Factory Digital Twin: Use Cases and Architecture
A practical guide to factory digital twin use cases and architecture, showing how line-level and plant-level twins are fed by ISA-95 structured MQTT data.
Practical guides on MQTT, managed brokers and connected products from the ConnectMQ team.
A practical guide to factory digital twin use cases and architecture, showing how line-level and plant-level twins are fed by ISA-95 structured MQTT data.
A beginner-friendly ESP32 digital twin: the board publishes a potentiometer, a button and an LED state over MQTT, a Three.js model in the browser mirrors them in real time, and clicking the 3D LED switches the real one.
Connect an ESP32 to an MQTT broker with Arduino IDE and PubSubClient, publish JSON temperature readings, control the onboard LED from the command line and upgrade to TLS with portal credentials.
Sparkplug metric aliases replace long metric names with small integers in DATA messages. This guide explains how the mapping works, when to use it, and how to debug alias mismatches.
Ten practical Raspberry Pi 5 IoT projects that use MQTT for messaging, with the hardware, topic layout and starting code for each, from a home sensor hub to an AI camera and a factory gateway.
Encrypt your Python MQTT traffic with paho-mqtt and TLS on port 8883: use the system CA store, keep hostname verification on, fix the common certificate errors, and connect over secure WebSocket when only 443-style ports are open.
Unexplained drive trips, hot transformers and power factor penalties all trace back to power quality. Learn what to measure, how analyzers report it and how to stream summaries and events over MQTT.
Node-RED subflows turn repeated groups of nodes into one reusable node. This explainer shows how to build an MQTT alert subflow with instance properties, status reporting and error handling, and how to reuse it across many topics.
Connect Node-RED to a Siemens S7 PLC with node-red-contrib-s7: enable PUT/GET in TIA Portal, address data block variables correctly, publish changes to MQTT and handle setpoint writes safely.
How to move data from PLCs and machines to a cloud MQTT broker without opening the plant network: outbound-only design, DMZ patterns, segmentation, credentials and monitoring.
Build a browser chat app on MQTT over secure WebSocket, with rooms, retained presence that survives crashes via Last Will, and the MQTT 5 No Local option, running on broker.connectmq.com.
Learn which MQTT broker metrics actually predict trouble, how to alert on them without noise, how to build an end-to-end latency probe, and how to watch your broker in the ConnectMQ portal.
Clip a CT clamp around a motor lead, measure RMS current with an ESP32, publish it over MQTT and use a small Python service to detect overloads, frequent starts and drift away from normal load.
A copy-paste reference of 25 mosquitto_pub and mosquitto_sub commands covering QoS, retained messages, Last Will, TLS, output formatting and MQTT 5 properties, all runnable against broker.connectmq.com.
IT OT convergence is less about merging networks and more about giving two very different teams the same trustworthy data. This explainer covers the cultural gap, the technical building blocks and a practical shared-namespace pattern built on MQTT.
A guide to using the ISA-95 equipment hierarchy to organize digital twin models and MQTT topics, including Sparkplug B republishing, naming rules and a validation script.
An industrial AI copilot is only as good as the data it can see. This guide shows how to ground an operator assistant in live, ISA-95 structured MQTT topics so its answers are current, traceable and safe.
Build a small, headless Raspberry Pi Zero 2 W sensor node that reads a BME280, publishes environment and health data over MQTT 5, uses less power and survives months of unattended operation.
Measure voltage, current, power and accumulated energy with a Raspberry Pi and an INA219, publish the readings as JSON over MQTT, and learn when to use a CT clamp HAT for AC mains circuits instead.
MQTT and NATS are both lightweight publish/subscribe systems, but they target different clients. This comparison covers device support, delivery guarantees, persistence and ecosystem so you can place each one correctly.
How usernames and passwords travel in the MQTT CONNECT packet, why they must always be paired with TLS, how brokers reject bad credentials and how to manage per-device credentials on a managed broker.
How MQTT brokers defend against connection floods, publish storms and oversized payloads, what limits a managed broker applies, and how to write clients that respect them.
Step-by-step iOS MQTT Swift tutorial: add CocoaMQTT with Swift Package Manager, wrap it in an ObservableObject, show live sensor data in SwiftUI and publish commands over TLS.
Expose MQTT sensors, switches and lights as HomeKit accessories with Homebridge and the mqttthing plugin, including JSON payloads, TLS credentials and a sensible topic layout.
Publish BMS data such as state of charge, pack voltage, current, cell voltage spread and temperature to an MQTT broker, then add low-battery and imbalance alerts with hysteresis so you hear about problems before the inverter shuts down.
How wind turbine digital twins use SCADA data published over MQTT to monitor yield against the power curve, estimate loads and plan maintenance, with topic design and code.
A practical guide to predictive maintenance machine learning: which condition data to collect over MQTT, how to engineer features and labels, which models to start with, and how to validate them honestly.
Every broker restarts eventually. Learn the client-side patterns that turn an MQTT broker outage into a non-event: jittered reconnects, offline buffering, Last Will status, session handling and idempotent commands.
High availability for MQTT is a shared responsibility between broker and clients. Learn the core concepts, the failover behavior to expect, how to design resilient clients, and the questions to ask any provider.
The nine pillars of Industry 4.0 are often presented as separate technologies. This explainer walks through each one in plain terms and shows how a shared MQTT messaging layer is what actually connects them on a real plant floor.
Create an account, get your broker credentials and connect your first device — no servers to install, patch or scale.