====== OT Demo — GitOps Helm Chart ======

Simulated industrial OT environment deployed via Fleet on ZKS. All components run as Kubernetes pods in the ''ot-demo'' namespace and communicate over Kubernetes DNS.

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===== GitOps Source =====

The Helm chart source for this demo is maintained in the ZEDEDA ZKS repository:

  * [[https://github.com/ManCalAzure/zks/tree/main/demo/charts/inactive/ot-demo|OT Demo Helm Chart — GitHub]]

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===== Architecture Flow =====

<mermaid>
flowchart TD
    subgraph Sensors["Sensor Simulators (zedmanny/mqtt-demo:hum-vib-v1)"]
        S1[temp-sim]
        S2[humidity-sim]
        S3[press-sim]
        S4[vibration-sim]
        S5[gas-sim]
        S6[rpm-sim]
        S7[conveyor-actuator]
    end

    MQTT["MQTT Broker eclipse/mosquitto:1.4.8 :1883"]
    vPLC["vPLC Sim - vplc_engine.py"]

    subgraph Dashboards["Node-RED Dashboards"]
        NR["node-red 172.16.8.252:1880/ui"]
        NRO["node-red-ops 172.16.8.253:1880/ops"]
    end

    S1 & S2 & S3 & S4 & S5 & S6 & S7 -->|"factory/sensors/type"| MQTT
    MQTT -->|"factory/sensors/+"| vPLC
    vPLC -->|"factory/plc/state, alarms, cmd"| MQTT
    MQTT -->|"factory/sensors/+ plc/state alarms"| NR
    MQTT -->|"factory/sensors/+ alarms state conveyor"| NRO
    NRO -->|"factory/plc/cmd/manual reset"| MQTT
</mermaid>

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===== Components =====

^ Pod ^ Image ^ Purpose ^
| ''mqtt-broker'' | ''eclipse/mosquitto:1.4.8'' | Central MQTT message bus on port 1883 |
| ''temp-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Publishes temperature to ''factory/sensors/thermometer'' |
| ''humidity-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Publishes humidity to ''factory/sensors/humidity'' |
| ''press-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Publishes pressure to ''factory/sensors/press'' |
| ''vibration-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Publishes vibration to ''factory/sensors/vibration'' |
| ''gas-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Publishes gas level to ''factory/sensors/gas'' |
| ''rpm-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Publishes RPM to ''factory/sensors/rpm'' |
| ''conveyor-actuator'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Simulates conveyor actuator feedback |
| ''vplc-sim'' | ''zedmanny/mqtt-demo:hum-vib-v1'' | Evaluates sensor alarms, commands conveyor, publishes PLC state |
| ''node-red'' | ''nodered/node-red:latest'' | Sensor gauge dashboard + vPLC status widgets |
| ''node-red-ops'' | ''nodered/node-red:latest'' | Wind Turbine Ops Board with stop/run/reset controls |

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===== vPLC Alarm Thresholds =====

^ Sensor ^ Warn ^ Trip ^ Mode ^
| thermometer | 37.5 °C | 40.0 °C | high |
| humidity | 75% | 85% | high |
| press | 1000 hPa | 500 hPa | low |
| vibration | 37.5 mm/s | 45.0 mm/s | high |
| gas | 850 PPM | 920 PPM | high |

When any sensor hits **TRIP**, the vPLC latches ''trip_latched=true'' and commands the conveyor to STOP. A manual **Reset Trip** from the Ops board clears the latch.

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===== Access =====

^ Dashboard ^ URL ^
| Sensor Dashboard | [[http://172.16.8.252:1880/ui]] |
| Ops Board | [[http://172.16.8.253:1880/ops]] |

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===== Chart Structure =====

<code>
ot-demo/
├── Chart.yaml
├── fleet.yaml                     # Fleet: namespace ot-demo, createNamespace: true
├── values.yaml                    # Images, IPs, sensor instances
├── files/
│   ├── vplc_engine.py             # vPLC Python logic (mounted via ConfigMap)
│   ├── node-red-flows.json        # Sensor dashboard flows
│   └── node-red-ops-flows.json    # Ops board flows
└── templates/
    ├── mqtt-broker.yaml           # Deployment + ConfigMap (mosquitto.conf) + Service
    ├── sensors.yaml               # Deployment per sensors.instances entry
    ├── vplc.yaml                  # Deployment + ConfigMap (vplc_engine.py)
    └── node-red.yaml              # Deployments + ConfigMaps + LoadBalancer Services
</code>

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===== Deployment Notes =====

  * All pods resolve each other by service name (e.g. ''mqtt-broker'') via Kubernetes DNS within the ''ot-demo'' namespace.
  * Node-RED flows and the vPLC script are embedded in ConfigMaps from the ''files/'' directory using ''.Files.Get''.
  * The ''node-red-dashboard'' npm package is installed at container startup via the ''start_nodered.sh'' script.
  * MetalLB must be installed manually (''kubectl apply -f metallb-native.yaml'') before the LoadBalancer IPs will be assigned.