The team began with UI design. The client requested a variety of pages, which DMC engineers created using React TypeScript and Material UI. Back-end programming was completed using C#, Microsoft Azure, and .NET Core. The resulting solution consolidated previous processes and streamlined the monitoring process. Staff watching the app to monitor alerts now have a cleaner interface, faster reporting, and more control over machines.

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MD4IoT goes beyond monitoring computers on a network. It can scan, detect, and report on OT equipment such as PLCs, HMIs, VFDs, and more. This information is aggregated into a local dashboard on the MD4IoT appliance and in the Azure dashboard for the product. It is ingestible by SOC software like Service Now (SNOW), Splunk, and LogRhythm.

DMC’s client reached out to get AD4IoT implemented at their various sites across the globe. We implemented the program in four phases: Discovery, Design, Deployment, and Operationalization.

Discovery

DMC began by collaborating with the client site and their third-party vendor to remotely gather information from the client’s existing network. We developed a questionnaire, and the answers helped us to determine the type of network the client used, the types of devices used, and the number of devices on that network. Our discovery included switch diagnostic information, which allowed developing detailed network diagrams and device relationships.

Design

Using the information gathered during the discovery phase, DMC built a map that plotted the connections between switches at each site. Once we had a thorough understanding of how each switch was connected, we created switch configurations to route OT traffic via SPAN/RSPAN to the central manager.

RSPAN was used for the distribution switches and SPAN was used for traffic mirroring to the sensor. We then developed commands for the sensor that was to be installed. The sensor is a local AD4IoT instance that aggregates traffic and sends data to the global central manager instance of MD4IoT used for reporting.

Deployment

Next, DMC installed the MD4IoT operating system, which is Ubuntu based, on the client-provided Dell R350 PowerEdge Server at each site. There were three network ports to configure on the server: one that was used for AD4IoT Management, one used for ingesting SPAN data, and one used for Dell server administration (iDRAC).

We reconfigured their network by adding around 15 – 20 configuration changes for each distribution and core switch. To minimize risk and issues that are likely to occur in OT Networks such as the high traffic caused by high-definition cameras, we performed thorough testing.

Operationalization

DMC then made improvements to the monitored targets and subnets that the SPAN brought in. We also applied alert filtering to reduce anomalies and false positives in reports. Any alert determined to be a false positive was cleared and filtered so that future alerts provided the most meaningful data.

Each server was connected to a central manager, which allowed the client to access data from multiple sites via a single pane of glass. DMC then conducted administrator training for IT and OT personnel so that they could operate the AD4IoT sensor appropriately.

Learn more about DMC’s Microsoft Azure Cloud Solutions and Services expertise and contact us today for your next project.

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The team began with UI design. DMC used React TypeScript and Material UI to create a variety of pages for viewing and interacting with events and live data from RES’ sites. We completed back-end programming using C#, Microsoft Azure, and .Net Core. The resulting solution consolidated previous processes and streamlined the monitoring process. Staff who use the app to monitor alerts now have a cleaner interface and faster reporting.

Learn more about DMC’s Application Development expertise. 

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DMC consultants began by migrating the client’s existing content from SharePoint to the cloud. This migration included many custom features DMC had created throughout the years. Due to differences between the on-premises and online versions of SharePoint, engineers were required to recreate several tools and custom web parts for use in the new online environment.

Additionally, the SharePoint implementation was heavily integrated with third-party systems. DMC updated the integration so that the online tools were still able to integrate with the on-premises third-party systems. Integration included the retrieval of the client’s budget and project info from QuickBooks and a Homegrown ERP System.

Finally, DMC modernized the interface using SharePoint Modern to create modern widgets and web parts. Afterwards, the solution was thoroughly tested, and the cutover was remigrated to go live.

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DMC first collaborated with the client to understand their networking and user interface requirements. From there, DMC engineers architected the cloud-based solution and DMC’s UI/UX team developed front-end mockups. This initial specification phase established a solid solution roadmap for DMC to follow, and the resulting system allowed clients to manage energy assets, send commands, view live data at customizable intervals, and request historical data exports. The system has been live since 2018 and is used for monitoring and performing data analytics to improve energy management and load balancing.

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Device Management

Working with Vital Command, the AWSAM application demonstrates DMC’s experience with managing a host of devices in many different locations. In this application, devices are managed throughout their supply chain by different organizations and users, therefore, it was very important to carefully design a flexible permissions scheme so that each user can do everything they need, but nothing they shouldn’t, with the device. DMC added live-update functionality to the web application to display device data and alerts in real-time. Thorough historical logging and CSV report export functionality allow users the ability to dig through what happened in the case of an incident.

Vital Command requested that DMC change many of the protocols and also added new device types into the Vital Command ecosystem. These protocol changes and new sensors required firmware and software changes in C, Java, SQL, C#, and React Typescript. During development, DMC improved and streamlined the existing communication system for the devices to allow users to confidently command all device functionality from anywhere, including updating the device with the latest firmware.

DMC continues to support and enhance the application as the customer finds opportunities for new features and enhancements.

Learn more about DMC’s Application Development Services and Contact Us with any inquiries.

