A method to prevent crashes in an ECAT bus system

Abstract

This invention discloses a method for preventing ECAT bus system crashes, comprising the following steps: Step 1: Constructing a basic ECAT bus system architecture; building an ECAT bus system including CPU slots, several I / O modules, a backplane bus, an ECAT bus / PN bus, and signal termination devices; Step 2: Implementing a separation design for the communication side and the electrical side; Step 3: Establishing a fault detection mechanism in the communication core board; Step 4: Formulating and implementing a fault handling strategy; Step 5: Maintaining communication functionality and recording fault information; Step 6: Implementing a system state recovery strategy; Step 7: Employing redundancy design to improve system reliability. This invention, through separation design, fault detection, rapid handling, and redundancy design, improves the stability of the ECAT bus system, effectively avoiding serious consequences caused by electrical faults, and providing a safe and efficient solution for industrial automation.

Description

Technical Field

[0001] This invention relates to the field of industrial automation, and in particular to a method for preventing crashes in an ECAT bus system. Background Technology

[0002] ECAT bus, as an advanced industrial communication network technology, has been widely used in the field of industrial automation due to its high speed, high efficiency, and flexibility. ECAT bus systems typically employ a ring network structure, which under normal circumstances provides robust communication performance, ensuring efficient and reliable data transmission between nodes.

[0003] However, in practical applications, the ECAT bus system faces the challenge of electrical faults. Due to the complex and variable industrial environment, electrical circuits are prone to failures such as short circuits and open circuits. In the ring network structure of the ECAT bus system, once an electrical fault occurs in a node, such as a short circuit or open circuit, this fault will quickly affect subsequent nodes in the ring network, and may even lead to the communication interruption and collapse of the entire ECAT bus system.

[0004] Traditional ECAT bus systems are not designed with sufficient consideration of the impact of electrical faults on the communication system. Therefore, they lack effective mechanisms to isolate electrical faults and prevent them from spreading throughout the system. When electrical faults occur, the communication system often cannot respond in time, affecting the overall operation of the system and even causing serious consequences such as production stoppages or equipment damage. Therefore, this paper proposes a method to prevent ECAT bus system crashes. Summary of the Invention

[0005] In view of the shortcomings of the prior art, the present invention provides a method for preventing crashes in an ECAT bus system, so as to solve the problems mentioned in the background art.

[0006] To achieve the above objectives, the present invention provides the following technical solution: a method for preventing crashes in an ECAT bus system, comprising the following steps:

[0007] Step 1: Construct the basic ECAT bus system architecture;

[0008] An ECAT bus system is constructed, comprising a CPU slot, several I / O modules, a backplane bus, an ECAT bus / PN bus, and signal termination devices. The CPU slot, as the core controller, is configured at the beginning of the system. It directly accesses local I / O modules through the backplane bus and establishes connections with remote I / O modules via the ECAT bus / PN bus. The CPU slot and several I / O modules are cascaded using left and right side connectors to ensure that the main controller can access all slots through relay communication. Electrical services of the CPU slot and each I / O module slot are accessed through front or upper / lower terminal structures. The bus interconnection between modules adopts a slot-coupled backplane design, eliminating the need for separate wiring. The beginning and end modules are equipped with signal termination devices to maintain stable signal transmission.

[0009] Step 2: Implement a separate design for the communication side and the electrical side;

[0010] In the ECAT bus system, each ECAT node is divided into two parts: a communication core board and a service side circuit board. The communication core board handles communication tasks and ensures smooth data transmission, while the service side circuit board is responsible for the execution of electrical services. The communication core board and the service side circuit board are powered separately, which achieves complete isolation between the physical and logical layers, thereby effectively preventing electrical side faults from interfering with the communication side.

[0011] Step 3: Establish a fault detection mechanism in the communication core board;

[0012] A fault detection mechanism is integrated inside the communication core board. The fault detection mechanism continuously monitors the working status of the service side circuit board. When there is a short circuit or overload on the electrical side, an alarm signal is triggered and an interrupt request is quickly sent to the CPU. A current sensor is integrated to monitor the circuit current. A reasonable threshold is set. When the threshold is exceeded, an alarm is triggered and the CPU is interrupted for rapid detection of short circuit or overload.

[0013] Step 4: Develop and implement a troubleshooting strategy;

[0014] After receiving an interrupt request, the CPU performs shutdown or isolation operations on the faulty service-side circuit board according to the fault handling strategy to prevent the fault from spreading further. The system starts up the backup circuit board or takes remedial measures to ensure the continuous and stable operation of the ECAT bus system. The fault handling strategy includes, but is not limited to, accurate classification and handling based on fault type, graded response mechanism based on fault severity, and fast fault switching based on system redundancy design.

