Detection and early warning system for key hardware of industrial personal computer

Abstract

The invention relates to the technical field of industrial hardware detection and early warning, and discloses an industrial industrial personal computer key hardware detection and early warning system, which comprises a double-path data acquisition module for constructing main and standby dual acquisition channels; the acquisition switching control module is used for screening and outputting effective monitoring data streams; the dual-redundancy storage management module is used for encapsulating the data to generate a standardized record; the trend analysis pre-judgment module is used for generating quantitative trend indexes; the grading early warning decision module is used for generating a risk state judgment result; and the automatic response execution module is used for executing light popup prompt or heavy sound-light alarm and remote notification according to the judgment result. The problem of data loss caused by failure of a single monitoring interface is solved by constructing the two-way data acquisition module and the acquisition switching control module, the system calls an operating system management interface and a hardware bottom layer instruction set at the same time, and it is ensured that the data loss is reduced under the working conditions of high load of the operating system or abnormal driving. And the monitoring system can still continuously obtain effective hardware operation parameters.

Description

Technical Field

[0001] This invention relates to the field of industrial hardware detection and early warning technology, specifically to a key hardware detection and early warning system for industrial control computers. Background Technology

[0002] Industrial control computers, as the core control nodes of automated production lines, undertake the critical tasks of data interaction and command issuance. Equipment typically needs to operate continuously and without interruption in environments with high temperatures, vibrations, or electromagnetic interference. In the hardware architecture of industrial control computers, the power supply module is responsible for power supply, and the hard disk drive (HDD) is responsible for data reading and writing; these two components have the highest wear and tear rates and are most prone to physical aging. Failure of critical hardware can lead to production stoppages or loss of important production data, causing incalculable economic losses. Therefore, status monitoring of the critical hardware within industrial control computers is a fundamental requirement for ensuring the continuity of industrial production.

[0003] Existing hardware detection and early warning technologies primarily run as software agents on industrial control computer operating systems. The monitoring program mainly obtains parameters such as voltage, speed, and bad sectors by calling standard management interfaces provided by the operating system. The acquired data is typically saved in log files on the local disk. For early warning determination, a static numerical comparison method is commonly used. This involves pre-setting a fixed safety range or absolute threshold; as long as the collected parameter values ​​do not exceed this range, the monitoring system determines that the hardware is normal, triggering an alarm only when the values ​​exceed the limits.

[0004] However, existing hardware detection and early warning technologies often fail to address these shortcomings. When the industrial control computer's operating system experiences high load lag or low-level driver conflicts, the standard interface is often the first to become unresponsive. This results in monitoring software struggling to acquire data during the most unstable periods, creating monitoring blind spots. Furthermore, when the hard drive suffers physical failures such as head damage or circuit board burnout, the stored historical logs are lost. Maintenance personnel are left with a device that is difficult to boot and has no data to access, making it difficult to trace the root cause of the fault. Moreover, hardware performance degradation typically manifests as increased parameter volatility or a linear decline; these early characteristics are often overlooked by the system within static safety limits, leading to delayed alarm triggering. Therefore, this invention provides a critical hardware detection and early warning system for industrial control computers to address the deficiencies of existing technologies. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a key hardware detection and early warning system for industrial control computers, which solves the problems of low reliability of single monitoring methods, easy loss of data storage, and difficulty in identifying early performance degradation of hardware in industrial environments.

[0006] To achieve the above objectives, the present invention provides the following technical solution: The first aspect of this invention provides a key hardware detection and early warning system for industrial control computers, comprising: The dual-channel data acquisition module is used to call the operating system management specification interface and the hardware underlying instruction set respectively to build a main acquisition data channel and a backup acquisition data channel that are independent of each other for power supply and hard disk parameters. The acquisition switching control module is used to compare the data quality of the main acquisition data channel and the backup acquisition data channel in real time based on the data integrity verification logic, and lock the current data source pointer based on the comparison result in order to filter the effective monitoring data stream from the two channels; The dual-redundant storage management module is used to structure and encapsulate the effective monitoring data stream, generate standardized data records by adding system timestamps and unique device identifiers, and simultaneously write them to the local hard disk and external USB flash drive to build a historical traceability database. The trend analysis and prediction module is used to locate and extract historical data samples that are separated by a preset time interval in the historical traceability database, using the real-time data timestamp of the current moment as the anchor point, establish the parameter alignment relationship between the real-time data and the historical data samples, and perform differential operations to generate a quantitative trend indicator that reflects the rate of hardware performance degradation. The graded early warning decision module is used to map the quantitative trend indicators to a preset fault threshold model and generate risk status judgment results through multi-level logical comparison. An automated response execution module is used to drive the risk status determination result, construct a visual prompt window data packet when the determination result is a mild warning, and simultaneously trigger a local audible and visual alarm drive command and construct a remote network notification data packet when the determination result is a severe warning.