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We then made a protocol gateway that communicated the relevant information from the MQTT service to the correct location in the cloud through an Azure IoT Hub. The MQTT messages were received in the cloud by the broker service, which parsed the data through the gateway for storage in to our SQL cloud database. The gateway is also capable of receiving commands from the website via the API and passing the commands to the PLC.

Finally, DMC built a custom REACT webpage with all the same functionality as the system’s HMI screen on site, as well as a few additional features. The webpage provides a complete user experience with all controls and functionality for the PLC. The website includes access to user administration, additional units of measurement, and the ability to see historical data including flow rates, pressures, alarm logs, setpoints, and usage. The webpage interacts with the API to send and receive data from the cloud database.

DMC also created a mobile version of the application.

Additional Information

DMC trained the client on emerging technologies that are available and guided them toward a more high-tech yet cost effective solution. Additionally, we trained the client on using the custom REACT website we built, the capabilities of the technologies used, and on debugging and troubleshooting.

The customer was also working with multiple other vendors and clients, and DMC navigated communication challenges to manage and complete the project. Finally, we accommodated scope changes and completed additional programming to add features relevant to the client.

Learn more about DMC’s PLC Programming Services and Application Development expertise. 

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The Kiosk Controller Software provides a touch screen user interface for interaction with the kiosk. Different on-screen workflows are initiated based on the type of user logging in. Additionally, transaction flows are supported, which rely on single-use codes instead of user accounts.

The software sends and receives data over a WebSocket using MQTT. Data is also persisted locally in an SQLite database allowing for offline functionality.

Furthermore, the software manages multiple hardware devices, including a camera for security, a barcode scanner for easy login capability, and locker modules for storing packages.

Administrative Portal

DMC developed a front-end portal for managing clients and kiosks. The portal makes it simple to assign newly created kiosks to clients, manage user access for both the portal and kiosks and provision API Keys and webhooks to allow clients to integrate with the system programmatically. It also provides the ability to group sets of users and kiosks for easy bulk-management and to view a combined dashboard summarizing kiosk activity.

Locker Controller Firmware

DMC developed the firmware for custom PCBs designed to control the locker modules. The firmware communicates with the kiosk controller software using the Modbus protocol over TCP and allows it to command lockers to open on demand. The status of each door is also reported back as doors are physically opened and closed.

Learn more about DMC’s Application Development and Embedded Development solutions.

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The solution has a series of sensor nodes connected to an Azure IoT Hub that collect environmental data. The sensor nodes are controlled by firmware programmed in Python, which runs on a Raspberry Pi using Embedded Linux. The collected raw data is processed using proprietary algorithms on Docker containers hosted in a cluster. After the data is processed, it is stored in Azure Table Storage so that it can be stored in a cost-effective manner and still be retrieved quickly. The server can also push firmware updates to the nodes manually or automatically.

A web application retrieves data from the datastore and displays it in graphical dashboards that are easy for end-clients to analyze. In addition to displaying dashboards, the web application also handles node management, account creation, and user login, and sends alerts when certain environmental thresholds or conditions are met. DMC built the website infrastructure for C2Sense’s end-customers using ASP.NET MVC, C#, JavaScript, HTML, and CSS, and created the user interface with assistance from DMC’s in-house graphic designer. 

Learn more about DMC’s Custom Software and Hardware Development services.

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The NI cRIO platform is used for the IoT system’s operational technology, enabling a variety of signals to be acquired, including high and low voltages, vibration, temperature, and proprietary or industry-specific sensors. CompactRIO hardware is also rugged and highly available and well-suited to field measurements and industrial environments. An open and connected LabVIEW programming environment allows multiple stations in the field, working in parallel while staying connected to the larger data system. 

The cRIO-based remote collection system will collect raw data at 10kHz (or higher), and analyze data according to the end user’s IP, making decisions according to rules and user configuration. The cRIO also interacts with the local system, enabling a safe state if needed, declaring alarms, or performing control changes to optimize performance. The cRIO’s operation is logged and made available by the system’s information technology. 

Microsoft Azure IoT is a critical scalable part of the system’s information technology. This framework is built to consume raw and summary data from the NI cRIOs, to enable automated workflows according to user rules, and to converge raw and summary data across a fleet of remote systems. Custom web applications then consume this data and provide it to a variety of users, who have the ability of looking at low-level effects and high-level trends. 

Microsoft Azure user interface

Rugged Physical Deployment

• Multiple stations in the field
• Industrial shock and vibration specs
• Temperature range -40C to +70C 

Data Acquisition

• 10kHz data acquisition
• Steady state and transient burst collection
• Varied signal sources, including reference electrodes, pipe-to-soil, corrosion coupons, ER probes

cRIO + Microsoft Azure IoT

Operational Technology

• Data processing at edge
• On-site alarm detection and action
• Remote-configurable high-speed data processing
• Open connectivity to other smart devices

Information Technology

• MQTT and JSON to Microsoft Azure IoT hub
• Microsoft Azure Stream Analytics and Azure Functions, serving data to multiple destinations
• HTTP file transfer of raw data to Data Storage service
• Web applications for user consumption and analysis

cRIO-based Monitoring of Electric Fish Barrier

Learn about DMC’s approach to business intelligence, read more about DMC’s IoT Solutions, and contact us today to get started on your next project.

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