Scaling to medium-sized solutions

This chapter describes the architecture recommendations for scaling the OPC Router from small to medium-sized solutions. These recommendations are specifically intended for companies that operate a growing number of machines or devices, pursue a more comprehensive digitization strategy, and require an advanced solution for data integration and processing.

Transition from small to medium-sized solutions

The OPC Router offers companies a flexible and scalable platform that enables them to start with small use cases and expand them step by step. This approach supports a sustainable digitization strategy in which more and more machines and devices are integrated step by step. The transition from small to medium-sized solutions requires careful planning and adaptation of the existing infrastructure.

Important steps:

• Evaluating current and future requirements
• Planning the scaling of hardware and software
• Implementing a scalable network architecture
• Ensuring data security and system reliability
• Recognizing the right time to transition from small to medium-sized solutions

Advanced hardware and software requirements

Hardware requirements:

• More powerful servers or multiple servers
• Increased CPU capacity (at least 8 cores)
• At least 16 GB RAM
• Extended storage solution, e.g. RAID arrays or SAN

Software requirements:

• Operating system: Windows Server or Linux
• OPC Router software with advanced plug-ins and features
• Network infrastructure: Gigabit Ethernet or higher

Virtualized and containerized environments:

• Virtualized environments: Use virtualization solutions such as VMWare or HyperV to run multiple virtual machines on powerful servers. Containerized environments: Use Docker and Docker Compose to run the OPC Router in a scalable and portable environment.

Example architecture: Medium-sized production site

Network structure:

• Central OPC Router instance: Multiple instances of the OPC Router are run on powerful servers or in virtual machines. These instances manage the communication between the machines and devices in the production facility. Separation of Concerns (SoC): Workflows are distributed across individual OPC Router instances to efficiently manage the load and improve scalability.
• Redundancy for failover: Implement redundancy concepts to ensure failover.
• Machine and device data: The machines and devices are connected to the OPC Router instances via a robust network (LAN). The data is collected and processed in real time.
• Data integration: The OPC Router integrates data from various sources, such as PLCs, sensors and other devices, and transfers it to central databases or MES systems.

Example of a configuration:

• Server: Two powerful servers with Windows Server 2019, each with 32 GB RAM and 1 TB SSD in a RAID array.
• OPC Router instances: Installation of two OPC Router instances, configuration of the required plug-ins (e.g. OPC UA, MQTT, REST).
• Network: Robust network with gigabit Ethernet connections and redundant network structure.
• Data integration: Configuration of data connections to the machines, real-time data processing and forwarding of data to central MES systems and databases.

Security aspects

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

• 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 web management can be accessed from the outside. HTTPS should always be configured for OPC Router management and secure passwords should be used.

Use HTTPS (Docker)

Use HTTPS (Windows)

• 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.

Connect Microsoft Entra ID/Azure AD

User management

Backup and updates

Regular backups:

• Automated backups: Implementing automated backups of the OPC Router configuration and databases.
• External storage locations: Storing backups in external storage locations, e.g. in the cloud or on external hard disks.
• 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.
• Operating system updates: Make sure that the operating system of the server is regularly updated.
• Easy updates in container environments: In Docker environments, updates can be performed by simply updating the image tag and restarting the container.

Introduction of “Separation of Concerns” (SoC)

As complexity increases, the introduction of SoC becomes increasingly important. SoC means that different tasks and responsibilities are split into separate components to improve the maintainability and extensibility of the system. In the context of the OPC Router, this can mean that different instances or containers are used for different tasks such as data acquisition, processing and forwarding.

See also: Separation of Concerns in the OPC Router

Advantages of SoC:

• Easier extensions: New functions can be added without affecting the entire system.
• Easy scaling: Each component can be scaled independently.
• Improved maintainability: Problems can be isolated and resolved more easily.

Horizontal scaling and availability

Horizontal scaling:

• Add additional OPC Router instances to distribute the load across multiple servers or containers. Workflows are manually distributed to each instance to manage the load.
• Use separation of concerns to ensure that different tasks are distributed to different instances.

Availability:

• Implement high availability solutions to ensure that the OPC Router remains available even if individual components fail.
• Use redundancy concepts to ensure fail-safe operation.

Test and development environment

As complexity and scale increase, a separate test and development environment becomes more and more important. This environment allows changes and updates to be tested before implementation in the production environment, minimizing risks and ensuring stability.

Recommendations:

• Set up a separate environment that replicates the production environment as closely as possible.
• Run regular tests to ensure the stability and compatibility of new updates and changes.
• Use automated testing tools to increase the efficiency and accuracy of testing.

Summary

For medium-sized solutions, the OPC Router offers a scalable and robust solution for data integration and processing. By implementing multiple instances on powerful servers or in virtualized/container environments and using a robust network, companies can ensure efficient and reliable communication between their machines and devices. The introduction of separation of concerns, the consideration of security aspects, and regular backups and updates also ensure the protection of data and systems, as well as the continuous performance and security of the entire system.