Problem Description
Modern industrial environments demand robust, scalable, and cost-effective testing solutions before deploying to the shop floor. Traditional methods relying on physical infrastructure are expensive, inflexible, and slow. Our client needed a virtual testing framework to simulate industrial OPC UA communication in a cloud environment—securely and efficiently.
Approach
We designed and deployed a fully cloud-based OPC UA simulator leveraging the AWS ecosystem. The solution replicates machine behavior and data flow, allowing teams to develop, test, and validate industrial automation systems remotely. It’s scalable, lightweight, and integrates seamlessly with AWS services, enabling rapid prototyping and real-time data emulation.
Results
✅ Real-time simulation of machine data
✅ Reduced testing and deployment time
✅ Remote collaboration for global engineering teams
✅ Elimination of hardware dependency
✅ Seamless integration with AWS IoT and data processing pipelines
The simulator empowered the client to accelerate innovation, reduce costs, and build smarter, cloud-ready industrial solutions.
Tools
- AWS Cloud Infrastructure
- OPC UA Protocol
- Python – for simulation logic and data generation
- Docker – for containerized deployment and scalability
- Azure DevOps – CI/CD automation and project management
