IoT & Connectivity Tips

  Hello, ThingWorx Users!   As promised, we are back with Episode 02 of ThingWorx on Air. Listen to our PM Milan share the secrets of Operator Advisor and how we built the solution with an eye for IIoT developers.   Learn how Operator Advisor provides you with pre-built snippets of code for widgets, services, etc. targeted specifically for shop floor operators. No more starting from scratch!   Reach out if you have any questions or topic requests!   Stay connected, Kaya   P.S. Keep your ears peeled for the “Wowza Widget of the Week!”

  Some call him JB. Some call him Joe. Others call him @bironology. I call him an awesome guy—he’s our CTO of IoT here at PTC—Joe Biron!   Joe’s an architect at heart, a developer, an avid gamer and a technologist (check him out on Twitter @bironology).   Watch as he guest stars in the Microsoft Channel 9 “IoT Deep Dive Live” show! Listen to him explain how you can build end-to-end industrial solutions with ThingWorx and Azure. ­­ And, guess who’s running the demo behind the scenes: our Global ThingWorx COE Lead, Neal Hagermoser, who you may recognize from a previous Ask Kaya post where I interviewed him on why we chose to partner with Azure.   Enjoy the show and stay connected! Kaya

Help the ThingWorx product team with some key strategic questions about developing apps in the cloud!   Let us know what you think here!   Stay connected, Kaya

  Meet Anthony. Anthony came to PTC from a large industrial company as a user of Axeda, a leading device connectivity company that PTC acquired in 2014. With a background in aerospace engineering and experience in a variety of industries including life safety, healthcare, nuclear power, and oil and gas, Anthony has been working to create new value around innovation for customers transitioning to ThingWorx. When he’s not working on IIoT, he’s playing music on Cape Cod, photographing Hawaiian landscapes or bringing awesome inflatable chairs into the office.    You may recall from last week's post that Thing Presence is one of the top three features in 8.4 that you might not know about. This week, I spoke with Anthony for a deeper dive on Thing Presence. Check out how it went.   Kaya: What was the challenge users were facing that led us to create Thing Presence? Anthony: Axeda customers transitioning to ThingWorx were struggling with the connectivity use case and kept asking, ‘why is my asset always offline?’ When we evaluated it, we discovered that it was tied to the difference between AlwaysOn and Axeda eMessage protocol architectures. IsConnected will always report false for polling and duty cycle devices.   The use case of Thing Presence is to know that the asset is reporting into the network and is ready to provide information (push) or be accessed to retrieve information or do a remote desktop support (pull). This use case is relevant for any asset in ThingWorx that uses duty cycle.   In ThingWorx 8.4 (coming in early 2019), the new IsReporting state will inform the user when a polling device is communicating on a regular basis. If it is, then IsReporting will be true. The IsReporting state resolves the discrepancy wherein devices that are on duty cycle appear disconnected due to the IsConnected state reporting false.  New "IsReporting" state improves visibility of an asset's communication state Kaya: How exactly does Thing Presence work? Anthony: You can think of it in terms of having teenagers. You tell them they need to check in with you on a regular basis through text message. If a text is missed, all of a sudden you take action.   Now, imagine the teenager is a device. If a device was supposed to check in every five minutes and it misses one poll, I want to flag that as a problem. The challenge with that from a service perspective is that sometimes your service personnel will go out and work on a device and may need to take it offline for a bit of time; we need to factor that in. We certainly don’t want to deploy someone or try to fix something when a service technician is already there.   You might decide, ‘my average service visit is an hour, so, if I miss a couple of pings, I’m okay; but, if I’m offline for more than an hour, then I’d like to know about it because I’d like to take action.’ Thing Presence allows you to define that window.   Kaya: You’ve mentioned ‘duty cycle’ and ‘polling cycle.’ Can you explain these terms? Anthony: Duty cycle and polling cycle are the same thing. It means that a device has a time for which it is expected to check in, and, provided that it checks in within that timeframe, all is good with the connection.   Connected services rely on a connection. As soon as the connection is broken, I no longer have the ability to service the asset.   Kaya: Given everything we’ve discussed, where do you see Thing Presence headed? Anthony: The next piece of the equation for us is to provide information on the health of the connection. When you look at servicing a remote asset, you need to a) know that it is communicating, and b) know that the connection is healthy before you try anything. I wouldn’t want to try a software update if I am losing connection with my asset on a regular basis.   What do we mean by health? We mean: is the device checking in when it should be? If it’s not, is there a pattern to that connection, and are those patterns tied to applications? For example, is it only on during working hours? Does it turn off during holidays? If the device is in a school, does it turn off during summer maintenance work? This allows us to garner insights on how and when the equipment is being used, not just operating status. At the end of the day, does this mean I can apply analytics and AI tools to it? Absolutely. Is it the first place I would apply it? Probably not.   Kaya: In your mind, what is the next big thing coming in ThingWorx that you’re particularly excited about? Anthony: Mashup 2.0 and Asset Advisor 8.4. (Double mic drop.)   Kaya: That’s awesome. My last question is related to you. Can you tell me what your favorite aspect is about working at PTC? Anthony: The chaos. Very often it’s chaos that breeds innovation. What I mean by that is that, if you try to create something because you sit down and you say, ‘I am going to innovate,’ very often that is a failure because the majority of the time it’s the influence of a deadline, a customer need or an application at hand that makes the environment trying and sometimes hectic. But, it is in these challenging environments where you can be the most creative and innovative as an engineer.

