With Cybus Connectware 2.0, we take a decisive step toward realizing our vision: turning manufacturing into a sustainable, agile business that truly delivers on the promise of Industry 4.0. This new generation builds on more than a decade of real-world experience in mission-critical factories and our team’s extensive expertise in distributed systems. Developed in close collaboration with customers, partners and internal stakeholders, it marks the next stage in the evolution from a powerful Factory Data Hub to an architecture designed to meet future demands more quickly and predictably.
Expert article by
Pablo Vicente
Lead Software Architect, Cybus
In modern factories, downtime isn’t an option. Cybus Connectware runs 24/7, often for months without human intervention. That reality demands an architecture that is not only robust but autonomous – capable of recovering seamlessly from infrastructure changes or disruptions.
It must scale predictably, no matter the size of the factory. It must earn absolute trust from both OT and IT – as the single reliable source of truth for production data.
These expectations shaped the core architectural principles behind Connectware 2.0:
As a distributed system, it must also handle unexpected situations quickly to minimize production interruptions while enabling faster feature delivery to meet customer and market demands.
At the heart of Connectware 2.0 lies a fundamental shift: replacing the central control plane with a fully decoupled, event-driven architecture. This redesign makes the system easier to extend, inspect, scale and maintain, aligning with proven industry best practices.
Decoupled Microservices
The core logic is now divided into fully decoupled microservices. This strict separation ensures fault isolation, accelerates feature delivery and enhances observability for faster troubleshooting.
Persistent State in PostgreSQL
All service and resource data are stored in PostgreSQL, creating a solid, reliable foundation for system state and paving the way for advanced future functionalities.
NATS JetStream as a Resilient Backbone
The event-driven backbone is powered by NATS JetStream. It delivers high availability, high throughput and replay capabilities that simplify design, recovery and scalability.
Trust is built on transparency and reliability. Therefore, resilience and observability were integrated as core principles into the architecture. Every operation is idempotent and automatically retried upon failure, while advanced mechanisms control peak load scenarios.
The system self-heals from infrastructure issues and services can replay missed events to ensure consistency. Every state change is fully traceable through three independent sources: logs, the PostgreSQL database and the JetStream event log. Critical operations carry unique IDs that can be traced across microservice boundaries, giving operators the transparency needed to resolve issues within minutes.
New components are developed as independent packages, simplifying upgrades, minimizing downtime and keeping the system future-proof and easily adaptable.
The new architecture unleashes concrete, measurable potential. It delivers improvements across all operational dimensions. Concurrent service installation drastically reduces rollout times – deploying 20,000 Cybus Resources takes just 1.5 seconds, with all services becoming fully available in around 10 seconds.
Recovery from infrastructure operations like upgrades or agent restarts is also extremely reliable. In tests, setups with 500,000 Cybus Resources distributed across 35 instances returned to full operation within minutes after a complete Kubernetes outage.
This evolution also accelerates troubleshooting, reducing fault detection time from days to minutes and resolution time from weeks to hours, aided by advanced internal tools that identify inconsistencies in seconds. Furthermore, thanks to its modular design, individual components can be updated with minimal downtime, ensuring continuous operation.
Through a systematic validation process, the new architecture was put to the test under the most demanding conditions and has proven its capabilities:
The transformation to Cybus Connectware 2.0 was a collective effort across many teams to refactor large parts of the codebase, apply proven distributed-systems patterns and validate the design through extensive testing.
The evolution was driven by close collaboration with our customers, partners and internal stakeholders whose feedback and priorities shaped every decision. This release is both a technical milestone and testament to what can be achieved when teamwork, shared expertise and dedication come together.
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