2018 Global Internet of Things Summit (GIoTS)
IoT Solution for Energy Optimization in Industry 4.0:
Issues of a Real-life Implementation
Guillermo del Campo, Silvia Calatrava, Guillermo Cañada, Jorge Olloqui, Rocio Martinez and Asuncion Santamaria
CeDInt
Universidad Politecnica de Madrid
Madrid, Spain
gcampo@cedint.upm.es
Abstract— The fourth industrial revolution -the so called
Industry 4.0 strategy- fosters to provide devices/assets/machines
at industrial plants with a reliable connectivity, by means of the
use of innovative technologies such as Cyber Physical Systems,
Internet of Things, Cloud and Big Data services. Energy
consumption monitoring in manufacturing plants provides useful
information to save energy while reducing CO2 emissions, but
also for predictive maintenance or process optimization
applications what results in costs reduction. This paper describes
an Open-IoT solution to measure energy consumption in factories
that reveal in detail the use of energy at each industrial machine
and the energy consumed to perform a particular industrial
process. This solution, based on BatNET wireless communication
technology, has been installed worldwide at 16 factories dedicated
to the manufacture of steel and aluminum parts for the
automotive industry. BatNET is built on open and standard
protocols and it was initially envisaged for building and Smart
City applications. Some adaptations in hardware, firmware and
software have been required to fulfil the industrial harsh
environment. The implementation issues faced when installing
this Industrial IoT system in real environments are presented in
this paper. Special attention has been paid to the constraints
motivated by factory requirements and embedded processing and
data storage capabilities, as well as their solutions and the final
results.
Index Terms— Internet of Things, Wireless Communications,
Real-life Implementation, 6LoWPAN, Industry 4.0, Energy
Consumption Monitoring.
I. INTRODUCTION
The industrial sector is responsible for over 80% percent of
private research and innovation, and as such is one of the key
elements of sustainable economic growth [1]. However, the
relative contribution of industry to the EU economy is
declining [2]. In 2012, as a response, the European
Commission set a target that manufacturing should represent
20% of total value added in the EU by 2020. The European
Commission wants to help all industrial sectors exploit new
technologies and manage a transition to a smart, Industry 4.0
industrial system. Indeed, industry 4.0 is expected to have a
major effect on global economies, since it can deliver estimated
annual efficiency gains in manufacturing of between 6% and
8% [2], by allowing increased flexibility in production,
improving the speed with which a product can be produced and
increasing productivity, among others.
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Regarding productivity, optimizing energy use in industry
is a decisive competitive factor. Currently, industrial processes
need to reduce costs and increase production. Process
optimization in production plants would be possible by
detecting energy efficiency improvements and reduction of
person-hours spent on the processes. For this purpose, it is
necessary to solve some problems for which there is currently
no commercial solution: e.g., the development of advanced
sensor devices that enable analysis and data management by
means of flexible communication technologies with IoT
(Internet of Things) capabilities and that must be integrated
with signals present in the industrial environment,
implementing also the appropriated security.
In this paper, an Open-IoT solution is presented, with the
aim to contribute to the creation of an intelligent industry by
measuring energy consumption at machine and process level,
therefore calculating the costs associated with each phase of the
production process. The solution consists on a three-phase
meter device for Industry 4.0 and a specific device that detects
changes in the manufacturing processes that occur in machines
or production lines (events). There is a wide catalogue of
research works around IoT, including architectures and
applications, but a very few have been real-life implemented
and tested [3, 4]. The solution presented here has been installed
and is currently working in 16 Gonvarri plants (distributed in
Spain, Germany, Portugal, Brazil, Argentina and Mexico)
dedicated to the manufacture (cutting and pressing) of steel and
aluminum parts, mainly for the automotive, road safety, energy
and storage industries.
The structure of this paper is the following: section II
describes the related work. Section III presents the industrial
scenario and the solution requisites with its technical
description. Section IV presents the most important issues
aroused during the implementation phase (and how they have
been solved): the adaptation of measuring devices to the
requirements of the industrial environment (voltage, current,
protection, insulation, etc.); real-time monitoring of
consumption parameters and quality of the power grid; and the
use of standard communication protocols overcoming potential
interference problems while complying with security
requirements. Section V shows the current performance of the
IoT solution and section VI presents the conclusions.
 2018 Global Internet of Things Summit (GIoTS)
II. RELATED WORK
Industry is currently under a digitalization process, which
entails the integration of enabling technologies as embedded
systems, wireless sensor networks or cloud computing [5].