[0007] Preferably, the dual-channel data acquisition module is specifically used for: Set the main data acquisition channel to call the WMI interface of the operating system or the lm-sensors hardware monitoring tool interface, and set the first sampling frequency to obtain regular monitoring data; The backup data acquisition channel is configured to call the PMBus instruction set to read the power controller register and call the SMART tool to read the hard disk health status. When the main data acquisition channel is working normally, the backup data acquisition channel remains in a passive standby state, only receiving data for comparison and verification.

[0008] Preferably, the data integrity verification logic executed by the acquisition switching control module specifically includes: The system monitors the data flow of the main data acquisition channel. When the duration of no data return exceeds a preset time threshold, the system determines that the main channel has failed and locks the data source pointer to the backup data acquisition channel. Alternatively, the parameter values ​​of the main acquisition data channel and the backup acquisition data channel can be acquired simultaneously at the same time, and the numerical deviation ratio between the two can be calculated. When the numerical deviation ratio exceeds a preset deviation threshold, the main channel data is determined to be abnormal and the data source pointer is locked to the backup acquisition data channel.

[0009] Preferably, when generating standardized data records, the dual-redundant storage management module encapsulates four parameters—power load rate, power output voltage, number of bad sectors on the hard disk, and hard disk I / O latency—into the data payload segment. When building the historical traceability database, a lifecycle management strategy based on time sliding windows is adopted. A full scan of the storage directory is performed to filter and delete historical files whose file time attributes differ from the current system date by more than the preset retention period, so as to maintain the time coverage of the database.

[0010] Preferably, when the trend analysis and prediction module locates and extracts historical data samples, it sets the preset time interval to twenty-four hours. If there is no record in the historical traceability database that corresponds to the current time, then fuzzy matching logic is executed to retrieve and extract the most recent valid standardized data record before the corresponding time point as the historical data sample.

[0011] Preferably, the process by which the trend analysis and prediction module performs differential calculations to generate quantitative trend indicators includes: Extract the power load rate from the current real-time data and historical data samples, calculate the difference between the two to generate a power load rate change index. Extract the power supply output voltage from the current real-time data and historical data samples, calculate the absolute deviation of the two relative to the standard rated voltage, and calculate the difference between the two absolute deviation values ​​to generate a power supply voltage stability index. Extract the total number of cumulative bad sectors from the current real-time data and historical data samples, and calculate the difference between the two to generate an indicator of the increase in new bad sectors on the hard drive. Extract the disk I / O response time from the current real-time data and historical data samples, and calculate the difference between the two to generate a disk I / O latency increment metric.

[0012] Preferably, the fault threshold model preset by the hierarchical early warning decision module includes a first threshold set and a second threshold set, and the multi-level logical comparison step further includes: When the quantitative trend indicator exceeds the corresponding threshold in the first threshold set, and the current real-time data value exceeds the basic warning line, a risk status judgment result indicating a mild warning is generated. When the quantitative trend indicator exceeds the corresponding threshold in the second threshold set, and the current real-time data value exceeds the severe warning line, a risk status judgment result indicating a severe warning is generated, and the judgment priority of the severe warning is higher than that of the mild warning.

[0013] Preferably, when constructing a remote network notification data packet, the automated response execution module activates the SMTP client only when it receives the risk status determination result of a severe warning, calls the preset notification template, fills in the fault device identifier, the name of the hardware component that triggered the warning, and the estimated damage time based on the current trend, combines them to generate an alarm email data stream and sends it to the preset email address.

[0014] Preferably, the dual-redundant storage management module further includes a log recording interface, used to receive the early warning event snapshot generated by the automated response execution module, and synchronously append the event information, including the trigger time, early warning level, and corresponding quantitative trend indicators, to the log files of the local mechanical hard drive and the external USB flash drive.

[0015] The second aspect of this invention provides a method for detecting and warning of key hardware in industrial control computers, comprising the following steps: S1. Call the operating system management specification interface and hardware low-level instruction set to build a main data acquisition channel and a backup data acquisition channel that are independent of power supply and hard disk parameters; S2. Based on the data integrity verification logic, the data quality of the main acquisition data channel and the backup acquisition data channel are compared in real time. Based on the comparison result, the current data source pointer is locked to filter the effective monitoring data stream from the two channels. S3. The effective monitoring data stream is structured and encapsulated, and standardized data records are generated by adding system timestamps and unique device identifiers. The records are then synchronously written to the local hard disk and external USB flash drive to build a historical traceability database. S4. Using the real-time data timestamp of the current moment as the anchor point, locate and extract historical data samples that are separated by a preset time interval in the historical traceability database, establish the parameter alignment relationship between real-time data and historical data samples, and perform differential operation to generate a quantitative trend indicator that reflects the rate of hardware performance degradation. S5. Map the quantitative trend indicators to a preset fault threshold model, and generate a risk status judgment result through multi-level logical comparison. S6. Driven by the risk status determination result, when the determination result is a mild warning, a visual prompt window data packet is constructed, and when the determination result is a severe warning, a local sound and light alarm driving command is triggered and a remote network notification data packet is constructed simultaneously.