[0015] Step 5: Maintain communication functionality and record fault information;

[0016] During the fault handling process, the communication core board continuously maintains the communication function of the ECAT bus to ensure that other unaffected nodes can carry out data transmission and synchronization operations normally. The system records fault information in detail, including the time of the fault, the specific location, the fault type, and the handling measures taken, which provides strong support for subsequent system analysis and optimization.

[0017] Step Six: Implement system state recovery strategies;

[0018] Once the electrical fault is successfully isolated or repaired, the CPU gradually restores the function of the faulty circuit board according to the system state recovery strategy, thereby ensuring that the entire ECAT bus system can be restored to normal operation. The system state recovery strategy includes a gradual recovery plan based on the fault repair situation, a dynamic adjustment strategy based on system load balancing, and a recovery sequence based on user presets.

[0019] Step 7: Employ redundant design to improve system reliability;

[0020] The ECAT bus system also employs a redundancy design, which includes redundant configuration of communication lines, redundant power supply, and redundant backup of critical components. These redundancy designs ensure that the system can still operate normally when a single or a small number of components fail, thereby effectively avoiding the risk of system crash.

[0021] First, the system achieves efficient connection between CPU slots and multiple I / O modules, as well as flexible communication between local and remote I / O modules, through a robust infrastructure. This modular and scalable design makes the system easier to maintain and upgrade. Simultaneously, the inter-slot coupling backplane design eliminates the need for separate wiring, significantly improving installation efficiency and system neatness. Second, the separation of the communication and electrical sides is a major innovation of this system. By dividing each ECAT node into a communication core board and a service-side circuit board, and powering them separately, complete isolation at the physical and logical levels is achieved. This design effectively prevents electrical side faults from interfering with the communication side, improving system stability and reliability. Furthermore, the system establishes a comprehensive fault detection mechanism and handling strategy. The fault detection mechanism integrated within the communication core board continuously monitors the operating status of the service-side circuit board. Once a fault is detected, an interrupt request is quickly sent to the CPU. The CPU, based on the fault handling strategy, shuts down or isolates the faulty circuit board and activates a backup circuit board or takes remedial measures to ensure the system's continued stable operation. Compared to existing technologies, this system also emphasizes the recording and analysis of fault information, providing strong support for subsequent system analysis and optimization. Simultaneously, the adopted system state recovery strategy ensures that the system can quickly return to normal operation after the fault is isolated or repaired. Finally, the integration of redundancy design further enhances the system's reliability. Redundant configuration of communication lines, redundant power supply, and redundant backup of key components ensure that the system can continue to operate normally even when a single or a small number of components fail, effectively avoiding the risk of system collapse. These improvements give this ECAT bus system a wider range of application prospects and higher market competitiveness in the field of industrial automation.

[0022] Furthermore, the CPU slot in step one is further configured with a redundant CPU, which automatically switches to the redundant CPU when the main CPU fails, ensuring the continuity of system control functions.

[0023] The ECAT bus system, by configuring redundant CPUs in the CPU slots, ensures automatic switching to redundant CPUs when the main CPU fails, thereby effectively guaranteeing the continuity of system control functions and greatly improving system reliability and stability. This design not only avoids system paralysis caused by CPU failure but also ensures the continuous and smooth operation of industrial automated production, providing strong support for enterprise production efficiency and equipment safety, and reducing economic losses and risks caused by downtime due to failures. At the same time, the automatic switching function of redundant CPUs simplifies the fault handling process, reduces the need for manual intervention, and improves the system's automation level and maintenance efficiency, making it an efficient and reliable solution in the field of industrial automation.

[0024] Furthermore, the physical isolation between the communication core board and the service side circuit board in step two is achieved through an optical coupler or a magnetic coupler to enhance the isolation effect and prevent electrical noise interference.

[0025] By employing optocouplers or magnetic isolators to achieve physical isolation between the communication core board and the service-side circuit board, this ECAT bus system effectively enhances the isolation effect, effectively prevents electrical noise from interfering with the communication system, improves the system's stability and reliability, and ensures the accuracy and smoothness of data transmission, providing a more robust communication guarantee for industrial automation production. This design not only reduces the system's failure rate caused by electrical noise but also improves the system's anti-interference capability and operating efficiency, enabling the entire ECAT bus system to maintain a highly efficient and stable operating state in complex and ever-changing industrial environments. It provides strong support for enterprise production safety and efficiency and is an important technological innovation in the field of industrial automation.