  If you’ve ever wished you could see into the future, you’ve come to the right place! Put your reflective suits and sunglasses on to prepare for a glimpse into the future of our upcoming ThingWorx 8.4 release! Here are sneak peeks of the top three features you may not have known are coming in ThingWorx 8.4.   1. Thing Presence While it sounds like something from an episode of Ghost Hunters, Thing Presence provides insight into the communication state of polling or duty cycle Things (those that check in and out on a periodic basis). We’re introducing a new IsReporting state, which would be set to true when polling assets check in on time and are considered “present in the network.” This helps to bridge the gap where the traditional ThingWorx IsConnected state reports offline and does not coincide with the actual network presence of the device.   Thing Presence: New "IsReporting" State2. Data Helpers You may not know what Data Helpers are, but if you’re a longstanding ThingWorx developer you likely know about Expression and Validator widgets. These widgets were handy because they allowed you to write conditional logic or input validation to drive behaviors in the UI, but were super frustrating to use. They took up lots of room on the visual layout canvas and only had a very little textbox to edit them. In the 8.4 release, we are happy to announce that these two widgets will no longer be placed on the layout canvas. Instead, they will have a dedicated editor to work from with plenty of room for code development, parameter configuration and event definition and binding. We’re wrapping all of this functionality into a nice little feature called…Data Helpers. Data Helpers: Expression and Validator Widgets No Longer in Layout Canvas3. ThingWorx Flow In case Thing Presence and Data Helpers aren’t exciting enough, we’re also introducing ThingWorx Flow, a neat new feature set that dramatically speeds development of connected applications through integrations with business systems like Salesforce and SAP. Imagine that, when a certain alert triggers, you want to automatically create a Salesforce service ticket and even send an emergency text to an operator to prevent damage to a device. A large set of out-of-the-box system connectors (PTC Windchill, Office 365, Google Docs, Slack, Jira and more) are included, which you can drag and drop onto a canvas to visually define a workflow. In the example below, a ThingWorx-connected device element, a Salesforce “create case” action and a Twilio text message connector were dropped into the canvas to create a visual workflow. Orchestration: Example Workflow that Creates Salesforce Cases and Alerts OperatorsThing Presence, Data Helpers & Flow—get ready for these and more in ThingWorx 8.4!   Stay tuned for future posts that go into greater depth about each of these features and comment your thoughts below!   Stay connected, Kaya

