Architecture for small use cases

This chapter describes the architecture recommendations for using the OPC Router in small use cases. These recommendations are specifically intended for companies that operate a manageable number of machines or devices and require a cost-effective solution for data integration and processing. It also discusses how small use cases can serve as a basis for future growth and expansion.

The OPC Router is the ideal platform for digitization and offers companies the opportunity to start small and grow step by step. With the OPC Router, you can start with a small use case and expand the solution as needed. This supports a sustainable digitization strategy in which the platform grows with the company's ideas and requirements.

Definition and characteristics of small use cases

Small use cases are characterized by a limited number of machines or devices that need to communicate with each other. Typically, these are individual production lines, smaller workshops or locations with a low data volume.

Typical characteristics of small use cases

• A small number of machines or devices
• Limited data volume
• Simple network infrastructure
• Basic requirements for data integration and processing

Typical examples of small use cases

Example 1: Small production line A small production line consisting of several machines that need to communicate with each other to optimize the production process.

Example 2: Automated warehouse management A small warehouse in which various automated systems (such as conveyor belts, robots and sensors) are networked with each other to make warehouse operations more efficient.

Minimum hardware and software requirements

Hardware requirements

• Standard server or high-performance PC
• Sufficient CPU capacity (at least 4 cores)
• At least 8 GB RAM
• SSD with sufficient capacity for data processing and storage

Software requirements

• Operating system: Windows or Linux
• OPC Router software with the required plug-ins for communication with the existing machines and devices
• Network infrastructure: LAN or WLAN with sufficient bandwidth and stability

Virtualized environments

• The OPC Router can also be operated in virtualized environments such as VMWare or HyperV.
• Advantages of virtualization:
  • Flexibility: Easy scalability of resources as needed.
  • Efficiency: Better resource utilization by consolidating multiple virtual machines on a single physical server.
  • Backup and restore: Easy creation of snapshots and backups of the entire virtual machine.
• Requirements for virtualization:
  • Ensure that the host server provides sufficient resources (CPU, RAM, storage) for the virtual machines to operate.
  • Configure the network connection of the virtual machines carefully to ensure optimal performance and security.

Containerized environments

• The OPC Router can also be operated in containerized environments such as Docker.
• Advantages of containerization:
  • Portability: Containers can be easily moved between different environments without the need for customization.
  • Isolation: Containers provide an isolated environment for applications, resulting in improved security and stability.
  • Efficiency: Containers require fewer resources than full virtual machines and can be started and stopped more quickly.
  • Easy updates: Container updates are easy to perform by updating the image tag and restarting the container.
• Requirements for containerization:
  • Ensure that the host system supports Docker and provides sufficient resources for the containers to run. Use Docker Compose to orchestrate and manage complex multi-container applications.

Example architecture: Small production site

Network setup

• Central OPC Router instance: A single instance of the OPC Router is installed on a server or high-performance PC. This instance manages the communication between the machines and devices in the production line.
• Machine and device data: The machines and devices are connected to the OPC Router instance via a local area network (LAN). The data is collected and processed in real time.
• Data integration: The OPC Router integrates data from various sources, such as PLCs (programmable logic controllers), sensors and other devices. The data can be transferred to a central database or an MES (Manufacturing Execution System).

Example of a configuration

• Server: A standard server with Windows Server 2019, 16 GB RAM and 500 GB SSD.
• OPC Router instance: Installation of the OPC Router on the server, configuration of the required plug-ins (e.g. OPC UA, MQTT).
• Network: Local area network (LAN) with gigabit Ethernet connections to the machines and devices.
• Data integration: Configuration of data connections to the machines, real-time data processing and forwarding of data to a central MES.

Redundancy: Nice to Have

Redundancy can be a useful feature for small use cases as well, increasing the reliability and resilience of the systems. Although redundancy is often used in larger installations, it can also be implemented sensibly in smaller scenarios.

Options for redundancy

• Local redundancy: Implementation of a second OPC Router server or a second instance that takes over in the event of a failure of the main instance.
• Database redundancy: Use redundant database servers or configure a locally redundant database to avoid data loss.
• Network redundancy: Use redundant network connections to ensure connectivity in the event of a network failure.

Example of a simple redundancy configuration

• Second server: An additional server that is configured identically to the main server.
• Failover mechanism: Setting up a failover mechanism that automatically switches to the second server if the main server fails.
• Synchronization: Regular synchronization of data and configurations between the two servers.

Advantages of redundancy

• Increased reliability: Minimizes downtime and ensures that data processing continues even in the event of a system error.
• Fast recovery: Automatic switchover to the redundant system ensures minimal interruptions to operations.

Security aspects

Security is an important aspect even in small use cases. The following measures should be considered:

• Network security: Implement firewalls and network segmentation to prevent unauthorized access.
• Data encryption: If possible, data transmission between the machines and the OPC Router instance should be encrypted. However, older systems used in industry often do not support this. In such cases, it is recommended to implement physical separation or segmentation via VLANs. The OPC Router system can be present in multiple networks so that the web management can be accessed from the “outside”. HTTPS should always be configured for OPC Router management and secure passwords should be used.

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• User access control: Setting up user accounts and roles to control access to the OPC Router instance and the data. Each user should have their own user, or there should be a connection to e.g. Azure EntraID / Active Directory.

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Backup and updates

Regular backups

• Automated backups: Implement automated backups of the OPC Router configuration and databases. This can be done using regular scripts or backup software.
• External storage locations: Storing backups in external storage locations, e.g. in the cloud or on external hard disks, to avoid data loss in the event of hardware failure.
• Recovery testing: Regularly test backup recovery to ensure that data can be quickly and completely restored in the event of an emergency.
• Simple backups in virtualized environments: Virtualized systems offer the option of creating snapshots and backups of the entire virtual machine, which simplifies backup and recovery.

Regular updates

• Software updates: Keep the OPC Router and all plug-ins up to date. Install software updates and patches regularly to close security gaps and improve performance.
• Operating system updates: Ensure that the server's operating system is regularly updated to close security gaps and ensure stability.
• Test environment: First, run updates in a test environment to identify possible compatibility issues before implementing the updates in the production environment.
• Maintenance windows: Schedule regular maintenance windows for updates and backups to minimize disruption to operations.
• Easy updates in container environments: In Docker environments, updates can be performed by simply updating the image tag and restarting the container, which greatly simplifies maintenance.

Summary

For small use cases, the OPC Router offers a flexible and cost-effective solution for data integration and processing. By implementing a single instance on a standard server and using a local network, companies can ensure efficient and reliable communication between their machines and devices. Taking security aspects into account also ensures that data and systems are protected. Redundancy is a useful feature that, although not mandatory, can further increase reliability and resilience. In addition, the OPC Router offers a scalable platform that grows with the company and supports future expansions.

Outlook: Companies that decide to use the OPC Router in small use cases have the option of scaling up to medium and enterprise solutions in stages. For more information and inspiration, see the chapters on architecture for medium-sized solutions and architecture for enterprise solutions to further develop and expand your digitization strategy.