[0026] Furthermore, the fault detection mechanism in step three also includes a temperature monitoring function. When the temperature of the communication core board or the service side circuit board exceeds a preset threshold, an alarm signal is triggered and an interrupt request is sent to the CPU.

[0027] When the temperature of the communication core board or service-side circuit board exceeds a preset threshold, the system can automatically trigger an alarm signal and send an interrupt request to the CPU. This design effectively realizes real-time monitoring and abnormal response of the circuit board temperature, preventing system failures or damage caused by overheating, improving system safety and reliability, and ensuring the continuity and stability of industrial automated production. This function not only helps to detect and handle potential overheating problems in a timely manner, but also extends the service life of equipment, reduces maintenance costs and downtime, and provides strong support for the production efficiency and economic benefits of enterprises. It is an important innovative measure of ECAT bus system in temperature management.

[0028] Furthermore, the fault handling strategy in step four also includes a predictive maintenance strategy based on historical fault data. This predictive maintenance strategy analyzes historical fault data to predict potential faults and takes measures in advance to prevent them from occurring.

[0029] By deeply analyzing historical fault data to accurately predict potential faults and taking preventive measures in advance, the occurrence of faults is effectively avoided, significantly improving the maintenance efficiency and operational reliability of the ECAT bus system, reducing the risk of production interruption caused by sudden faults, ensuring the continuity and stability of industrial automated production, and providing strong support for enterprises to achieve efficient and safe production management. It is an important technological innovation in the field of fault prevention and management.

[0030] Furthermore, the fault information recorded in step five also includes system state parameters before and after the fault, in order to more comprehensively analyze the causes and effects of the fault;

[0031] The fault information recorded by the system not only includes basic fault details, but also additionally records the system status parameters before and after the fault. This approach provides detailed data support for a more comprehensive analysis of the fault causes and an assessment of the fault impact. It helps to quickly and accurately locate the root cause of the fault, formulate effective repair measures, and optimize the system design, thereby significantly improving the system's reliability and maintenance efficiency, reducing the fault recurrence rate, ensuring the continuous and stable operation of the ECAT bus system, and providing a solid guarantee for industrial automation production. It is an important practical innovation in the field of fault information management and system optimization.

[0032] Furthermore, the system state recovery strategy in step six also includes an automatic recovery mechanism based on the system self-diagnosis function. When the system detects that the fault has been repaired, it automatically attempts to restore the function of the faulty circuit board.

[0033] The system state recovery strategy incorporates an automatic recovery mechanism based on the system's self-diagnostic function. When the system detects that the fault has been repaired, it can automatically attempt to restore the function of the faulty circuit board. This design greatly improves the system's self-repair capability and operating efficiency, reduces the need for manual intervention, and ensures that the system can recover from faults quickly and accurately, maintaining the continuity and stability of industrial automated production. At the same time, it reduces maintenance costs and time, and improves the overall reliability and availability of the system. It is an important technological innovation in the field of system fault recovery, providing stronger protection for the production safety and efficiency of enterprises.

[0034] Furthermore, the redundancy design in step seven also includes redundant backups of data storage to ensure rapid recovery in the event of data loss or damage.

[0035] Redundancy design encompasses redundant backups of data storage. This measure ensures rapid and accurate data recovery in the event of system data loss or corruption, effectively preventing the impact of data loss on system operation and business continuity. It significantly improves data security and reliability, providing a solid guarantee for enterprise data management and business operations. At the same time, redundant backups of data storage simplify the data recovery process, reduce the time and cost required for data recovery, and improve the overall maintenance efficiency and availability of the system. It is an important practice in the field of data protection and is of great significance for ensuring enterprise information security and business continuity.

[0036] Furthermore, step seven also includes performing regular system health checks. These regular system health checks ensure the stable operation of the system by simulating faults, testing response speed, and verifying redundancy functions, and adjust fault handling strategies and system state recovery strategies based on the check results.

[0037] By conducting regular system health checks, simulating faults, testing response speed, and verifying redundancy functions, the stable operation of the system is ensured. Based on the check results, fault handling strategies and system state recovery strategies are flexibly adjusted. This approach effectively enhances the system's self-monitoring and optimization capabilities, enabling timely detection and resolution of potential problems, strengthening system reliability and resilience, reducing the likelihood and impact of faults, optimizing fault handling and recovery processes, improving system maintenance efficiency and availability, and providing a more stable and reliable system guarantee for enterprise industrial automation production. This represents a significant practical innovation in the field of system maintenance and optimization.