If your mashups are feeling cramped and crowded, we’ve got some good news for you. Coming in our next release, ThingWorx will offer truly responsive layouts for your mashups, allowing you to adjust the size of your viewport or present a mashup on a variety of displays—laptop, tablet, phone, etc.—without compromising presentation or responsiveness. This new layout capability is based on Flexbox. Check out this article to learn more.   Here’s a sneak peek of our new layout editor. It’s still in development, but I hope you can start to see how you can use this in your UI development.   Sneak Peek: Responsive Mashup Layout Notice the ability to split the layout into containers. Each of the containers allows you to horizontally or vertically layout, distribute from left or right, align from top or bottom, justify space between widgets, etc. This gives you as the developer ultimate control to define the responsiveness of the mashup.   Like what you see? Any feedback? Let me know below!   Stay connected, Kaya

Meet Neal. When Neal joined PTC five years ago, he immediately hit the ground running on IoT initiatives, working in multiple areas ranging from pre-sales to partner relations. Today, he is a Worldwide ThingWorx Center of Excellence Principal Lead at PTC, and his biggest focus is supporting the go-to-market for the Microsoft partnership.   I sat down with Neal recently to hear the details on exactly how Azure and ThingWorx can be used to develop world-class IIoT applications.   Kaya: Can you explain how Azure and ThingWorx work together? Neal: Yes, so Azure provides the cloud infrastructure that our customers need in order to deploy ThingWorx.   By having Azure as our preferred cloud platform, we’re able to specialize our R&D efforts into utilizing functionality that is available in Azure, rather than having to reinvent the wheel ourselves for each cloud platform in the attempt to remain cloud-agnostic. By leveraging a single, already quite powerful, cloud platform through Azure, we’re able to maximize our development efforts.   Kaya: What was the major problem that led to us investigating cloud options? Neal: There were two issues that our users had. The first was we often had complicated installs and setup procedures because we were genericizing the whole process, so the initial setup and run was complicated and expensive. For example, we were requiring them to setup additional VMs and components, and we were giving them generic instructions because we were being very agnostic, when they had already chosen outside of us to use one of the cloud platforms. We knew our customers wanted to move fast, so we had to make it easier and faster for them to see results.   The other issue we ran into with customers was the confusion in the offerings. For ThingWorx, ingest is just one aspect of IoT. ThingWorx is particularly strong in areas like enabling mixed reality and augmented reality as well as application enablement. And, while we also have the ability to perform ingest capabilities, Microsoft is especially powerful when it comes to ingest capabilities and security. We decided that the smartest solution was to leverage Microsoft’s expertise in data ingestion to make ThingWorx even more powerful; so, we made the Azure IoT Hub Connector. By partnering with Microsoft, we have joint architecture where you can see how Microsoft provides key features and ThingWorx will run on top of those features and get you faster to the market to develop the application.   Below is an example of a high-availability deployment of ThingWorx on Azure that utilizes ThingWorx Azure IoT Connectors to access an Azure IoT Hub.  High-Availability Deployment of ThingWorx on Azure Kaya: Why did we partner with Azure? What specific benefits does Azure offer over other cloud services providers? Neal: When we started to look at what our customers were using for cloud services, we noticed that a lot were using Microsoft. When we join forces with Microsoft, we have a much more wholistic offering around digital transformation. With the partnership, PTC and Microsoft are able to leverage each partner’s respective strengths to provide even more powerful IIoT solutions. You have Windchill and Microsoft’s business application strategies; you have Vuforia and Microsoft’s mixed reality and augmented reality strategies; and, you have ThingWorx on the Microsoft Azure cloud. Overall, you have a much more complete and powerful offering together.   Kaya: What is your favorite aspect about working at PTC? Neal: The growth. There’s been a lot of changes over the last five years that I’ve been here. PTC has been able to leverage its strengths and long-time experience in the CAD and PLM markets to enter and ultimately become a leader in the IIoT market, according to reports by research firms like Gartner and Forrester. In short, the growing IIoT market and PTC’s leadership in the industry.   Note to Readers: You’ve likely heard about our major strategic partnership with Microsoft to leverage our respective IIoT and cloud technologies to optimize the creation, deployment, management and overall use of your IIoT applications. If you haven’t heard about the partnership, check out the press release here. If you’re curious about more aspects of PTC’s partnership with Microsoft, check out this site devoted to sharing how ThingWorx and Azure are better together.

