsite presence, especially in remote
monitoring. This hindered their ability to predict maintenance locations.
needs and respond to real-time operational issues.
 Manual Monitoring of Equipment: With traditional monitoring
methods, the plant operators were unable to easily detect early IV. MONITORING AND CONTROL IN REAL TIME
signs of equipment wear, increasing downtime and In a real-time industrial application, a machine is equipped with
maintenance costs. a PLC (Programmable Logic Controller) that collects data from
sensors monitoring various parameters, such as temperature,
 Fragmented Data: Operational data was scattered across pressure, or motor speed. The PLC processes this sensor data and
different systems and required significant manual effort to prepares it for transmission using the MQTT (Message Queuing
gather insights and make decisions. Telemetry Transport) protocol. The data is then sent to an MQTT
Solution: broker, which acts as an intermediary, forwarding the information to
the AWS Cloud. In AWS, the data is stored and analyzed in real-
 Enel Green Power implemented Ignition to consolidate their time, allowing for insights such as detecting anomalies or
systems and upgrade their monitoring capabilities. This optimizing machine performance. This entire process happens
involved: seamlessly and efficiently, even in environments with limited
 Predictive Maintenance via Condition Monitoring: bandwidth, thanks to MQTT's lightweight messaging architecture.
Accelerometers were installed to monitor the vibration of Once the data is in the cloud, it is accessible to users via web or
critical assets like turbines and generator shafts. The data mobile applications, enabling real-time monitoring of industrial
collected from these sensors allowed the company to detect processes from remote locations. If any adjustments are needed
anomalies early, triggering maintenance alerts before based on the data (e.g., temperature is too high), the user can send
equipment failure occurred. control commands from their device. These commands are sent
 Cloud Integration and Remote Access: Using MQTT and back to the AWS Cloud, which then relays them through MQTT to
Ignition Perspective, data from sensors and systems was sent the PLC. The PLC receives the command and makes the necessary
to the cloud for real-time monitoring. Plant operators could adjustments to the machine in real-time, completing the feedback
now access live data and alerts from anywhere using mobile loop. This integration of PLCs with MQTT and AWS allows for
devices, improving their response time. robust, scalable, and efficient industrial automation, ensuring both
real-time monitoring and control capabilities. Transfer of data in
 Trash-Rack Cleaner Integration: To improve water flow into the real time using MQTT and AWS is shown in figure 3.
turbines, Enel Green Power integrated trash-rack cleaners into
 only optimizes maintenance strategies through predictive analytics
but also allows for better decision-making and resource
management. As industries continue to evolve, the adoption of such
advanced automation solutions will be crucial in maintaining
competitiveness, reducing operational costs, and addressing the
challenges of modern manufacturing environments.

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