[0038] Furthermore, the redundancy design in step seven to improve system reliability also includes establishing a remote monitoring and diagnostic system. This remote monitoring and diagnostic system is connected to the ECAT bus system, receives and analyzes system operating status data in real time, issues early warning signals when an anomaly or potential fault is detected, and provides remote fault diagnosis and repair suggestions to assist users in responding quickly and handling system faults, thereby further ensuring the stable operation of the ECAT bus system.

[0039] By adopting a redundant design and establishing a remote monitoring and diagnostic system, which is closely connected to the ECAT bus system, the system receives and analyzes system operation status data in real time. Once an anomaly or potential fault is detected, an early warning is immediately issued and remote fault diagnosis and repair suggestions are provided. This measure greatly improves the system's fault early warning and rapid response capabilities, helps users quickly locate and handle system faults, effectively shortens fault handling time, reduces the impact of faults on production, and further ensures the stable operation and reliability of the ECAT bus system. It provides enterprises with a more intelligent and efficient system maintenance and management solution for industrial automation production.

[0040] In summary, compared with the prior art, the present invention provides a method for preventing crashes in an ECAT bus system, which has the following beneficial effects:

[0041] This invention constructs a basic ECAT bus system architecture and implements a separation design between the communication side and the electrical side. This method ensures that electrical faults will not interfere with the communication system, improving the system's stability and reliability. At the same time, a fault detection mechanism is established in the communication core board, which can monitor the working status of the service-side circuit board in real time. Once an electrical fault is detected, an alarm is immediately triggered and an interrupt request is sent to the CPU. Combined with the established fault handling strategy, the system can quickly shut down or isolate the fault to prevent the fault from spreading and ensure the continuous and stable operation of the system.

[0042] In addition, this method also focuses on recording fault information and restoring system status, providing strong support for subsequent system analysis and optimization; the use of redundancy design further improves the reliability of the system, ensuring that the system can still operate normally when a single or a small number of components fail.

[0043] The ECAT bus system's crash prevention method not only improves the system's stability and reliability but also effectively avoids serious consequences such as production stoppages or equipment damage caused by electrical faults, providing a safer and more efficient solution for the field of industrial automation. Attached Figure Description

[0044] Figure 1 This is a schematic diagram of the method steps of the invention.

[0045] Figure 2 This is a schematic diagram of the basic interconnection structure of the system of this invention.

[0046] Figure 3 It is the backplane bus architecture of this invention. Detailed Implementation

[0047] This invention provides a technical solution, a method for preventing crashes in an ECAT bus system. Please refer to [link / reference]. Figure 1 , Figure 2 and Figure 3 This includes the following steps:

[0048] Step 1: Construct the basic ECAT bus system architecture;

[0049] An ECAT bus system is constructed, comprising a CPU slot, several I / O modules, a backplane bus, an ECAT bus / PN bus, and signal termination devices. The CPU slot, as the core controller, is configured at the beginning of the system. It directly accesses local I / O modules through the backplane bus and establishes connections with remote I / O modules via the ECAT bus / PN bus. The CPU slot and several I / O modules are cascaded using left and right side connectors to ensure that the main controller can access all slots through relay communication. Electrical services of the CPU slot and each I / O module slot are accessed through front or upper / lower terminal structures. The bus interconnection between modules adopts a slot-coupled backplane design, eliminating the need for separate wiring. The beginning and end modules are equipped with signal termination devices to maintain stable signal transmission.

[0050] Step 2: Implement a separate design for the communication side and the electrical side;

[0051] In the ECAT bus system, each ECAT node is divided into two parts: a communication core board and a service side circuit board. The communication core board handles communication tasks and ensures smooth data transmission, while the service side circuit board is responsible for the execution of electrical services. The communication core board and the service side circuit board are powered separately, which achieves complete isolation between the physical and logical layers, thereby effectively preventing electrical side faults from interfering with the communication side.

[0052] Step 3: Establish a fault detection mechanism in the communication core board;

[0053] A fault detection mechanism is integrated inside the communication core board. The fault detection mechanism continuously monitors the working status of the service side circuit board. When there is a short circuit or overload on the electrical side, an alarm signal is triggered and an interrupt request is quickly sent to the CPU. A current sensor is integrated to monitor the circuit current. A reasonable threshold is set. When the threshold is exceeded, an alarm is triggered and the CPU is interrupted for rapid detection of short circuit or overload.

