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Architecture for Medium-Sized 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:​

The system requirements serve as a baseline; mid-range solutions exceed these:

  • One or more high-performance servers
  • Increased CPU capacity (at least 8 cores), CPU with AVX2 support
  • At least 16 GB of RAM
  • Expanded storage solution, e.g., RAID arrays or SAN

Software requirements:​

  • Operating System: Windows Server—either as a native installation or as a container—or Linux with Docker. There is no native Linux installation.
  • 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: Without a license, OPC Router runs in 2-hour demo mode; see Licensing.

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 Topology:​

  • 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 on the production floor.
  • 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. The Redundancy section describes the concepts provided by the OPC Router and how to configure them; redundancy is included in the Enterprise license—see License Levels.
  • Machine and Device Data: The machines and devices have robust network connections (LAN) to the OPC Router instances. 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:​

  • 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, Backup, and Updates​

The measures regarding network security, data encryption, user access control, backups, and updates apply unchanged to medium-scale solutions. They are described in the section on small-scale solutions.

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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