[0016] This invention provides a key hardware detection and early warning system for industrial control computers. It has the following beneficial effects: 1. This invention solves the problem of data loss caused by the failure of a single monitoring interface by constructing a dual-channel data acquisition module and an acquisition switching control module. The system simultaneously calls the operating system management interface and the hardware low-level instruction set. When the main channel experiences data interruption or excessive verification deviation, it can automatically switch to the backup channel. This mechanism ensures that the monitoring system can still continuously acquire effective hardware operating parameters under conditions such as high operating system load or driver abnormality, thus ensuring the integrity and continuity of monitoring data.

[0017] 2. This invention utilizes a dual-redundant storage management module to achieve physical isolation and backup of monitoring data. The system synchronously writes standardized data records to both the local hard drive and an external USB flash drive. Even if the local storage device becomes unreadable due to physical damage or file system failure, maintenance personnel can still retrieve historical records from the external USB flash drive before the failure occurred. This dual-storage strategy effectively prevents the loss of critical operational data and provides reliable data support for attribution analysis after equipment failure.

[0018] 3. This invention employs trend analysis technology based on linear difference, which enhances the ability to identify gradual hardware failures. The trend analysis prediction module calculates the difference between the current real-time data and historical samples to quantify the rate of hardware performance degradation. It can promptly detect early abnormal features such as increased power supply voltage fluctuations or linear growth of hard drive bad sectors, and issue warnings before irreversible physical damage to the hardware, thereby reserving sufficient time for preventive maintenance. Attached Figure Description

[0019] Figure 1 This is a system architecture diagram of the present invention; Figure 2 This is a flowchart of the method of the present invention. Detailed Implementation

[0020] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] See attached document Figure 1 , Figure 1 This is a system architecture diagram according to an embodiment of the present invention. The present invention provides a key hardware detection and early warning system for industrial control computers, which runs on an industrial control computer and is used for real-time monitoring and fault early warning of key hardware such as power supplies and hard drives.

[0022] The hardware of this industrial control computer includes a central processing unit (CPU), RAM, a local hard disk drive (HDD), and a power supply module. In this embodiment, the CPU is an Intel Core i5-6500, the RAM is 8GB, the HDD is 1TB, and the power supply module is an ATX 500W. The motherboard is equipped with an HDMI display interface, a VGA display interface, four USB 3.0 ports, and two network interfaces. The system connects to an external USB flash drive with a capacity of 8GB or more via the USB 3.0 ports to create an external redundant storage environment.

[0023] This hardware detection and early warning system consists of a dual-channel data acquisition module, an acquisition switching control module, a dual-redundant storage management module, a trend analysis and prediction module, a hierarchical early warning decision module, and an automated response execution module. Each module resides in the background of the industrial control computer operating system and operates collaboratively to perform hardware parameter monitoring tasks. The dual-channel data acquisition module establishes two independent hardware parameter acquisition channels (primary and backup); the acquisition switching control module verifies data integrity and performs channel switching; the dual-redundant storage management module performs both local and external data writing; the trend analysis and prediction module calculates the linear change trend of hardware parameters; the hierarchical early warning decision module determines the fault risk level; and the automated response execution module performs differentiated alarm operations.

[0024] After system startup, an initialization program is executed. The dual-channel data acquisition modules initialize the main acquisition interface and the backup acquisition interface respectively, establishing a data communication link with the underlying hardware. Simultaneously, the system checks the connection status and read / write permissions of the local hard drive and the external USB flash drive to ensure uninterrupted dual storage path operation.

[0025] After initialization, the dual-channel data acquisition module begins periodic data reading. This module covers four key parameters: power supply output voltage, power supply load rate, hard drive bad sector count, and hard drive I / O latency. Under normal operating conditions, the system acquires data through the main acquisition interface by default, while the backup acquisition interface remains in a low-power standby state, receiving data only from the main interface for comparison.

[0026] The data acquisition switching control module monitors the data stream status of the main acquisition interface in real time. When the system detects that the data interruption at the main acquisition interface lasts for more than 3 seconds, or the deviation between the values ​​read from the main acquisition interface and those read from the backup acquisition interface exceeds 5%, the data acquisition switching control module switches the data source path to the backup acquisition interface. This switching action is completed within 1 second to maintain the continuity of the monitored data.