[0054] The hardware architecture of the fault detection mechanism employs Hall effect sensors or shunt resistors to monitor the current in the service-side circuit in real time. Signal processing is achieved through ADC sampling, filtering, and hardware comparators, enabling instantaneous overcurrent protection and threshold determination. At the algorithm level, the system may combine static threshold methods (e.g., 150%-200% of the rated current) with dynamic threshold adjustment (based on temperature compensation or historical data learning). Fault classification is performed through rule-based judgment (e.g., overload is determined by a continuous over-limit time ≥ 500ms, and short circuit is determined by an instantaneous peak value ≥ 5 times the rated value) or machine learning models (e.g., SVM for fault mode classification). Simultaneously, reliability is improved by utilizing multi-sensor redundancy, cross-validation (voltage / temperature parameter linkage analysis), and dual-core verification mechanisms. The "predictive maintenance" mentioned in the patent suggests that it may predict potential faults based on current fluctuation statistical analysis (e.g., moving average, standard deviation), and ensure the safety of the detection circuit through optocoupler isolation design. In practical applications, the false alarm rate can be optimized through adaptive threshold algorithms, and edge computing-cloud collaborative analysis of complex faults can be introduced to further improve the system's robustness and real-time performance.

[0055] Step 4: Develop and implement a troubleshooting strategy;

[0056] After receiving an interrupt request, the CPU performs shutdown or isolation operations on the faulty service-side circuit board according to the fault handling strategy to prevent the fault from spreading further. The system starts up the backup circuit board or takes remedial measures to ensure the continuous and stable operation of the ECAT bus system. The fault handling strategy includes, but is not limited to, accurate classification and handling based on fault type, graded response mechanism based on fault severity, and fast fault switching based on system redundancy design.

[0057] Step 5: Maintain communication functionality and record fault information;

[0058] During the fault handling process, the communication core board continuously maintains the communication function of the ECAT bus to ensure that other unaffected nodes can carry out data transmission and synchronization operations normally. The system records fault information in detail, including the time of the fault, the specific location, the fault type, and the handling measures taken, providing strong support for subsequent system analysis and optimization.

[0059] Step Six: Implement system state recovery strategies;

[0060] Once the electrical fault is successfully isolated or repaired, the CPU gradually restores the function of the faulty circuit board according to the system state recovery strategy, thereby ensuring that the entire ECAT bus system can be restored to normal operation. The system state recovery strategy includes a gradual recovery plan based on the fault repair situation, a dynamic adjustment strategy based on system load balancing, and a recovery sequence based on user presets.

[0061] Step 7: Employ redundant design to improve system reliability;

[0062] The ECAT bus system also employs a redundancy design, which includes redundant configuration of communication lines, redundant power supply, and redundant backup of critical components. These redundancy designs ensure that the system can still operate normally when a single or a small number of components fail, thereby effectively avoiding the risk of system crash.

[0063] This system, through its robust infrastructure, achieves efficient connectivity between CPU slots and multiple I / O modules, as well as flexible communication between local and remote I / O modules. This modular and scalable design makes the system easier to maintain and upgrade. The inter-slot coupling backplane design eliminates the need for separate wiring, significantly improving installation efficiency and system neatness. A major innovation of this system is the separation of the communication and electrical sides. By dividing each ECAT node into a communication core board and a service-side circuit board, and powering them separately, complete physical and logical isolation is achieved. This design effectively prevents electrical side faults from interfering with the communication side, improving system stability and reliability. The system also establishes a comprehensive fault detection mechanism and handling strategy. The fault detection mechanism integrated within the communication core board continuously monitors the operating status of the service-side circuit board, and detects faults immediately upon detection. Upon detecting a fault, the system quickly sends an interrupt request to the CPU. The CPU, based on the fault handling strategy, shuts down or isolates the faulty circuit board and activates a backup circuit board or takes remedial measures to ensure the system's continued stable operation. Compared to existing technologies, this system also emphasizes the recording and analysis of fault information, providing strong support for subsequent system analysis and optimization. The adopted system state recovery strategy ensures that the system can quickly return to normal operation after a fault is isolated or repaired. The integration of redundancy design further enhances the system's reliability. Redundant configuration of communication lines, redundant power supply, and redundant backup of key components ensure that the system can continue to operate normally even when a single or a small number of components fail, effectively avoiding the risk of system collapse. These improvements give the ECAT bus system a wider range of application prospects and higher market competitiveness in the field of industrial automation.