Cyber-physical systems (CPS) are identified as the main
enabling technologies on which the development of Industry
4.0 is based [6], and there is an increasing necessity of defining
aspects such as reliability, security and data management [7].
Focusing on the different technologies and protocols
specific for IoT, several authors refer to the standard IEEE
802.15.4, as one of the fundamental pillars [8, 9]. The use of
6LoWPAN (IPv6 over Low power Wireless Personal Area
Networks), which enables the use of IPv6 over the IEEE
802.15.4 standard, allows that each device on the network
(each CPS) is accessible via its IP address [10]. This way,
communication is optimized from the CPS devices to the cloud
as well as the direct communication between CPS devices.
Considering CPS implementation, different researchers
suggest the use of wireless communications to integrate them
as part of the industrial processes [11]. In addition, to optimize
and increase functionality as well as direct communication
between systems, IoT is presented as the most successful
approach [12]. The use of different case studies for different
types of industry has been analyzed, such as automotive
industry [13] or textile industry [14], where their specific needs
are pointed out. Concerning data management, a six-layer
Industry 4.0 architecture is proposed for the aluminum
production and full lifecycle supply chain management [15].
Finally, regarding energy monitoring in factories, there are
a few IoT works such as the monitoring of air-conditioning
consumption to prevent electrical faults [16] or the observing
of the degradation of power grid quality that may help the fault
cause-effect diagnosis [17], but none of them is oriented to
measure energy consumption of individual machines and
processes.
III. SCENARIO AND SYSTEM DESCRIPTION
A. Real World Scenario
The factories where the Open-IoT Solution has been
installed are dedicated to the manufacture of steel and
aluminum parts for the automotive and energy industries,
Fig 1. Aluminum and steel reels behind a production line
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Fig 2. Communications protocols of BatNET
Average factory dimensions are an area of 25,000 m2
(250 m * 100 m) and a height of 15 m divided in a warehouse,
a big area with multiple production lines and other facilities
(e.g. offices, cafeteria and restrooms). Steel and aluminum
reels enter production lines where either cutting or pressing
processes take place. Figure 1 shows part of the factory in
Barcelona (Spain) with multiple reels behind a production line.
The goal of the Open-IoT Solution, established by an
ESCO (Energy Service Company), is to monitor the energy
consumption of the different facilities of the factory and
specifically the energy consumption of the cutting and pressing
processes. Previously to this solution, two different commercial
systems were considered and tested. One of them was based on
RS-485 Modbus and another one was a WiFi-based solution.
However, none of them met the client requisites nor the
factories scenarios. Wired solutions, although more reliable,
demand a complex and expensive installation. Besides,
interferences caused by the coexistence of power and
communications wires resulted in erroneous data. In order to
solve these problems while meeting factory requirements, the
adaptation of BatNET [19], an Open-IoT wireless system
previously implemented in buildings and public infrastructures
was proposed. This solution comprises a wireless sensor
network and a software management platform (BatMP).
B. BatNET
BatNET connectivity is based on a capillary network of
nodes with mesh topology that communicates through
Std.IEEE802.15.4 Physical Layer and 6LoWPAN over IPv6
to implement Link and Network Layers. The Transport
Layer is UDP and the Application Layer is based on CoAP
(Constrained Application Protocol) (see Fig. 2). Information
encryption is done accordingly to AES-128. For the
communication and processing tasks, the nodes include an
Atmel ATmega256RFR2 microprocessor with a Contiki OS.
Network nodes (metering, sensing, dimming, etc.) from the
mesh network, which access to internet through a border router.
C. BatMP
BatMP [19] is a a platform middleware that runs in a
Beaglebone Black board and establishes a service oriented
architecture, which assures the systems scalability. Figure 3
shows the BatMP architecture for industrial applications.
The core of BatMP is the “Model” API. It defines the
interfaces between the “Measure” object and all modules in
BatMP. “Measure” object contains the information
necessary for system operation: measure_id, device_id,
parameter_id, devices and network configuration. The
“COAP Driver” module implements the communication
 2018 Global Internet of Things Summit (GIoTS)
Fig 3. BatMP architecture
with the IoT network (for information exchange and
devices/network configuration purposes). The “DAO
Services” module implements the database management. In
this case a SQLite database has been used. The
“Websocket” module implements the communication with
the external server. BatMP is included in a Jetty server and
it can be accessed through an URL.