[0027] The acquired valid monitoring data is transmitted to the dual-redundant storage management module. This module synchronously writes the monitoring data packets, containing timestamps, hardware identifiers, and parameter values, to the database file on the local hard drive and the storage area of ​​the external USB flash drive. This module is configured with a data lifecycle management policy, retaining monitoring data from the most recent 30 days and automatically overwriting historical data that has exceeded this period.

[0028] The trend analysis and prediction module periodically extracts historical monitoring data from the 24 hours preceding the current moment. Based on this data, the module calculates the daily average growth rate of power load rate, the daily average offset of power supply voltage, the daily average increase in hard drive bad sectors, and the daily average increase in hard drive I / O latency. This calculation process is based on a linear trend over 24 hours and does not involve deep learning or complex probabilistic algorithms.

[0029] The tiered early warning decision module receives the calculation results output by the trend analysis and prediction module and compares them with a preset fault threshold table. The fault threshold table includes judgment conditions for four types of faults: increased power load rate, unstable power voltage, increased number of bad sectors on the hard drive, and deterioration of hard drive read / write performance. Based on the comparison results, the system determines the current hardware status as normal, mild warning, or severe warning.

[0030] The automated response execution module performs corresponding operations based on the judgment results output by the hierarchical early warning decision module. When the system determines that the state is a mild early warning, this module drives the industrial control computer display to pop up a blue prompt window, displaying the fault prediction information, and writes the early warning event to the system log. At this time, remote data transmission is not performed.

[0031] When the system determines a severe warning state, the automated response module executes a dual response, both locally and remotely. Locally, the module displays a red warning window on the screen and controls the industrial computer's buzzer to emit a continuous alarm sound. Remotely, the module uses an email transmission protocol to send a notification email to a pre-configured administrator email address. This email includes the name of the faulty hardware, the predicted time of the fault, a trend chart, and suggested operational measures. All warning trigger records and corresponding peak data are synchronously saved to both the local hard drive and an external USB flash drive by a dual-redundant storage management module.

[0032] The dual-channel data acquisition module and the acquisition switching control module together form an acquisition redundancy layer, which is used to build two parallel data paths and a millisecond-level fault switching mechanism.

[0033] The dual-channel data acquisition module is configured with logically independent primary and backup acquisition interfaces. The primary acquisition interface serves as the system's default data source, used to call the management interface of the industrial control computer's operating system. Under a Windows operating system environment, the primary acquisition interface is configured to call the WMI interface; under a Linux operating system environment, the primary acquisition interface is configured to call the lm-sensors hardware monitoring tool. The specific calling methods and return data format parsing of the WMI interface and the lm-sensors hardware monitoring tool can be implemented by those skilled in the art based on the relevant operating system development documentation, and are well-known technologies in the field, so they will not be elaborated here. The sampling frequency of the primary acquisition interface is set to once every 30 seconds. This frequency setting ensures data timeliness while avoiding excessive CPU resource consumption by high-frequency polling.

[0034] The backup acquisition interface is configured as a physical layer interface for direct communication with the underlying hardware controller. For power module parameter acquisition, the backup acquisition interface uses the PMBus instruction set tool to read register data from the power controller; for hard disk module parameter acquisition, it uses the SMART reading tool to obtain hard disk health status data. When the main system channel is operating normally, the backup acquisition interface remains in passive standby mode, only receiving data streams from the main acquisition interface for background comparison, and does not send active read commands to the hardware bus to reduce bus load.

[0035] The set of monitoring parameters acquired by the dual-channel data acquisition module Defined as: In the formula, Indicates the power load rate; Indicates the power supply output voltage; This indicates the number of bad sectors on the hard drive. This indicates disk I / O latency. The data acquisition switching control module resides in the system background to maintain data link continuity. This dual-channel data acquisition module determines data source switching by real-time monitoring of the communication heartbeat and data quality of the main acquisition interface. This dual-channel data acquisition module has a built-in switching trigger function. This is used to determine whether to switch the data source from the main acquisition interface to the backup acquisition interface.

[0036] The data acquisition and switching control module executes the first level of decision-making logic, namely, communication interruption determination. System Definition The duration during which the main data acquisition interface returns no data continuously, when detected. If a preset time threshold is exceeded, the main data acquisition interface is deemed to have failed, triggering a switchover. This mechanism primarily addresses the issue of interface hangs or unresponsive services at the operating system level.

