Scaling to Mid-Size Solutions

This chapter describes the architectural recommendations for scaling the OPC Router from small to mid-size solutions. These recommendations are specifically intended for companies that operate a growing number of machines or devices, are pursuing a more comprehensive digitalization 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 incrementally. This approach supports a sustainable digitalization strategy in which 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.

Key Steps:

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

Advanced Hardware and Software Requirements

Hardware Requirements:

• One or more high-performance servers
• Increased CPU capacity (at least 8 cores)
• CPU with AVX2 support
• 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 features
• Network infrastructure: Gigabit Ethernet or higher

note

No license is required for testing. A 2-hour demo mode is available.

Virtualized and Containerized Environments:

• Virtualized Environments: Use virtualization solutions such as VMware or Hyper-V to run multiple virtual machines on high-performance servers.
• Containerized Environments: Use Docker and Docker Compose to run the OPC Router in a scalable and portable environment.

Sample Architecture: Medium-Sized Production Facility

Network Architecture:

• Multiple OPC Router Instances: Multiple instances of the OPC Router are run on high-performance 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 Fault Tolerance: Implement redundancy concepts to ensure fault tolerance.
• Machine and Device Data: The machines and devices are connected to the OPC Router instances via a robust network (LAN). 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:

• Servers: Two high-performance servers running Windows Server 2019, each with 32 GB RAM and a 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 a 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-scale use cases. The following measures should be considered:

• Network Security: Implementation of firewalls and network segmentation 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.

Use HTTPS

Use HTTPS (Windows)

• User Access Control: 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.

Integrate Microsoft Entra ID/Azure AD

User Management

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 storage locations, e.g., in the cloud or on external hard drives, is advisable to prevent data loss in the event of hardware failures.
• Restoration Tests: Regular backup restoration 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 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 vulnerabilities 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 containing the data from the previous version.
• Operating System Updates: Ensure that the server’s operating system is updated regularly to address security vulnerabilities and ensure stability.
• Maintenance Windows: Schedule regular maintenance windows for updates and backups to minimize disruption to operations.

Introduction of "Separation of Concerns" (SoC)

As complexity increases, the implementation of SoC becomes increasingly important. SoC means that different tasks and responsibilities are distributed across 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

Advantages of SoC:

• Easier Extensions: New features 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. Connections are manually distributed across the individual instances to manage the load.
• Use separation of concerns to ensure that different tasks are sensibly distributed across 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 reliability.

Test and Development Environment

As complexity and scale increase, a separate test and development environment becomes 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, the OPC Router offers a scalable and robust solution for data integration and processing. By deploying multiple instances on high-performance servers or in virtualized/containerized environments and utilizing 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. Addressing security aspects 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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