[0064] Please see Figure 2 and Figure 3The main function of the end-locking module is to maintain stable signal transmission and ensure signal integrity between the start and end modules of the ECAT bus system. It may use physical locking mechanisms (such as screw locking, snap locking, etc.) to ensure a secure connection of signal cables or connectors, preventing signal interruption or attenuation caused by vibration, loosening, or other factors. The end-locking module may include a locking mechanism, signal contacts, and a mounting bracket. The locking mechanism is used to firmly fix the signal cables or connectors to the module; the signal contacts are responsible for the electrical connection of the signal, ensuring accurate signal transmission; and the mounting bracket provides structural support, allowing the module to be stably installed at the end of the ECAT bus system.

[0065] In the ECAT bus system, each ECAT node is divided into two parts: a communication core board and a service-side circuit board. This division is a form of "internal isolation," which physically and logically separates communication functions from electrical service functions. The physical isolation between the communication core board and the service-side circuit board is achieved through optocouplers or magnetic couplers. This physical isolation method further enhances the isolation effect within the node and effectively prevents electrical noise from interfering with the communication system. Therefore, internal isolation and physical isolation complement each other and together constitute one of the important mechanisms for preventing ECAT bus system crashes.

[0066] Please see Figure 1 , Figure 2 and Figure 3 The CPU slot in step one is further configured with a redundant CPU. When the main CPU fails, it automatically switches to the redundant CPU to ensure the continuity of system control functions.

[0067] The ECAT bus system, by configuring redundant CPUs in the CPU slots, ensures automatic switching to redundant CPUs when the main CPU fails, thereby effectively guaranteeing the continuity of system control functions and greatly improving system reliability and stability. This design not only avoids system paralysis caused by CPU failure but also ensures the continuous and smooth operation of industrial automated production, providing strong support for enterprise production efficiency and equipment safety, and reducing economic losses and risks caused by downtime due to failures. At the same time, the automatic switching function of redundant CPUs simplifies the fault handling process, reduces the need for manual intervention, and improves the system's automation level and maintenance efficiency, making it an efficient and reliable solution in the field of industrial automation.

[0068] Please see Figure 1 , Figure 2 and Figure 3 In step two, the physical isolation between the communication core board and the service side circuit board is achieved through optical couplers or magnetic couplers to enhance the isolation effect and prevent electrical noise interference.

[0069] By employing optocouplers or magnetic isolators to achieve physical isolation between the communication core board and the service-side circuit board, this ECAT bus system effectively enhances the isolation effect, effectively prevents electrical noise from interfering with the communication system, improves the system's stability and reliability, and ensures the accuracy and smoothness of data transmission, providing a more robust communication guarantee for industrial automation production. This design not only reduces the system's failure rate caused by electrical noise but also improves the system's anti-interference capability and operating efficiency, enabling the entire ECAT bus system to maintain a highly efficient and stable operating state in complex and ever-changing industrial environments. It provides strong support for enterprise production safety and efficiency and is an important technological innovation in the field of industrial automation.

[0070] Please see Figure 1 , Figure 2 and Figure 3 The fault detection mechanism in step three also includes a temperature monitoring function. When the temperature of the communication core board or the service side circuit board exceeds a preset threshold, an alarm signal is triggered and an interrupt request is sent to the CPU.

[0071] When the temperature of the communication core board or service-side circuit board exceeds a preset threshold, the system can automatically trigger an alarm signal and send an interrupt request to the CPU. This design effectively realizes real-time monitoring and abnormal response of the circuit board temperature, preventing system failures or damage caused by overheating, improving system safety and reliability, and ensuring the continuity and stability of industrial automated production. This function not only helps to detect and handle potential overheating problems in a timely manner, but also extends the service life of equipment, reduces maintenance costs and downtime, and provides strong support for the production efficiency and economic benefits of enterprises. It is an important innovative measure of ECAT bus system in temperature management.

[0072] Please see Figure 1 , Figure 2 and Figure 3 The fault handling strategy in step four also includes a predictive maintenance strategy based on historical fault data. This strategy analyzes historical fault data to predict potential faults and takes preventative measures to prevent them from occurring.

[0073] By deeply analyzing historical fault data to accurately predict potential faults and taking preventive measures in advance, the occurrence of faults is effectively avoided, significantly improving the maintenance efficiency and operational reliability of the ECAT bus system, reducing the risk of production interruption caused by sudden faults, ensuring the continuity and stability of industrial automated production, and providing strong support for enterprises to achieve efficient and safe production management. It is an important technological innovation in the field of fault prevention and management.