D. System Description
Figure 4 shows the solution architecture, composed of three
type of nodes: BatSignal, BatMeter and BatLink. BatSignals
are in charge of signaling events that occur in the production
lines. When an event happens, BatSignal sends a message to
BatLink with the information to monitor. Events are detected
by a change of state in selected signals (inputs). Messages sent
from BatSignals to BatLink are called “observations”.
Fig 4. Solution architecture
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The BatLink matches the production line where the event
has occurred with its corresponding BatMeter device.
BatMeters include registers (accumulators) where the energy
consumption for each process is stored. Therefore,
BatSignals send a change of state signal to BatLink. BatLink
asks its corresponding BatMeter for the measurement.
BatMeters measure energy consumption at the electric board
and send the energy measurement to BatLink.
Measurements are stored at BatLink and, periodically,
they are sent from BatLink to an external server (application
server). The external server has an application software to
monitor and analyze the energy consumption in the
factory. Collected data are used for a detailed analysis of
energy consumption in the production plant (and its
associated facilities) and to detect saving actions that could
be implemented to improve the plant productivity.
As stated, the Open-IoT solution for Industry 4.0 is an
adaptation of a previous system. Different modifications
have been included to adapt it to the industrial requirements:
1) BatSignal
It is a device designed for the new industrial scenario,
with the purpose of knowing the energy consumption
associated to specific industrial processes. It is in charge of
capturing the changes produced in the cutting and pressing
machines and registering cut-hits (events) and
cutting/pressing speed. BatSignal is connected to the control
board of each production line (or machine) through digital (D)
and analogue (A) inputs coming from existing industrial
Programmable Logic Controllers (PLCs), as follows:
 Cutting machine: Machine turned on/off (D),
Packet change (D), Reel change (D), Cuts
counter (D), Cutting Speed (A).
 Pressing machine: Reel change (D), Die change
(D), Packet change (D), Hits counter (D), Hits
Speed (A), Machine turned on/off (A).
Examples of events are, for instance, a reel (or a packet or
a die) has been changed in the production line, or the process
of cutting the steel has started. An event is detected by means
of a change in one of the inputs or because a counter has
reached a predefined value. Then, the BatSignal sends a
message to the BatLink. This message contains the nature of
the event (e.g. reel change) and the date and time of its
occurrence in EPOCH format. Figure 5a shows a BatSignal
device next to the PLC that generates BatSignal digital inputs
at the control board of a production line.
2) BatMeter
This device is devoted to measure energy consumption. It
has been adapted to measure the three phases of a single line,
monitoring real time voltage and current of the electric lines at
the panel board (see Fig.5b). Real power, apparent power, real
energy, apparent energy, power factor and frequency are
calculated and sent to the BatLink periodically (by default
15 min) and when the BatMeter receives a request. In order to
measure the energy consumption of individual processes within
a production line, an accumulator is associated to each process.
 2018 Global Internet of Things Summit (GIoTS)
Fig 5. a) BatSignal installed at the control board of a production line and
b) BatMeter installed at the panel board
Energy consumption calculation for specific processes is
done by measuring the energy consumption between
consecutive events. Latency from BatSignal to BatMeter has an
especial importance for this calculation. Latency measurements
or transmissions from nodes to BatLink, under stressed
conditions (measurement period: 1 min, 2 packets of 100 bytes
and 70 bytes respectively) are shown in Table I.
Although latency values are acceptable, system reliability
has been increased using a buffer of measurements managed
by the date and time sent in the messages generated at
BatSignal. Other modifications aimed to improve the
communications IoT system include the reinforcement of
filtering and protection electronics for the current/voltage and
power inputs and the use of the AD7858 to manage all the
electric related measurements and calculations.
3) BatLink
BatLink is the IoT capillary network border-router. In
consists on a BatMote to communicate with the IoT network,
and, as single board computer, a BeagleBone Black has been
chosen. BatMP is the software management platform that
controls the system operation. BatMP includes functionalities
for IoT network configuration and supervision&maintenance
tools, and communication tasks to communicate with the
external server through an Internet.
BatMP driver manages BatSignals waiting/listening states
until an observation message is received from a BatSignal.
Then, the BatLink driver looks for the BatMeter associated to
the BatSignal, and it sends it a request. As response to this
request, BatMeter sends a message including the accumulated
energy consumption that is stored in the BatLink database when
received. In order to include those Accumulation measurements
in the database, two tables have been implemented:
Accumulator and Accumulations. Accumulator identifies the
associations between the BatSignal inputs and the BatMeter
accumulators while Accumulations stores the accumulators’
measurements.
