Scalable MQTT-Based Communication Architecture for Distributed Manufacturing Systems
Abstract
Distributed manufacturing requires communication that remains observable and recoverable as device populations, publish rates, and site boundaries grow. This paper presents a Message Queuing Telemetry Transport (MQTT) reference architecture and evaluates its communication core in a controlled, reproducible single-host experiment. The architecture combines a governed multi-factory topic namespace, message-class-specific Quality of Service (QoS), bounded queues, idempotent command handling, and randomized exponential reconnect control. Eclipse Mosquitto 2.1.2 was exercised with MQTT 5 clients on an Apple M3 Pro host. Forty-two steady-state trials covered 10–1000 concurrent publishers, aggregate loads of 25–2500 messages/s, and QoS 0–2 using 512-byte JSON payloads; six additional trials imposed a nominal 5 s broker outage on 250 publishers. Across 406,350 steady-state and 39,000 outage-test messages, measured delivery was 100%, with no duplicates or publisher errors. At 1000 publishers and 1000 messages/s, trial-level mean latency was 0.63 ± 0.61 ms and P95 latency was 1.43 ± 1.22 ms (mean ± 95% confidence interval), while broker CPU averaged 2.79 ± 0.64%. At 2500 messages/s, mean broker CPU was 4.81 ± 0.60%. QoS 2 increased mean broker CPU from 1.72 ± 0.10% at QoS 0 to 3.39 ± 0.20% under the matched 500-message/s workload. During recovery, jittered exponential backoff reduced peak connection attempts from 237.3 ± 54.5 to 57.0 ± 6.6 per 100 ms, although P95 reconnection…
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