[0074] Please see Figure 1 , Figure 2 and Figure 3 The fault information recorded in step five also includes system status parameters before and after the fault, so as to more comprehensively analyze the cause and impact of the fault.

[0075] The fault information recorded by the system not only includes basic fault details, but also additionally records the system status parameters before and after the fault. This approach provides detailed data support for a more comprehensive analysis of the fault causes and an assessment of the fault impact. It helps to quickly and accurately locate the root cause of the fault, formulate effective repair measures, and optimize the system design, thereby significantly improving the system's reliability and maintenance efficiency, reducing the fault recurrence rate, ensuring the continuous and stable operation of the ECAT bus system, and providing a solid guarantee for industrial automation production. It is an important practical innovation in the field of fault information management and system optimization.

[0076] Please see Figure 1 , Figure 2 and Figure 3 The system state recovery strategy in step six also includes an automatic recovery mechanism based on the system self-diagnosis function. When the system detects that the fault has been repaired, it will automatically attempt to restore the function of the faulty circuit board.

[0077] The system state recovery strategy incorporates an automatic recovery mechanism based on the system's self-diagnostic function. When the system detects that the fault has been repaired, it can automatically attempt to restore the function of the faulty circuit board. This design greatly improves the system's self-repair capability and operating efficiency, reduces the need for manual intervention, and ensures that the system can recover from faults quickly and accurately, maintaining the continuity and stability of industrial automated production. At the same time, it reduces maintenance costs and time, and improves the overall reliability and availability of the system. It is an important technological innovation in the field of system fault recovery, providing stronger protection for the production safety and efficiency of enterprises.

[0078] Please see Figure 1 , Figure 2 and Figure 3 The redundancy design in step seven also includes redundant backups of data storage to ensure rapid recovery in the event of data loss or corruption.

[0079] Redundancy design encompasses redundant backups of data storage. This measure ensures rapid and accurate data recovery in the event of system data loss or corruption, effectively preventing the impact of data loss on system operation and business continuity. It significantly improves data security and reliability, providing a solid guarantee for enterprise data management and business operations. At the same time, redundant backups of data storage simplify the data recovery process, reduce the time and cost required for data recovery, and improve the overall maintenance efficiency and availability of the system. It is an important practice in the field of data protection and is of great significance for ensuring enterprise information security and business continuity.

[0080] Please see Figure 1 , Figure 2 and Figure 3 Step seven also includes conducting regular system health checks. Regular system health checks ensure stable system operation by simulating faults, testing response speed, and verifying redundancy functions, and adjust fault handling strategies and system state recovery strategies based on the check results.

[0081] By conducting regular system health checks, simulating faults, testing response speed, and verifying redundancy functions, the stable operation of the system is ensured. Based on the check results, fault handling strategies and system state recovery strategies are flexibly adjusted. This approach effectively enhances the system's self-monitoring and optimization capabilities, enabling timely detection and resolution of potential problems, strengthening system reliability and resilience, reducing the likelihood and impact of faults, optimizing fault handling and recovery processes, improving system maintenance efficiency and availability, and providing a more stable and reliable system guarantee for enterprise industrial automation production. This represents a significant practical innovation in the field of system maintenance and optimization.

[0082] Please see Figure 1 , Figure 2 and Figure 3 Step seven, which adopts redundant design to improve system reliability, also includes establishing a remote monitoring and diagnostic system. This system is connected to the ECAT bus system to receive and analyze system operating status data in real time. When an anomaly or potential fault is detected, it issues an early warning signal and provides remote fault diagnosis and repair suggestions to help users respond quickly and handle system faults, thereby further ensuring the stable operation of the ECAT bus system.

[0083] By adopting a redundant design and establishing a remote monitoring and diagnostic system, which is closely connected to the ECAT bus system, the system receives and analyzes system operation status data in real time. Once an anomaly or potential fault is detected, an early warning is immediately issued and remote fault diagnosis and repair suggestions are provided. This measure greatly improves the system's fault early warning and rapid response capabilities, helps users quickly locate and handle system faults, effectively shortens fault handling time, reduces the impact of faults on production, and further ensures the stable operation and reliability of the ECAT bus system. It provides enterprises with a more intelligent and efficient system maintenance and management solution for industrial automation production.