TABLE I. MEASUREMENT OF LATENCY FOR TRANSMISSIONS FROM NODES TO
BATLINK, UNDER STRESSED CONDITIONS (MEASUREMENT PERIOD: 1 MIN).
Number 1 5 10 15 20 25 30 35 40
of IoT
nodes
Latency 40 43 44 44.5 55 57 57 98.5 101
(ms)
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IV. IMPLEMENTATION ISSUES
Once the different nodes were manufactured,
programmed and calibrated, the solution was installed in
factories located in different countries in Europe and Latin
America. Several problems related with the installation of
electronic devices, scenario particularities, design and
working errors, change of requisites, appeared.
A. Problem Solving Methodology
The system installation, the monitoring and the
maintenance processes were responsibility of the ESCO. Data
losses in factories (at external server level) were reported.
For debugging tasks, external server and BatLink databases
are compared. BatLinks can be remotely accessed through
VPNs (Virtual Private Network) and SSH (Secure Shell). If
there is a coincidence between data stored in the external
server database and in BatLink database, the problem derives
from the IoT network. Thus, the BatNET network behavior
is analyzed searching for network worsening. For this task,
three tools have been implemented in BatLink:
 Map: this tool shows the connections (in real time)
between devices (nodes) in the IoT network.
 UDP-Info: This tool generates a table with the
following information (for each IoT network
device): parent device, RSSI, svn (FW version),
resets and cause of the last reset.
 Graphs-day: Generates a graphic representation of
the information generated by the UDP-Info tool.
If the data at the external server and the BatLink differ, the
problem is located in the access to the external server.
B. Installation and Scenario Issues
Though the solution is delivered with an installation guide,
some problems aroused regarding IoT devices.
1) Voltage higher than 380 V
The initial requisites defined 380 V at most for the electric
lines voltage. However, in reality there are lines up to 500 V,
which meant the breakdown of many devices and the HW
redesign to admit those voltages.
2) Current sensors isolation
The BatMeter devices are designed to work with both Shunt
sensors and current transformers (i.e. clumps), though being
isolated. The existence of other current sensors devices and the
series connection of the BatMeter provoked their failure.
3) Existence of multiple interferences due to the noisy
environment
After analyzing the frequency spectrum, it was observed
that the main interference came from the industrial machines
switching on and off, which leaked into the antenna cables
producing unexpected reboots of the devices. This problem was
solved replacing wiring antennas with SMA direct connection,
This patch reduced the range due to the devices being enclosed
in the electrical and control board. Despite this range reduction,
no performance decrease was noticed in the solution.
 2018 Global Internet of Things Summit (GIoTS)
4) Machines turn-off
In many cases, the turn-off of the factory machines, which
were the direct power source of the IoT devices, provokes the
absence of measurements.
C. BatNET Nodes Issues
1) Unexpected sending of periodically measurements from
the BatMeter
It was observed that apart from the scheduled
periodically delivery of energy measurements, there were
additional random measurements. Nodes do not have a
real-time clock, slowing down over time. A synchronization
protocol h a s b e e n d e v e l o p e d to receive the time from
the BatLink and correct it. However, at the beginning the
protocol did not consider the possibility that the node could
move the time forward, causing these undesired deliveries.
The protocol was modified to solve this problem.
2) Failure in the register of changes in processes
When a quick sequence of signals related to process
changes took place, some could be overstepped if there was a
communication error. To avoid this problem, we implemented
a queue delivery system: while the BatSignal does not receive
the ACK from the BatLink corresponding to a determined
signal change, it does not send the next signal change message.
Likewise, until the BatMeter does not receive the ACK from
the BatLink, it does not send new accumulator data.
D. BatMP Issues
1) Customizable system for client specifications
There was a change of requisites on how to connect to the
Analysis SW that runs in the cloud. The existing REST
interface had to be replaced with a SOAP protocol. The BatMP
software had to be modified, adding a new process to fulfil the
SOAP structures and the communication protocol.
2) System optimization
A highly usage of CPU and memory overload were
detected after installing the BatLink in the factory, despite
having optimized the BatMP SW during the solution
adaptation. This was due to periodic data sending, devices
discovery service and measurements management processes
that lead to system congestion and therefore malfunctioning.
To solve these problems, the following measures were taken:
a) Architecture redesign
The first approach was to change the whole system
architecture. Original Karaf was replaced with a Jetty web
server since the latter is much lighter. A new version of the
software was developed, removing the modular architecture
(the entire OSGi framework) and simplifying the database
structure by removing some of its tables.
b) New driver development
In order to use less memory to store the auxiliary variables
of the IoT devices, a simpler driver to control de different types
of devices was developed. Some functions (e.g. message
request return) of the driver were entrusted to Californium, an
open-source implementation of CoAP, reducing the driver
execution time.
