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 allows them to start with small solutions and expand them step by step. This approach supports a sustainable digitization strategy in which more machines and devices are integrated gradually. The transition from small to medium-sized solutions requires careful planning and adaptation of the existing infrastructure.

Important steps:

• Assess current and future requirements
• Plan hardware and software scaling
• Implement a scalable network architecture
• Ensure data security and system reliability
• Recognize the right time to transition from small to medium-sized solutions

Advanced hardware and software requirements

Hardware requirements:

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

Software requirements:

• Operating system: Windows Server or Linux with Docker (native installation is not supported)
• OPC Router with a license that includes advanced plug-ins and functions
• Network infrastructure: Gigabit Ethernet or higher

note

No license is required for testing. There is a 2-hour demo mode.

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 OPC Router in a scalable and portable environment.

Sample architecture: Medium-sized production facility

Network structure:

• Multiple OPC Router instances: Multiple instances of the OPC Router are run on powerful servers or in virtual machines. These instances manage 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 reliability: Implement redundancy concepts to ensure reliability.
• 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: OPC Router integrates data from various sources, such as PLCs, sensors, and other devices, and transfers it to central databases or MES systems.

Example configuration:

• Servers: Two powerful servers running 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 also an important aspect in medium-sized use cases. The following measures should be taken into account:

• Network security: Implementation of 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 "outside." For OPC Router management, HTTPS should always be configured and secure passwords should be used.

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• User access control: 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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user management

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 option of creating 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: 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.
• Operating system updates: Ensure that the server's operating system is updated regularly to close security gaps and ensure stability.
• Maintenance windows: Schedule regular maintenance windows for updates and backups to minimize disruption to operations.

Introduction of "Separation of Concerns" (SoC)

With increasing complexity, the introduction of SoC is becoming increasingly important. SoC means that different tasks and responsibilities are divided among separate components to improve the maintainability and extensibility of the system. In the context of the OPC Router, this can mean that different instances are used for different tasks such as data acquisition, processing, and forwarding.

See also: [#separation-of-concerns-in-the-opc-router](grundlegende-konzepte.md#separation-of-concerns-im-opc-router "mention")

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 fixed more easily.

Horizontal scaling and availability

Horizontal scaling:

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

Availability:

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

Test and development environment

With increasing complexity and scaling, a separate test and development environment is becoming increasingly important. This environment allows changes and updates to be tested before implementation in the production environment to minimize risks and ensure stability.

Recommendations:

• Set up a separate environment that replicates the production environment as closely as possible.
• Perform 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, 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 improves the structure and maintainability of the project. Taking security aspects into account protects data and systems. Regular backups ensure data security. Regular updates ensure the continuous performance and security of the entire system.

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