What is Cloudio?

Cloudio is an ultra power-efficient multiprotocol industrial gateway that digitizes existing manufacturing processes. It connects industrial machinery to edge or cloud infrastructure for real-time data collection, remote monitoring, and management. It gathers data from machinery, filters, and structures them and sends data via encrypted MQTT protocol.

What are the main benefits of using Cloudio?

Cloudio offers seamless and instant integration with new or existing machinery without adding operational costs in terms of power consumptions, onboarding cost, and time. It is efficient with data acquisition on multiple protocols, secure connectivity, scalable deployment, and significant cost savings by ultra-low self consumption, at the same time helping prevent downtime, predicting maintenance needs, and improving overall equipment effectiveness (OEE).

Hardware

What are the key hardware components of Cloudio?

• Interfaces: OPCUA, Siemens S7, Modbus RTU/TCP, Serial RS422 & RS485 ASCII, Serial TWAI (ISO 11898-1), REST API
• Connectivity: WiFi 6 (802.11ax), BLE 5.3, Zigbee (802.15.4) – Matter & Thread
• Power Options: 3-5.5 VDC, 110/220VAC adapter, 24 V DC adapter, onboard connectors for solar panel and LiPo battery
• Security: TLS v1.2, TLS v1.3, Trusted Platform Module
• Expansion Ports: 2 x 12-bit ADC, 1 x I2C, 1 x SPI, 4 x DIO
• Enclosure: IP66 to IP68 rated, polycarbonate material, dimensions 98 mm x 89 mm x 45 mm

How does Cloudio manage power consumption?

Cloudio uses efficient power management systems. It uses very efficient low quiescent components and cleverly designed power sharing algorithm in firmware to reduce operational power requirement without compromising functionalities.

•  0.15 W – full-time operation mode. We have tested it down to 5 millisecond data polling rate.
• 49 µW  in idle/sleep mode.
• Backup: Out of the box support for a backup rechargeable 4.7 V LiPO battery.
• Energy harvesting: Out of the box support for Solar panel, with Supercapacitor for sustained unattended, off-grid, rugged   use cases.

Firmware and Software

How do I update the firmware for Cloudio?

Cloudio firmware update takes place over the air (FOTA). The RTOS firmware (only 1.2 MB) is secure and efficient, utilizing a code-signing process to ensure integrity and authenticity. The device obtains firmware over MQTT after TLS authentication.

1. Code Signing: The firmware is code signed using self-created certificates through OpenSSL. This initial signing ensures that the firmware is verified and trusted.
2. AWS Signing: The code-signed firmware is then further signed through AWS, adding an additional layer of security and validation.
3. Deployment: The signed firmware is deployed through AWS IoT Jobs. Updated firmware  file can be pushed individually or in groups simultaneously. This ensures that all devices receive the update in a coordinated and secure manner.

What communication protocols does Cloudio support?

Cloudio supports multiple communication protocols, including:

• MQTT over TLS v1.2 or TLS v1.3
• CoAP over DTLS
• Modbus TCP/RTU
• OPCUA
• Profinet
• Siemens S7
• REST API

How is data security ensured in Cloudio?

Cloudio’s firmware is code-signed and verified to prevent capture by malicious actor. Data security is ensured through TLS v1.2 and TLS v1.3 encryption for data transmission and FOTA via MQTT. The device also incorporates a Trusted Platform Module (TPM) for secure hardware and key pair encrypted communication.

Installation and Integration

How do I install Cloudio on existing machinery?

Cloudio is designed for easy installation:

1. Mounting: Use screws or zip ties to secure the device on a stable surface.
2. Interface: Use the RJ45 cable for Modbus TCP, OPCUA, Profinet, Siemens S7, REST API data acquisition. Use RS485 (3 pole A, B, G) cable for RS485 acquisition.
3. Provisioning: Ensure Cloudio is in Provision mode. On the Vaiota App, configure connectivity details, SSID, Password, and data acquisition settings. Touch your NFC-enabled smartphone to Cloudio for instant provisioning and onboarding.

Can Cloudio be integrated with legacy systems?

Yes, Cloudio can be integrated with legacy systems using various industrial protocols such as Modbus RTU/TCP, RS485/422, OPCUA, and Siemens S7. It provides seamless integration without the need for significant infrastructure changes.