Just like the perfect sandwich, we know that you have specific preferences and requirements for your ThingWorx deployment. Whether you like to keep things simple with a classic grilled cheese or you like to spice things up with a more elaborate chipotle mayo BLT, we’ve got you covered. Our ThingWorx Deployment Architecture Guide explains what you’ll need to deploy ThingWorx in three different scenarios: production, enterprise and high-availability (pictured below).   Deployment Architecture for ThingWorx on Azure in High-Availability We’ve recently published Version 1.1 of the ThingWorx Deployment Architecture Guide. In it, you can find updated deployment architecture diagrams to more distinctly show the data and application layers within a ThingWorx environment. Our team has also added a new section on what you’ll need to deploy ThingWorx on Microsoft Azure, PTC’s preferred cloud platform.   Check it out here or in the attachment section on the right.   Stay connected, Kaya

In this session, we pick up where we left off with the mashup which was worked on in part 1 of our Advanced Mashup Expert Session series. Specifically, we will explore the concepts of master mashups, session variables, and media entities, using each to further enhance the look and feel of our mashup.     For full-sized viewing, click on the YouTube link in the player controls. Visit the Online Success Guide to access our Expert Session videos at any time as well as additional information about ThingWorx training and services.

This video builds upon the mashup created in the basic session, and strives to create a more polished, user-friendly interface that is ready for deployment. In part 1, we’ll take a look at advanced layout designs and include a more varied set of widgets to help draw attention to some of the more pertinent properties being captured within the mashup.   For full-sized viewing, click on the YouTube link in the player controls. Visit the Online Success Guide to access our Expert Session videos at any time as well as additional information about ThingWorx training and services.  

Fresh look at getting started with ThingWorx in a relevant context that outlines the DEVOPS needed to kick-start your programming.     For full-sized viewing, click on the YouTube link in the player controls. Visit the Online Success Guide to access our Expert Session videos at any time as well as additional information about ThingWorx training and services.