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c) Measurements lost due to harsh environment
Some measurements and accumulations were lost due to the
network because of the high RF interferences. In order to
recover lost data, a new J a v a process was developed. Every
hour, the process checks the data stored in the BatLink
databased and, if it finds any missing measurement, it asks the
involved BatMeter to resend the missing measurement. This
reduced the system loss ratio to zero but it also rose the CPU
and memory usage. So, the database was migrated from
MySQL to SQLite. Although it does not support multi-client
access it has lower memory needs than MySQL. Due to this
database change, data queries needed to be modified as well as
the manner this database was accessed. Also a set of indexes
has been included in the database to make the access easier and
faster. This improves the memory and CPU usage.
d) Process scheduling
Although a small losses ratio was achieved at this point and
the BatLink was working properly, once the system was tested
with a high rate of accumulations reception, it was noticed
that some of these accumulations got lost. This was because
of the temporal coincidence of two processes in the software
platform: the measurement recovery process and
communications with the external server process. The solution
to this problem was to perform a good schedule for these
processes so they would not happen at the same time. The
measurement recovery process is scheduled hourly and the
communication with the external server process is launched
between two measurement recovery processes and its duration
is limited to 15 min. Data transfer to the external server will
resume in the next process launch.
On the other hand, the periodic measurements from the
BatMeter nodes to BatLink start in a random time. This
avoids collisions when all BatMeters starts their transmissions
at the same time. Transmissions start at a random time
between 0 and measurement_period/2.
V. SOLUTION PERFORMANCE AND CURRENT SITUATION
Following the inaugural solution deployment at the factory
in Barcelona, where it was tested and validated, it has been
replicated in other factories across Spain, Portugal, Germany,
Brazil and Mexico. Every factory is a completely new scenario
in terms of existence of radio interferences, power source
voltage, current isolation, and machine configuration.
Currently, the global measurement delivery ratio for 16
factories, 18 IoT networks and more than 500 IoT devices is
88.84 %. Installation failures or power supply issues provoke
the losses. The external server application is waiting for all
possible measurements (96 measurements a day for a 15 min
period) but when production lines are turned off their
associated BatMeters and BatSignal are turned off too. In these
cases, there are not available measurements.
It is worth pointing out that the solution is continuously
being optimized (especially firmware debugging), as
occasionally appear new issues. Firmware update is done
using an OTAP (Over The Air Programming) process that is
automatically lunched every night.
 2018 Global Internet of Things Summit (GIoTS)
VI. CONCLUSIONS
Industry is a key element for EU countries economies. In
order to guarantee high production levels, new technologies
should be introduced in the manufacturing processes. In this
transition to Industry 4.0, IoT technologies and CPSs play an
essential role, since they enable flexible analysis and data
management preserving sustainability. In this work, we present
an Open-IoT solution conceived to optimize energy use in the
automotive industry by identifying energy consumption of
specific production processes. This solution comprises a three-
phase meter prototype and a device that detects processes
changes within the machines or production lines.
The solution, adapted from a building and Smart City
system, has been installed and is currently working at multiple
factories worldwide (with circa 90 % of measurement delivery
ratio). However, there is a vast difference between research
testbeds and the industrial harsh environment. Several issues
have aroused upon deployment, from installation mistakes to
change of requisites. This work collects the experiences of an
IoT solution real-life implementation, describing the main
problems faced and the diverse troubleshooting strategies
followed. Summarizing, the most relevant lessons learned from
this experience and that could be helpful for future IoT real-life
implementations are: Over dimension processing capabilities of
both IoT nodes and coordinator. Pre-validate the IoT network
capabilities in harsh environments and with a high number of
IoT nodes, flooding the network with transmissions. Finally, do
not take initial requisites as the final requisites for granted.
ACKNOWLEDGEMENTS
Authors thank the European Commission (TR@NSENER:
Interreg Sudoe; Grant Agreement No. SOE1/P1/F0005, CPS-
Labs: H2020 ICT-01-2014, Grant Agreement No. 644400), the
Spanish Ministry (MAIGE: RTC-2016-5006-3) and Madrid
Regional Government (ChequeInnovacion. 45/428219.9/17).
Author also thank T6000 and Dominion for their collaboration
in the presented work.
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