Architecture for Small Solutions
This chapter describes the architectural recommendations for using the OPC Router in small-scale solutions. These recommendations are specifically designed 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-scale solutions can serve as a foundation 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 begin with a small use case and expand the solution as needed. This supports a sustainable digitalization strategy in which the platform grows alongside the company’s ideas and requirements.
Definition and Characteristics of Small Solutions
Small solutions are characterized by a limited number of machines or devices that need to communicate with one another. Typically, these involve individual production lines, smaller workshops, or other locations with low data flow.
Typical Characteristics of Small Solutions
- Few machines or devices
- Low data flow
- Simple network infrastructure
- Simple requirements for data integration and processing
Typical application examples for small-scale solutions
Small production line: A small production line consisting of several machines that must 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 together 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)
- CPU with AVX2 support
- 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 necessary plug-ins for communication with existing machines and devices
- Network infrastructure: LAN or Wi-Fi with sufficient bandwidth and stability
No license is required for testing. A 2-hour demo mode is available.
Virtualized Environments
The OPC Router can also be run in virtualized environments such as VMware or Hyper-V.
Advantages of virtualization:
- Flexibility: Easy scalability of resources as needed.
- Efficiency: Better resource utilization through the consolidation of multiple virtual machines on a single physical server.
- Backup and Recovery: Easy creation of snapshots and backups of the entire virtual machine.
Virtualization Requirements:
- Ensure that the host server provides sufficient resources (CPU capacity, RAM, storage space) to run the virtual machines.
- 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 requiring any adjustments.
- Isolation: Containers provide an isolated environment for applications, leading to 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 containing the data from the previous version.
Containerization Requirements:
- 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 high-performance PC. This instance manages communication between the machines and devices on 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 running Windows Server 2019, with 16 GB of RAM and a 500 GB SSD.
- OPC Router Instance: Installation of the OPC Router on the server. The required 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-scale solutions, redundancy can be a useful feature to increase the reliability and fault tolerance of the systems. Although redundancy is often associated with larger installations, it can also be meaningfully implemented in smaller scenarios.
Redundancy Options
- Local Redundancy: Implementing a second OPC Router server or a second instance that takes over in the event of a failure of the main instance.
- Database Redundancy: Using redundant database servers or configuring a locally redundant database to prevent data loss.
- Network redundancy: Use of 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.
- Rapid Recovery: Automatic switching to the redundant system ensures minimal disruption to operations.
- Maintenance without interruptions: With redundant systems, maintenance work can be performed on one system while the other system maintains operations.
Security aspects
Security is an important aspect even in small-scale solutions. The following measures should be considered:
- Network security: Implementation of firewalls and network segmentation (dividing the network into smaller, manageable segments) to prevent unauthorized access.
- Data encryption: Where 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 deployed across multiple networks so that web management is accessible from "outside." For OPC Router management, HTTPS should always be configured and strong passwords used.
- User Access Control: It is important to set up user accounts and roles to control access to the OPC Router instance and the data. Each user should have their own account, or there should be an integration with, for example, Azure EntraID / Active Directory.
Connect to Microsoft Entra ID/Azure AD
Backups 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 locations, e.g., in the cloud or on external hard drives, is recommended to prevent data loss in the event of hardware failures.
- Restore Tests: Regular backup restore tests should be performed to ensure that data can be restored quickly and completely in an emergency.
- Simple Backups in Virtualized Environments: Virtualized systems offer the ability to create snapshots and backups of the entire virtual machine, which simplifies backup and restore.
Regular Updates
- Software Updates: Keep the OPC Router and all plug-ins up to date. Install software updates and patches regularly to close security vulnerabilities and improve performance.
- Easy Updates in Container Environments: Updates are easy to perform in Docker environments. You simply need to replace the old container with one containing a newer version and mount the same volumes and bind mounts. This significantly simplifies maintenance.
- Operating System Updates: Ensure the server’s operating system is updated regularly to close security vulnerabilities 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-scale solutions, the OPC Router offers a flexible and cost-effective solution for data integration and processing. By deploying a single instance on a standard server and utilizing a local network, companies can ensure efficient and reliable communication between their machines and devices. Taking security aspects into account also ensures the protection of data and systems. Redundancy is a useful optional feature that can further increase reliability and resilience. Additionally, the OPC Router offers a scalable platform that can grow with the company and supports future expansions.
Outlook: Companies that choose to use the OPC Router in small-scale solutions have the option to scale up gradually to medium-scale and enterprise solutions. For more information and inspiration, see the chapters Scaling to Mid-Size Solutions and Architecture for Enterprise Solutions to further develop and expand your digitalization strategy.