[0037] The data acquisition switching control module executes the second layer of judgment logic, namely data consistency verification. This module reads the verification value of the backup acquisition interface at the same timestamp in real time and compares it with the value of the primary acquisition interface. Let... This refers to the value of a specific parameter acquired by the main acquisition interface at the same time. This is the corresponding parameter value obtained from the backup acquisition interface. The system calculates the data deviation rate between the two. The calculation formula is as follows: When the calculation yields If the deviation exceeds the preset threshold, the main acquisition interface data is determined to be abnormal, triggering a switching action.

[0038] The switching trigger logic of the data acquisition and switching control module can be summarized as follows: In the formula, Indicates switching trigger functions, This indicates that a state switch has been triggered. This indicates maintaining the status quo. This indicates the duration during which the main data acquisition interface returns no data for an extended period. This indicates a preset time threshold. This indicates the preset deviation threshold. This indicates the data deviation rate.

[0039] when When the value is 1, the data acquisition switching control module executes a switching command, locking the system's data source pointer to the backup acquisition interface and blocking data input from the primary acquisition interface. The entire switching process takes less than one second. The system also records the timestamp and triggering reason of the switching event in the local log file to facilitate subsequent maintenance personnel in troubleshooting software interface faults. Through this dual verification and rapid switching mechanism, the system can ensure continuous acquisition of valid data even if a single acquisition link fails. , , and These parameters ensure the normal operation of subsequent trend analysis and early warning functions.

[0040] In this embodiment, the dual-redundant storage management module is used to establish a synchronous write mechanism between the local storage medium of the industrial control computer and the external mobile storage medium, and to ensure the retention rate of monitoring data through physical media isolation.

[0041] The dual-redundant storage management module performs storage path mapping and locking during the system initialization phase. This module identifies and locks the preset data storage directory on the local mechanical hard drive through the industrial control computer's operating system file system interface. Simultaneously, the module scans the industrial control computer's USB bus interface to identify connected external USB flash drives. This embodiment requires the external USB flash drive to have a storage capacity of at least 8GB, a threshold calculated based on the daily data volume and a preset retention period. The system identifies the USB flash drive's file allocation table (FAT32 or NTFS format), obtains its drive letter or mount point, and maps it to an external redundant storage path. File system mount and read / write permission verification can be implemented using standard APIs provided by the operating system, which is well-known technology in the field and will not be elaborated upon here.

[0042] During the data writing phase, the dual-redundant storage management module receives valid monitoring data from the dual-channel data acquisition module or the acquisition switching control module. This module encapsulates the received discrete parameters into standardized data records. Data Records The structure is defined as follows: In the formula, The system timestamp indicating the moment of data collection, accurate to the second; A unique device identifier code representing the monitored industrial control computer, used to distinguish the data source in a multi-machine environment; Indicates including power load rate Power supply output voltage Hard drive bad sectors and hard disk I / O latency The set of parameter values.

[0043] The dual-redundant storage management module includes a synchronous write unit, which constructs a data buffer in memory and encapsulates the data... Simultaneously, the database file is written to both the local hard drive and the backup file on the external USB flash drive. This write operation is designed to be atomic or guaranteed by a verification mechanism to ensure that data at the same timestamp remains consistent across the two physical media. If the external USB flash drive is not connected or the write operation fails, the dual-redundancy storage management module will mark the redundancy loss status for that time period in the local log, but will not interrupt the write process on the local hard drive.

[0044] For data maintenance with limited storage space, the dual-redundant storage management module implements a lifecycle management strategy based on a time-sliding window, and sets a data retention period for the dual-redundant storage management module. For a period of 30 days, this dual-redundant storage management module traverses historical data files in the storage directory during specific system idle periods each day, extracting the file's time attributes. The data cleaning logic is as follows: If the conditions are met ,in If the current system date is used, the dual-redundant storage management module will perform file deletion or overwrite operations.

[0045] Through the above mechanism, the system maintains complete monitoring data records for the most recent 30 days without manual intervention in storage space. This dual redundancy mechanism ensures that even if the local hard drive of the industrial control computer becomes unreadable due to physical failure (such as damaged read / write heads or burned circuit boards), maintenance personnel can still directly unplug an external USB flash drive and read historical monitoring data on other computing devices, thereby enabling fault tracing and analysis.

[0046] In this embodiment, the trend analysis and prediction module is used to analyze historical monitoring data using a low-complexity linear trend algorithm in an environment where the local computing resources of the industrial control computer are limited, in order to quantify the short-term decline direction of hardware performance.

[0047] The trend analysis and prediction module includes a data extraction unit. Within each preset analysis cycle, this unit retrieves two sets of key data records from the local database via the read interface of the dual-redundant storage management module. The first group represents the current time. Real-time recording of collected parameters; The second group consists of historical moments. Historical parameter records collected. Among them, historical moments... Defined as a point in time 24 hours from the current time, i.e. If there is no exact correspondence in the storage system Real-time data recording (e.g., data gaps due to system shutdown), the data extraction unit will retrieve and use... The most recent valid record from a previous time is used as a substitute to ensure the continuity of trend calculation.

