Application of Asset Administration Shell for Scalable IIoT System Design

Abstract

The rapid development of the Industrial Internet of Things, Cyber-Physical Systems, and Digital Twins brought new interest into the market about digital transformation. However, despite the theoretical maturity provided by the current literature, digitalization remains a significant challenge, particularly in complex, real-world environments characterized by fragmented architectures, multi-organizational initiatives, legacy systems, and low levels of technological integration. This dissertation addresses this gap by presenting scalable, modular, and interoperable digital solutions and validating one of them within an algae cultivation environment. Motivated by the constraints observed in the technological stack of a broader multidisciplinary initiative promoting sustainable aquaculture, this work explores two distinct approaches to address the same gap in different ways: a connector-based architecture using Apache PLC4X and Kafka Connect for protocol bridging, and an Asset Administration Shell (AAS)-based architecture for semantically enriched digital representation and leveraging Eclipse BaSyx for IIoT infrastructure integration. The connector-based solution focuses on rapid deployment and ease of integration with an IIoT Platform. This approach establishes bidirectional communication between an OPC UA server and a Kafka message broker. It enables protocol bridging and seamless integration with the data structure of the Platform. A custom-developed Connector UI was created to manage and simplify the configuration of these connectors, supporting rapid deployment and system adaptability. In contrast, the AAS-based solution introduces a standardized, semantically enriched representation of assets, leveraging Eclipse BaSyx to manage AAS components and coordinate data exchange with operational technologies. A custom RESTful Spring Boot application facilitates bidirectional communication between the AAS elements and a Siemens S7 Programmable Logic Controller, enabling real-time monitoring and remote control of the cultivation environment. This latter solution was implemented and validated within an algae cultivation environment, resulting in a fully digitized operational ecosystem. It supports asset lifecycle management, IIoT integration through MQTT, time-series data storage, and live system visualization via dashboard tools-demonstrating its potential for reuse in similarly complex production settings. Key contributions include the development of functional prototypes, modular, scalable, and customizable, and practical integration strategies for legacy infrastructures. The findings underscore the importance of reproducible digital approaches in accelerating industrial digitalization. The work concludes by offering actionable insights and outlining future research pathways for advancing interoperable, Industry 4.0-compliant solutions.