[0084] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0085] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for preventing a collapse of an ECAT bus system, characterized by, The method comprises the following steps: Step one, build the basic ECAT bus system architecture: Build an ECAT bus system including CPU slot, several IO modules, backplane bus, ECAT bus / PN bus and signal termination device, the CPU slot is configured as the core controller at the first end of the system, directly access the local IO modules through the backplane bus, and establish connection with remote IO modules through ECAT bus / PN bus, the CPU slot and several IO modules are cascaded by using left and right side connectors to ensure that the master controller can access all slots through relay communication, the electrical side business of the CPU slot and each IO module slot is connected through front terminal or up and down terminal structure, the bus interconnection between modules uses the coupling backplane design between slots, and the first end and the end module are respectively equipped with signal termination devices; Step two, implement the separation design of communication side and electrical side: In the ECAT bus system, each ECAT node is divided into communication core board and business side circuit board, the communication core board handles communication tasks, and the business side circuit board is responsible for the execution of electrical business; Step three, establish the fault detection mechanism in the communication core board: Integrate the fault detection mechanism in the communication core board, the fault detection mechanism continuously monitors the working state of the business side circuit board, when there is short circuit and overload in the electrical side, an alarm signal is triggered, and an interrupt request is quickly sent to the CPU, a current sensor monitoring circuit is integrated to monitor the circuit current, a reasonable threshold is set, when the threshold is exceeded, an alarm is triggered and the CPU is interrupted, and short circuit or overload rapid detection is performed; Step four, develop and execute fault handling strategy: After receiving the interrupt request, the CPU executes shutdown or isolation operation on the fault business side circuit board according to the fault handling strategy, the system starts the standby circuit board or takes remedial measures, the fault handling strategy includes but is not limited to accurate classification processing based on fault type, hierarchical response mechanism based on fault severity and rapid fault switching based on system redundancy design; Step five, maintain communication function and record fault information: During the fault handling process, the communication core board continuously maintains the communication function of the ECAT bus to ensure that other unaffected nodes normally perform data transmission and synchronization operation, and the system records fault information in detail, the fault information includes the time, specific position, fault type and treatment measures of the fault occurrence; Step six, implement system state recovery strategy: When the electrical side fault is successfully isolated or repaired, the CPU gradually restores the function of the fault circuit board according to the system state recovery strategy, the system state recovery strategy includes step-by-step recovery plan based on fault repair condition, dynamic adjustment strategy based on system load balancing and recovery sequence based on user preset; Step seven, use redundancy design to improve system reliability: The ECAT bus system uses redundancy design, the redundancy design includes redundancy configuration of communication line, redundancy guarantee of power supply and redundancy backup of key components.

2. The method for preventing a crash of an ECAT bus system according to claim 1, wherein: The CPU slot in step one is further configured with a redundant CPU, which automatically switches to the redundant CPU when the main CPU fails.

3. The method for preventing a crash of an ECAT bus system according to claim 2, wherein: The physical isolation between the communication core board and the service side circuit board in step two is achieved through optical coupling isolators or magnetic coupling isolators.

4. The method for preventing crashes in an ECAT bus system according to claim 3, characterized in that: The fault detection mechanism in step three also includes a temperature monitoring function that triggers an alarm signal and sends an interrupt request to the CPU when the temperature of the communication core board or the service side circuit board exceeds a preset threshold.

5. A method for preventing crashes in an ECAT bus system according to claim 4, characterized in that: The fault handling strategy in step four also includes a predictive maintenance strategy based on historical fault data, which predicts potential faults by analyzing historical fault data.

6. The method of preventing a crash of an ECAT bus system of claim 5, wherein: The recorded fault information in step five also includes system state parameters before and after the fault.

7. The method of preventing a crash of an ECAT bus system of claim 6, wherein: The system state recovery strategy in step six also includes an automatic recovery mechanism based on system self-diagnosis function, which automatically attempts to restore the function of the faulty circuit board when the system detects that the fault has been repaired.

8. A method for preventing crashes in an ECAT bus system according to claim 7, characterized in that: The redundancy design in step seven also includes redundant backup of data storage.

9. A method for preventing crashes in an ECAT bus system according to claim 8, characterized in that: Step seven also includes regular system health checks that ensure stable operation of the system by simulating faults, detecting response speed, and verifying redundancy functions, and adjusting fault handling strategies and system state recovery strategies based on the inspection results.

10. The method of claim 9, wherein: The use of redundancy design to improve system reliability in step seven also includes the establishment of a remote monitoring and diagnosis system connected to the ECAT bus system, which receives and analyzes system operation state data in real time, issues early warning signals when detecting abnormalities or potential faults, and provides remote fault diagnosis and repair recommendations. ​

Images