[0048] The trend analysis and prediction module includes a power trend calculation unit, used to quantify the operational stability of the power module. This power trend calculation unit performs the following two calculations based on the extracted data records: Calculate the daily average change in power load factor This is used to assess whether the power supply load is in a dangerous trend of continuous increase. The calculation formula is defined as: In the formula, This represents the current power load rate. This indicates the power load rate value 24 hours ago; The results are in percentage (%), with positive values ​​indicating an increase in load rate and negative values ​​indicating a decrease in load rate.

[0049] Calculate the daily average deviation stability of the power supply voltage This is used to assess whether the power supply output voltage is deviating from the standard value and showing a deteriorating trend. The calculation formula is defined as: And simultaneously calculate the current voltage absolute offset. : In the formula, and These represent the measured values ​​of the power supply output voltage at the current and historical moments, respectively. Indicates the standard rated voltage of the power supply; A positive value indicates that the voltage is deviating more from the standard value.

[0050] The trend analysis and prediction module includes a hard drive trend calculation unit, which quantifies the physical health and read / write performance of the hard drive. This hard drive trend calculation unit performs the following two calculations based on the extracted data records: Calculate the average daily increase in the number of bad sectors on a hard drive. It is used to identify whether there is physical damage spreading on the hard disk platter, and the calculation formula is defined as: In the formula, and These represent the total number of bad sectors recorded at the current and historical moments, respectively. The value represents the number of new bad sectors generated in the past 24 hours.

[0051] Calculate the daily average increase in disk I / O latency This is used to identify read / write performance degradation caused by hard drive head aging or mechanical structural jamming. The calculation formula is defined as: In the formula, and These represent the I / O response latency at the current and historical moments, respectively.

[0052] The hard disk trend calculation unit is equipped with auxiliary parameter monitoring logic, which reads the ECC check recovery count and uncorrectable sector count at the current moment. Although it does not directly perform 24-hour differential calculation on these two auxiliary parameters, it outputs the non-zero or abrupt state of these two parameters as Boolean flag bits to assist in subsequent early warning decisions.

[0053] The trend analysis and prediction module converts discrete monitoring data into trend indicators that reflect the rate of change in hardware status. , , and The calculation process involves only basic arithmetic operations and does not rely on complex regression analysis models or cloud-based big data training. Therefore, it can be completed in real time under low computing power conditions on the local industrial control computer, ensuring the lightweight and independence of the monitoring system.

[0054] In this embodiment, the hierarchical early warning decision module and the automated response execution module work together to form the system's decision output layer. Based on the quantitative indicators output by the trend analysis and prediction module, a two-level threshold judgment logic is used to identify hardware failure risks, and differentiated local or remote intervention operations are performed according to the risk level.

[0055] The tiered early warning decision-making module includes a threshold comparison unit, which contains an early warning threshold database. This database stores judgment parameters for various power supply and hard drive failure modes. The threshold comparison unit receives the daily average change in power load rate from the trend analysis and prediction module. Daily average deviation stability of power supply voltage Daily increase in the number of bad sectors on hard drives and daily increase in hard disk I / O latency The aforementioned trend indicators are then combined with the currently collected absolute value parameters for logical calculation.

[0056] The threshold comparison unit first executes the mild warning judgment logic, which is used to identify the hardware state in the early degradation stage. The system defines the trigger condition for a mild warning as satisfying any one of the following logical expressions: Condition 1 (Early overload of power supply): ; Condition 2 (Slight fluctuations in power supply voltage): ; Condition 3 (Early-stage bad sector proliferation on hard drive): ; Condition 4 (Slight Degradation of Hard Drive Performance): .

[0057] When any of the above conditions are met and no higher-level warning is triggered, the threshold comparison unit outputs a mild warning signal.

[0058] The threshold comparison unit simultaneously executes the severe warning determination logic, which is used to identify dangerous hardware states where functional failure is about to occur. The system defines the trigger condition for a severe warning as satisfying any one of the following logical expressions: Condition 1 (Severe power supply overload): ; Condition 2 (Severe power supply voltage instability): ; Condition 3 (Explosive growth of bad sectors on the hard drive): ; Condition 4 (Severe hard drive read / write congestion): .

[0059] When any of the above conditions are met, the threshold comparison unit outputs a severe warning signal, which has the highest priority. If both mild and severe conditions are met, the system will only execute a severe warning response.

[0060] The automated response execution module includes a local interaction unit and a remote communication unit, which are used to execute corresponding alarm actions according to the level of the received warning signal.

