Skip to content

Machine Connectors

Machine connectors are micro PLCs and sensors that send signals from your machines to Busroot. They work with any machine, old or new, whether or not it has its own PLC. If your machine or control system can already send data over MQTT, you can connect it directly instead.

Ways to connect a machine

  • Arduino Opta. A micro PLC that Output Industries supplies pre-configured. It reads on/off and 0–10 V signals from the machine or from sensors, and sends them to Busroot. See Arduino Opta.
  • Direct from a PLC or SCADA system. If you can publish MQTT messages, for example from an OPC UA gateway or an industrial IoT platform, you can send signals straight to Busroot. See MQTT.
  • Manually, in the Operator Interface. Operators can count production and record downtime reasons at the station. See Operator Interface.

Whichever way you choose, the signals are the same, so Busroot works with machines of any age or level of automation.

Station signals

Busroot receives the same standard set of station signals from every machine. This table shows which signal each capability needs. For the full definition of each field, see MQTT.

Capability Signal MQTT field(s) Typical source
Asset Utilisation Productive status: on when the station is producing productive A machine "run" or "cycle active" output, an andon light, or a movement sensor
Asset Utilisation (alternative) Electrical load above a threshold, or line speed electrical_kwh, electrical_kw, line_speed An energy meter or a speed signal
Downtime A productive status or production signal, from which stops are detected productive, production_complete As above
Production Tracking Production cycle complete: one pulse per unit or batch production_complete, production_count An exit sensor, an actuator signal or a counter output
Production Tracking (continuous processes) Line speed line_speed A 0–10 V motor drive or encoder signal
Quality Bad units, with an optional quality reason production_complete_bad, bad_production_reason A reject sensor or the machine control
Energy Efficiency Energy consumed electrical_kwh, electrical_kwh_interval, electrical_kw An energy meter
Scheduling Optional: a declared period of non-production non_production_reason External logic, for example interlocked stations
Any Status or error code from the machine status_code The machine control

OEE combines the Downtime, Production Tracking and Quality signals. Tasks needs no machine signal: operators complete them in the Operator Interface.

Choosing and fitting sensors

Where a machine has no suitable output, a sensor is fitted:

  • Use 24 V DC industrial sensors with a switched output, powered from the same 24 V supply as the connector.
  • For a production count, sense the point where the part leaves the machine, for example with an optical or inductive sensor.
  • For a productive signal, use an existing "run" contact, an andon light or a sensor that detects movement.
  • Use screened cable for runs over a few metres, and keep it away from motor power cables.
  • Mount sensors where they won't be knocked or covered by swarf, packaging or coolant.

Output Industries agrees the sensing point for each machine with you before installation. For power, mounting and wiring checks, see the Installation guide.

Device pages

Every connector needs a registered device in Busroot. See Devices.

FAQs

We have installed a new sensor on a station. How do we know it is working?

Update the installation work order with the new sensor and send it to support. The Busroot team connects the signal to the right settings in your account and tells you whether it is working as you expect.

What do the light patterns on the Arduino Opta mean?

Watch the light for at least 60 seconds before you decide what it shows. If you need help, take a video of the light for at least 60 seconds and send it to support. For the meaning of each pattern, see LED codes.

I have connected power to the correct pins, and the LED is flashing red. Why?

The device is not yet configured for your Wi-Fi. Follow Arduino Opta configuration to set it up. If you are also connecting an energy meter, see 3 Phase < 100A or 3 Phase < 4000A.

We have changed our Wi-Fi network. How do we update our Arduino Optas?

Send support an updated work order with the new network details. If you can, include a video of each device's light for at least 60 seconds, so the team can check the setup. You may be asked to re-flash the devices yourself: follow Flashing the device. You need the Wi-Fi SSID and password, the full device ID printed on the front of the Opta, and the device's access token from Devices. Use the Access Token field, not the ID. When it succeeds, the light flashes green.

The Blues cellular module doesn't seem to work. What should I do?

Power-cycle it completely: switch it off, disconnect it from its power supply so that it fully drains, then switch it on again. Check that it is getting power and that its lights are flashing. If it still doesn't work, follow the reset steps in Arduino Opta cellular connectivity.

Can we send signals directly from our PLC?

Yes. If you can send data over MQTT, you are not limited to the Opta's inputs, and you can send codes and statuses as well. You set up the MQTT client yourself, for example in an OPC UA gateway. Contact support and they will prepare the device credentials and instructions for the tool you use. The message format is on the MQTT page.