The shop floor or factory floor is the area inside a factory where manufacturing production is executed. The digitalisation of this area has been increasing in the last few years, introducing the Digital Twin (DT) and the Industry 4.0 concepts. A DT is the digital representation of a real object or an entire system. A DT includes a high diversity of components from different vendors that need to interact with each other efficiently. In most cases, the development of standards and protocols does not consider the need to operate with other standards and protocols, causing interoperability issues. Transducers (sensors and actuators) use the communication layer to exchange information with digital contra parts, and for this reason, the communication layer is one of the most relevant aspects of development. This paper covers DT development, going from the physical to the visualisation layer. The reference architecture models, standards, and protocols focus on interoperability to reach a syntactic level of communication between the IEEE 1451 and the IEC 61499 standards. A semantic communication layer connects transducer devices to the digital representation, achieving a semantic level of interoperability. This communication layer adds semantics to the communication process, allowing the development of an interoperable DT based on the IEEE 1451 standards. The DT presented reaches the syntactic and semantic levels of interoperability, allowing the monitoring and visualisation of a prototype system.

Industrial Internet of Things focuses on the manufacturing process and connects with other associated concepts such as Industry 4.0, Cyber-Physical Systems, and Cyber-Physical Production Systems. Because of the complexity of those components, it is necessary to define reference architectures models to manage Industry 4.0 and the Industrial Internet of Things. The reference architecture models aim to solve the interoperability problem enabling the syntactical and semantic levels of interoperability. A reference architecture model provides a bottom/top view of an industrial process, from the physical transducers at the physical layer to the business layer. The physical layer provides access to a twin representation of a physical thing in the digital world, extending the functionalities in the manufacturing process. This paper studies the syntactic interoperability between the IEEE 1451 and IEC 61499 in an industrial environment. The IEEE 1451 family of standards has the essential characteristics to support the information exchange between smart transducers (sensors and actuators), building the digital elements and meeting the Industry 4.0 requirements. The IEC 61499 standard enables industrial control and automation. These two standards combined at the syntactic level solve an interoperability problem. The IEC 61499 also provides data to the framework layer, supplying all the parameters defined for the communication layer specified by a reference architecture model. This paper combines the IEEE 1451 with the IEC 61499, enabling data exchange in a reference architecture model proposed for Industry 4.0. Network performance at the communication level of a reference architecture model in a local network and an external network is evaluated for the proposed application. The IEEE 1451 standard implementation and adoption to acquire data and communicate it inside an industrial process allowed the IEC 61499 standard to control an industrial process. The IEEE 1451 standard is implemented in a MSP430 low power microcontroller. A Raspberry Pi running FORTE and 4diac in the USA and Portugal were used to test a local network in Portugal and an external network in USA. Data related to network performance was obtained with Wireshark and processed with MATLAB. Tests using the Message Queuing Transport Telemetry Transport and Hypertext Transport Protocols verified the performance of these protocols, supported by the IEEE 1451 and IEC 61499 standards, showing that communication inside an Industry 4.0 environment is possible. MQTT protocol is faster, has a small packet size, and consumes less bandwidth. The HTTP protocol uses more bandwidth but is more reliable for real-time communication, essential for Industry 4.0.

Everyday tasks use sensors to monitor and provide information about processes in different scenarios, such as monitoring devices in manufacturing or homes. Sensors need to communicate, with or without wires, while providing secure information. Power can be derived from various energy sources, such as batteries, electrical power grids, and energy harvesting. Energy harvesting is a promising way to provide a sustainable and renewable source to power sensors by scavenging and converting energy from ambient energy sources. However, low energy is harvested through these methods. Therefore, it is becoming a challenge to design and deploy wireless sensor networks while ensuring the sensors have enough power to perform their tasks and communicate with each other through careful management and optimization, matching energy supply with demand. For this reason, data cryptography and authentication are needed to protect sensor communication. This paper studies how energy harvested with microbial fuel cells can be employed in algorithms used in data protection during sensor communication.