[0061] The local interaction unit is responsible for handling the audio-visual prompts from the industrial control computer. When a mild warning signal is received, the local interaction unit calls the operating system's graphical interface to display a blue-background prompt window on the front of the screen, showing the fault type and predicted information. At this time, the industrial control computer's audio output device remains silent. When a severe warning signal is received, the local interaction unit displays a red-background warning window and simultaneously calls the motherboard's buzzer driver interface or audio driver interface to control the sound-emitting unit to output a continuous alarm sound to attract the attention of the on-site operators.

[0062] The remote communication unit handles cross-network alarm notifications and is activated only under severe alert conditions. This unit is equipped with an SMTP client. Upon receiving a severe alert signal, the remote communication unit automatically constructs an alarm email. The email body is generated using a template and includes the identifier of the malfunctioning industrial control computer. The system includes the specific hardware component name that triggers the warning, the estimated time of failure based on current trends (e.g., "Damage is expected within 7 days based on current trends"), and recommended maintenance measures. The remote communication unit sends the prepared email to the preset administrator email address. For the specific handshake and transmission process of the SMTP protocol, those skilled in the art can refer to the RFC standard document for implementation; details will not be elaborated here.

[0063] The automated response execution module is also connected to a dual-redundant storage management module. Whether a minor or major alert is triggered, this module synchronously writes a snapshot of the alert event type, trigger time, and key parameters at the time of triggering to both the local log file and the external USB flash drive log file, thus achieving full traceability of the fault process. Through this tiered and differentiated response mechanism, the system can alert to minor risks without disrupting normal production and ensure notification delivery when facing major risks.

[0064] See attached document Figure 2 , Figure 2This is a flowchart of a method according to an embodiment of the present invention. The present invention provides a method for detecting and providing early warning of key hardware in an industrial control computer, comprising the following steps: S1, the system starts and initializes the dual-channel data acquisition module, establishes a data communication link between the main acquisition interface and the backup acquisition interface, and verifies the read and write permissions of the local mechanical hard drive and the external USB flash drive. S2 reads the hardware operating parameters of the power supply and hard disk through the main acquisition interface. The acquisition switching control module compares the data status of the main acquisition interface and the backup acquisition interface in real time. When the data interruption of the main acquisition interface exceeds 3 seconds or the deviation between the main and backup data exceeds 5%, it switches to the backup acquisition interface for acquisition. S3 synchronously writes the collected valid data to the local hard drive and external USB flash drive, and retains historical data from the most recent 30 days in timestamp order; S4 extracts historical data from the previous 24 hours before the current moment and calculates the daily average growth rate of power load rate, the daily average offset of power voltage, the daily average increase in the number of bad sectors on the hard disk, and the daily average increase in hard disk I / O latency. S5 compares the calculated trend data with the preset graded fault thresholds, determines the warning level based on the comparison results, and executes the corresponding local pop-up prompt, buzzer alarm, or remote email notification operation.

[0065] 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 key hardware detection and early warning system for industrial control computers, characterized in that, include: The dual-channel data acquisition module is used to call the operating system management specification interface and the hardware underlying instruction set respectively to build a main acquisition data channel and a backup acquisition data channel that are independent of each other for power supply and hard disk parameters. The acquisition switching control module is used to compare the data quality of the main acquisition data channel and the backup acquisition data channel in real time based on the data integrity verification logic, and lock the current data source pointer based on the comparison result in order to filter the effective monitoring data stream from the two channels; The dual-redundant storage management module is used to structure and encapsulate the effective monitoring data stream, generate standardized data records by adding system timestamps and unique device identifiers, and simultaneously write them to the local hard disk and external USB flash drive to build a historical traceability database. The trend analysis and prediction module is used to locate and extract historical data samples that are separated by a preset time interval in the historical traceability database, using the real-time data timestamp of the current moment as the anchor point, establish the parameter alignment relationship between the real-time data and the historical data samples, and perform differential operations to generate a quantitative trend indicator that reflects the rate of hardware performance degradation. The graded early warning decision module is used to map the quantitative trend indicators to a preset fault threshold model and generate risk status judgment results through multi-level logical comparison. An automated response execution module is used to drive the risk status determination result, construct a visual prompt window data packet when the determination result is a mild warning, and simultaneously trigger a local audible and visual alarm drive command and construct a remote network notification data packet when the determination result is a severe warning.

2. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, The dual-channel data acquisition module is specifically used for: Set the main data acquisition channel to call the WMI interface of the operating system or the lm-sensors hardware monitoring tool interface, and set the first sampling frequency to obtain regular monitoring data; The backup data acquisition channel is configured to call the PMBus instruction set to read the power controller register and call the SMART tool to read the hard disk health status. When the main data acquisition channel is working normally, the backup data acquisition channel remains in a passive standby state, only receiving data for comparison and verification.

3. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, The data integrity verification logic executed by the acquisition switching control module specifically includes: The system monitors the data flow of the main data acquisition channel. When the duration of no data return exceeds a preset time threshold, the system determines that the main channel has failed and locks the data source pointer to the backup data acquisition channel. Alternatively, the parameter values ​​of the main acquisition data channel and the backup acquisition data channel can be acquired simultaneously at the same time, and the numerical deviation ratio between the two can be calculated. When the numerical deviation ratio exceeds a preset deviation threshold, the main channel data is determined to be abnormal and the data source pointer is locked to the backup acquisition data channel.

4. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, When generating standardized data records, the dual-redundant storage management module encapsulates four parameters—power load rate, power output voltage, number of bad sectors on the hard disk, and hard disk I / O latency—into the data payload segment. When building the historical traceability database, a lifecycle management strategy based on time sliding windows is adopted. A full scan of the storage directory is performed to filter and delete historical files whose file time attributes differ from the current system date by more than the preset retention period, so as to maintain the time coverage of the database.

5. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, When locating and extracting historical data samples, the trend analysis and prediction module sets the preset time interval to 24 hours. If there is no record in the historical traceability database that corresponds to the current time, then fuzzy matching logic is executed to retrieve and extract the most recent valid standardized data record before the corresponding time point as the historical data sample.

6. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, The process by which the trend analysis and prediction module performs differential calculations to generate quantitative trend indicators includes: Extract the power load rate from the current real-time data and historical data samples, calculate the difference between the two to generate a power load rate change index. Extract the power supply output voltage from the current real-time data and historical data samples, calculate the absolute deviation of the two relative to the standard rated voltage, and calculate the difference between the two absolute deviation values ​​to generate a power supply voltage stability index. Extract the total number of cumulative bad sectors from the current real-time data and historical data samples, and calculate the difference between the two to generate an indicator of the increase in new bad sectors on the hard drive. Extract the disk I / O response time from the current real-time data and historical data samples, and calculate the difference between the two to generate a disk I / O latency increment metric.

7. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, The fault threshold model preset by the hierarchical early warning decision module includes a first threshold set and a second threshold set, and the multi-level logical comparison step further includes: When the quantitative trend indicator exceeds the corresponding threshold in the first threshold set, and the current real-time data value exceeds the basic warning line, a risk status judgment result indicating a mild warning is generated. When the quantitative trend indicator exceeds the corresponding threshold in the second threshold set, and the current real-time data value exceeds the severe warning line, a risk status judgment result indicating a severe warning is generated, and the judgment priority of the severe warning is higher than that of the mild warning.

8. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, When constructing remote network notification data packets, the automated response execution module activates the SMTP client only when it receives the risk status judgment result of a severe warning, calls the preset notification template, fills in the fault device identifier, the name of the hardware component that triggered the warning, and the estimated damage time based on the current trend, combines them to generate an alarm email data stream and sends it to the preset email address.

9. The industrial control computer key hardware detection and early warning system according to claim 1, characterized in that, The dual-redundant storage management module also includes a log recording interface, which is used to receive the early warning event snapshot generated by the automated response execution module and synchronously append the event information, including the trigger time, early warning level and corresponding quantitative trend indicators, to the log files of the local mechanical hard drive and the external USB flash drive.

10. A method for detecting and warning critical hardware of an industrial control computer, applied to the industrial control computer critical hardware detection and warning system as described in any one of claims 1-9, characterized in that, Includes the following steps: S1. Call the operating system management specification interface and hardware low-level instruction set to build a main data acquisition channel and a backup data acquisition channel that are independent of power supply and hard disk parameters; S2. Based on the data integrity verification logic, the data quality of the main acquisition data channel and the backup acquisition data channel are compared in real time. Based on the comparison result, the current data source pointer is locked to filter the effective monitoring data stream from the two channels. S3. The effective monitoring data stream is structured and encapsulated, and standardized data records are generated by adding system timestamps and unique device identifiers. The records are then synchronously written to the local hard disk and external USB flash drive to build a historical traceability database. S4. Using the real-time data timestamp of the current moment as the anchor point, locate and extract historical data samples that are separated by a preset time interval in the historical traceability database, establish the parameter alignment relationship between real-time data and historical data samples, and perform differential operation to generate a quantitative trend indicator that reflects the rate of hardware performance degradation. S5. Map the quantitative trend indicators to a preset fault threshold model, and generate a risk status judgment result through multi-level logical comparison. S6. Driven by the risk status determination result, when the determination result is a mild warning, a visual prompt window data packet is constructed, and when the determination result is a severe warning, a local sound and light alarm driving command is triggered and a remote network notification data packet is constructed simultaneously.

Images