Overview A global leader in chemical processing and industrial manufacturing, with a strong international footprint and multiple production sites worldwide, set out to transform its production ecosystem by adopting Industrial IoT (IIoT). The objective was to unify fragmented factory data, enable real-time analytics, and drive operational efficiency through AI-powered insights. Based on detailed use case documentation and architectural workshop findings, this reference architecture outlines a robust, scalable solution designed to integrate factory systems, deliver AI-supported insights in real time, and empower teams through self-service applications.   The solution leverages PTC’s ThingWorx suite—along with Microsoft Azure services and complementary technologies—to address key challenges in production, quality, and efficiency across engineering, manufacturing, and operations. About Beyond the Pilot series Use Case   A. Engineering – Process Optimization & Quality Control   Problem: Resolving Data Integration & Visibility Challenges   Customer’s engineering teams struggled with fragmented data across various factory systems, limiting their ability to analyze process performance and optimize production parameters. Without a unified data platform, engineers could not effectively compare historical and real-time machine center lining values, making it difficult to maintain consistent production quality.   Solution: Unified Data Integration & Advanced Process Analytics   The reference architecture establishes a central, cloud-based data platform that aggregates and correlates machine data from various sources in real time. By integrating OPC Aggregators and Kepware with Azure IoT Hub, factory data is ingested, processed, and made accessible via ThingWorx applications. Engineers can now visualize mechanical and digital process values, set dynamic thresholds, and receive alerts when deviations occur—ensuring precise process control and quality optimization.   Role of PTC Products:   PTC Kepware: Standardizes and integrates machine data from disparate factory systems, ensuring a seamless flow of real-time process variables. ThingWorx Platform: Provides a robust dashboard for analyzing centerlining data, visualizing production trends, and enabling data-driven decision-making. ThingWorx Digital Performance Management (DPM): Automates the identification of process inefficiencies, allowing engineers to fine-tune machine settings dynamically.   B. Manufacturing – Scrap Reduction & Production Efficiency   Problem: Enhancing Scalability and Reducing Operational Inefficiencies   Customer faced challenges in scaling its IIoT solution as new sensors and data sources were introduced. Traditional systems struggled with the increased volume of factory data, leading to slow system response times and ineffective real-time analytics. Additionally, manual process adjustments resulted in inconsistencies, contributing to increased scrap rates and wasted materials.   Solution: Cloud-Scalable Infrastructure with Real-Time Process Optimization   To address these issues, the architecture leverages Azure IoT Hub, Azure Data Explorer (ADX), and Influx DB to handle massive data streams and provide low-latency analytics. This ensures that production trends, environmental conditions, and machine parameters are continuously monitored and optimized in real time. Advanced machine learning models predict process inefficiencies, enabling operators to make automatic adjustments to reduce scrap and optimize yield.   Role of PTC Products:   ThingWorx Platform: Acts as the central command hub, enabling real-time decision-making based on factory data trends. ThingWorx Digital Performance Management (DPM): Uses historical data to provide AI-supported recommendations for reducing material waste and improving overall equipment effectiveness (OEE). PTC Kepware: Ensures reliable, high-speed data acquisition from sensors, production lines, and environmental monitoring systems, feeding critical information into ThingWorx for optimization.   C. Driving Digital Transformation & Quality Optimization   Problem: Lack of Digital Process Automation & AI-Powered Decision Making   Customer’s previous factory systems relied on manual reporting and fixed thresholds for process control, limiting the ability to detect and respond to process inefficiencies in real time. Operators needed a system that could provide intelligent, self-service applications with AI-driven recommendations for optimal production performance.   Solution: AI-Driven Automation & Dynamic Quality Control   The IIoT architecture integrates AI-powered predictive analytics to analyze deviations in real-time and suggest automatic machine adjustments. Real-time applications, customizable process recipes, and dynamic alerting systems empower production teams with actionable insights. By embedding self-service applications in ThingWorx, engineers and operators can fine-tune process settings and receive automated recommendations for improving quality and efficiency.   Role of PTC Products:   ThingWorx Platform: Serves as the central analytics hub, delivering AI-powered insights for continuous process improvement. ThingWorx DPM: Uses machine learning to correlate scrap rates with process variables, recommending changes that minimize waste and enhance quality. PTC Kepware: Captures real-time process data, ensuring that AI models receive accurate inputs for predictive analysis.   Customer’s digital transformation journey is now backed by a robust, PTC-powered IIoT ecosystem that delivers continuous improvement, higher production efficiency, and proactive maintenance capabilities—ultimately driving the future of smart manufacturing. Technical Architecture and Implementation Details   This section combines detailed technical descriptions with the overall reference architecture. It describes the core components, integration points, and implementation strategies that deliver a robust IIoT solution for the customer.   