How does Cloudio communicate with other devices and systems?

Cloudio communicates with other devices and systems through its supported data communication protocols and interfaces. It can connect to sensors, PLCs, and other industrial equipment, and transmit data to cloud or edge servers for further processing.

Data Collection and Management

What types of data can Cloudio collect?

Cloudio can collect a wide range of data, including:

• Machine Status: Operational status, error codes, performance metrics.
• Environmental Conditions: Temperature, humidity, vibration.
• Process-Specific Parameters: pH levels, ORP, conductivity.
• Custom sensors: 2 Open ADC’s, 1 I2C, and SPI allows any available sensor to be interfaced with it.

How is collected data transmitted and stored?

Data collection from machines happens through Ethernet or Serial cable. When sensors are connected then with any of the available interfaces described earlier. The collected data is structured and transmitted via MQTT to cloud or edge servers via WiFi or Ethernet. Data can be accessed through Vaiota’s dashboard for visualization, analysis, and remote management. Each Cloudio device comes with a dedicated API URL and Token for secure and easy integration with your own ERP, CRM, and BI systems.

Can Cloudio handle real-time data processing?

 It can capture, analyse, filter, structure, and transmit data with minimal latency, providing timely insights for operational decision-making. However, it does not have a full-fledged operating system so the capability is limited simpler descriptive statistics, FFT, short length vector operations. However, we are constantly adding new analytics functions so get in touch if you miss something.

Practical Use Cases

How can Cloudio be used in the food and beverage industry?

In the food and beverage industry, Cloudio can monitor production lines for quality control, track environmental conditions, read dedicated sensors, encodes, count boolean events, and so on.  In general, time series of machine status help ensure compliance with safety standards, and reduce downtime by providing real-time machine status updates.

What role does Cloudio play in water treatment systems?

Cloudio can monitor water quality parameters such as pH, ORP, and temperature, ensuring optimal conditions are maintained. It provides real-time data for remote management and alerts for any deviations from set standards. Over time, the timeseries data help our system to make predictions using bayesian statistics or modern predictive ML models.

How does Cloudio support predictive maintenance in manufacturing?

By continuously monitoring machinery parameters and environmental conditions, Cloudio can detect anomalies and predict potential failures. This enables proactive maintenance, reducing downtime and extending the lifespan of equipment.

How does Cloudio support manufacturing process optimization?

Cloudio can poll SIEMENS S7 PLC tags to count every single event from the bit status and values at data blocks. The full overview of all events on PLCs allow a digital representation of the every single run in the manufacturing process. The time series of such data allows improvement in workflow. 

Advanced Features

What advanced features does Cloudio offer for industrial automation?

Cloudio offers several advanced features, including:

• AI-Assisted Decision Making: Immediate data insights and deviation notifications for informed decision-making.
• Scalable Data Platform: Supports integration with multiple systems for comprehensive data analysis.
• Energy Efficiency: Ultra-low power consumption with options for solar and battery power.
• Robust Security: TPM, TLS v1.2/v1.3, and encrypted communication.

How does Cloudio handle data privacy and compliance?

Cloudio ensures data privacy and compliance through secure communication protocols, encrypted data storage, and adherence to industry standards for data protection. It supports GDPR and other regulatory requirements for data privacy.

Can Cloudio be customized for specific applications?

Yes, Cloudio’s firmware and hardware are designed to be customizable. Clients can configure data acquisition settings, integrate additional sensors, and adapt communication protocols to meet specific application requirements.

Troubleshooting and Support

What should I do if Cloudio is not connecting to the network?

1. Ensure the WiFi credentials are correctly configured using the Vaiota App.
2. Ensure your AP is using 2.4 GHz band.
3. Check the WiFi signal strength and ensure it meets the required RSSI ≥ -70 dBm.
4. Verify that the WiFi network uses WPA2 or newer access security.

How can I reset Cloudio to factory settings?

To factory reset Cloudio:

1. Press and hold the settings button until the LED indicator glows steadily orange (approximately 16 seconds).
2. Release the button and wait for the device to restart with factory settings.

How can I contact Vaiota for technical support?

For technical support, contact Vaiota UG at support@vaiota.com or visit Vaiota’s support page.