Architecture for small solutions
This chapter describes the architecture recommendations for using the OPC Router in small solutions. 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 solutions can serve as a basis for future growth and expansion.
The OPC Router is the ideal platform for digitalization and offers companies the opportunity to start small and grow gradually. With the OPC Router, you can start with a small use case and expand the solution as needed. This supports a sustainable digitalization strategy in which the platform grows with the ideas and requirements of the company.
Definition and characteristics of small solutions
Small solutions 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 other locations with a low data flow.
Typical characteristics of small solutions
- Few machines or devices
- Low data flow
- Simple network infrastructure
- Simple data integration and processing requirements
Typical application examples for small solutions
Small production line: A small production line consisting of several machines that need to communicate with each other to optimize the production process.
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 powerful PC
- Sufficient CPU capacity (at least 4 cores)
- At least 8 GB RAM
- SSD with sufficient capacity for data storage
Software requirements
- Operating system: Windows or Linux with Docker (native installation is not supported)
- OPC Router, with a license that includes the plug-ins required for communication with the existing machines and devices
- Network infrastructure: LAN or WLAN with sufficient bandwidth and stability
No license is required for testing. There is a 2-hour demo mode.
Virtualized environments
OPC Router can also be run 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 one physical server.
- Backup and recovery: Easy creation of snapshots and backups of the entire virtual machine.
Requirements for virtualization:
- Ensure that the host server provides sufficient resources (CPU capacity, RAM, storage space) for the virtual machines to operate.
- Carefully configure the network connection of the virtual machines to ensure optimal performance and security.
Containerized environments
Please note that all data in a Docker container that is not stored in volumes or bind mounts will be lost when the container is removed.
Therefore, please ensure that all important data in your Docker containers is stored in volumes or bind mounts.
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 adjustments.
- 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: In Docker environments, updates can be performed by simply updating the image tag in the Compose file and re-running the Compose command. Alternatively, a new container can be created with the updated version, which continues to use the volume with the data from the previous version.
Requirements for containerization:
- Ensure that the host system supports Docker and provides sufficient resources to run the containers.
- We recommend using Docker Compose to orchestrate and manage complex multi-container applications.
Sample architecture: Small production facility
Network setup
- Central OPC Router instance: A single instance of the OPC Router is installed on a server or powerful PC. This instance manages 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 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. The necessary plug-ins (e.g., OPC UA, MQTT) are configured to enable seamless communication between the machines and devices.
- Network: A local area network (LAN) with Gigabit Ethernet connections establishes the connection to the machines and devices.
- Data integration: The data connections to the machines are configured. The data is processed in real time and forwarded to a central MES, which is used to monitor and control production.
Redundancy: Nice to Have
Even for small solutions, redundancy can be a useful feature to increase the reliability and fail-safety of the systems. Although redundancy is often associated with larger installations, it can also be implemented in smaller scenarios.
Redundancy options
- 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 of redundant database servers or configuration of a locally redundant database to prevent 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, configured identically to the main server, serves as a backup and can take over if the main server fails.
- 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: Downtime is minimized and data processing continues even in the event of a system failure.
- Fast recovery: Automatic switching to the redundant system ensures minimal disruption to operations.
- Maintenance does not cause interruptions: With redundant systems, maintenance work can be carried out on one system while the other system maintains operation.
Security aspects
Security is also an important aspect in small solutions. The following measures should be taken into account:
- Network security: Implement firewalls and network segmentation (dividing the network into smaller, manageable segments) 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 "outside." In any case, HTTPS should be configured and secure passwords should be used for OPC Router management.
- User access control: It is important to set up user accounts and roles to control access to the OPC Router instance and data. Each user should have their own user account, or a connection to Azure EntraID / Active Directory, for example, should be established.
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Backup and Updates
Regular Backups
- Automated Backups: Automated backups of the OPC Router configuration and databases should be set up to prevent data loss. 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 drives, is a good idea to prevent data loss in the event of hardware failure.
- Recovery tests: Regular backup recovery tests should be performed to ensure that data can be quickly and completely restored in an emergency.
- Easy backups in virtualized environments: Virtualized systems offer the ability to create snapshots and backups of the entire virtual machine, which simplifies backup and recovery.
Regular updates
- Software updates: Keep OPC Router and all plug-ins used up to date. Install software updates and patches regularly to close security gaps and improve performance.
- Easy updates in container environments: Updates are easy to perform in Docker environments. All you have to do is replace the old container with a container with a newer version and connect the same volumes and bind mounts. This greatly simplifies maintenance.
- Operating system updates: Ensure that the server's operating system is updated regularly to close security gaps and ensure stability.
- Test environment: Perform updates in a test environment first to identify potential 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.
Summary
For small solutions, 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 optional feature that can further increase reliability and resilience. In addition, OPC Router offers a scalable platform that can grow with the company and support future expansions.
Outlook: Companies that decide to use OPC Router in small solutions have the option of gradually scaling up to medium and enterprise solutions. For more information and inspiration, see the chapters [scaling-to-medium-solutions.md](scaling-to-medium-solutions.md "mention") and [architecture-for-enterprise-solutions](architecture-for-enterprise-solutions/ "mention") to further develop and expand your digitalization strategy.