A. Architecture Overview Diagram       High-level architecture diagram for the final solution B. Detailed Technical Components     Component Role Key Features OPC Aggregators & Kepware Stream and bridge machine data from production, DEV, and QA environments to Azure IoT Hub for real-time processing in ThingWorx. Scalable ingestion; latency monitoring; secure device connectivity; segregated closed environments for DEV/QA. Azure IoT Hub Ingests and secures machine telemetry data for analytics. Centralized data ingestion; integration with Azure services. ThingWorx on VMs Hosts the core IIoT application that processes data, provides end-user applications, and manages workflows. High performance; disaster recovery via VM snapshots; enhanced security through Azure AD integration and SSL support. Managed PostgreSQL Provides high availability for persistent application data through replication and failover. Data redundancy; managed service benefits; automated backup and recovery. Azure Data Explorer / Influx DB Handles advanced analytics, timeseries visualization, and predictive insights for telemetry data. Real-time analytics; anomaly detection; cost-effective long-term storage. Monitoring & Logging Tools Ensure comprehensive observability and prompt incident response across all components. Real-time applications monitoring; alerting; centralized log aggregation. RESTful APIs Enable seamless integration with ERP systems, legacy data sources, and other IoT devices. Secure data exchange; standardized connectivity protocols.     C. User Personas   The success of this solution relies on a well-defined team of technical experts responsible for deployment and ongoing management:     Persona Key Responsibilities Plant Manager Oversee overall factory performance and use data insights for strategic decision-making Drive process improvements and efficiency Digital Transformation Lead Analyzes and prioritizes valuable use-cases for the business Implement IIoT solutions across factory operations and scale AI-driven automation and data analytics Ensure long-term digital innovation and adoption Operations Manager Oversee production lines and ensure efficiency and optimize machine settings based on real-time insights Troubleshoot and resolve process issues quickly Quality Assurance Engineer Monitor production quality in real time and ensure compliance with quality standards Reduce scrap and rework by addressing deviations early Maintenance Engineer Monitor equipment health and respond to alerts and perform predictive maintenance to prevent failures Minimize downtime through proactive repairs Software Engineer Develop and maintain IIoT backend and frontend systems and ensure seamless data integration and API connectivity Optimize system performance and scalability Cloud Architect Design and manage IIoT cloud infrastructure and ensure scalable and secure cloud deployments Optimize data storage and processing in the cloud Security Analyst Implement and monitor security measures for IIoT systems and conduct risk assessments and threat analysis Ensure compliance with cybersecurity standards DevOps Engineer Manage CI/CD pipelines for IIoT applications and automate deployments and infrastructure management Optimize system performance and reliability     NOTE : Although these personas were required, the needs were fulfilled by a team of only 4–5 developers effectively playing multiple roles. Outcome   Optimized Production Efficiency By unifying machine telemetry, process parameters, and historical trends, customer empowers engineers with real-time insights. AI-driven recommendations and automated adjustments replace trial-and-error, enabling precise, dynamic optimizations. Bottlenecks and inefficiencies are identified instantly, allowing rapid corrective actions for peak performance.   Reduced Waste & Enhanced Quality Real-time process optimization and automated quality control significantly reduce material waste and variability. The system detects deviations at the source, enabling instant adjustments and ensuring consistent product quality, minimizing scrap, rework, and compliance risks.   Seamless Data Visibility & Collaboration A centralized dashboard provides real-time access to critical metrics, eliminating fragmented reports and delays. Engineers and operators can compare production data across sites, standardize best practices, and drive continuous improvements across the network.   Future-Ready Innovation Beyond immediate gains, this IIoT transformation lays the foundation for scalable sensor integration, AI-driven automation, and advanced predictive analytics. It’s not just a solution for today—it’s a long-term framework for sustained digital innovation in smart manufacturing. This reference architecture is not just about solving today’s challenges—it establishes a long-term, adaptive framework that will continue to evolve, enabling our customer to remain at the forefront of smart manufacturing and industrial digitalization. Additional Information   This section provides further insights into the project implementation and future strategic direction.   Parameter Description Example/Notes Time to First Go-Live Estimated duration from project initiation to initial production deployment. Approximately 16 weeks Partner Involvement Key strategic and technical partners collaborating on the deployment. Microsoft, Ansys, and Deloitte were supporting the digital transformation initiative centered around ThingWorx. Customer Roadmap Future enhancements planned by customer, such as AI-based predictive analytics and further automation. An expansion to incorporate AI and advanced machine learning–driven insights is planned       Vineet Khokhar Principal Product Manager, IoT Security   Disclaimer: These reference architectures will be based on real-world implementation; however, specific customer details and proprietary information will be omitted or generalized to maintain confidentiality.   Stay tuned for more updates, and as always, in case of issues, feel free to reach out to <support.ptc.com>