Industrial Control Fault Analysis With Knowledge-Base Feedback
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Solution Overview
Problem
Existing control devices for industrial technical installations primarily provide generic fault messages without offering actionable directions for rectifying faults, limiting the operator's ability to efficiently address issues.
Innovation Solution
The control device transmits fault messages and associated histories to a knowledge base, receives a targeted response, and outputs this information to the operator, allowing for specific directions on fault rectification, while also optionally storing and transmitting histories of target and control variables, and receiving supplementary information for optimizing future behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If generic fault messages are displayed to operators, then fault information is provided, but actionable directions for rectification are not provided
Solution Approach 1:
The system transmits actual variable histories and fault information to a knowledge base, receives diagnostic responses with rectification directions, and feeds this information back to the operator through the display device. This closed-loop feedback mechanism transforms generic fault messages into actionable guidance.
Solution Approach 2:
A knowledge base acts as an intermediary between the control device and the operator. It processes fault information and historical data to generate diagnostic responses with specific rectification directions, bridging the gap between raw fault data and actionable guidance.
2Loss of information
If fault messages with accompanying values are displayed, then some fault information is conveyed, but no rectification measures are proposed
Solution Approach 1:
The knowledge base pre-processes fault information and prepares rectification directions in advance. When a fault occurs, the system quickly retrieves and transmits pre-analyzed diagnostic responses, eliminating the need for operators to manually analyze fault data and reducing rectification time.
Solution Approach 2:
The system establishes a feedback loop where fault information is transmitted to the knowledge base, which responds with pre-analyzed rectification measures. This automated feedback mechanism provides operators with ready-to-action guidance, significantly reducing fault rectification time.
3Measurement precision
If histories of actual variables are transmitted to a knowledge base, then fault analysis is improved, but data transmission and processing complexity increases
Solution Approach 1:
The knowledge base serves as a specialized intermediary that handles the complexity of historical data analysis. The control device simply transmits data to the knowledge base, which performs the complex processing and returns simplified diagnostic responses, distributing complexity to the appropriate component.
Solution Approach 2:
The knowledge base is designed as a multi-functional component that can handle various types of fault analysis, data processing, and diagnostic tasks. This universal approach consolidates complexity in a single component rather than distributing it across multiple specialized systems.
Data Source
AI summary
A control device of a technical installation receives in normal operation cyclically measurement variables from sensors, and outputs control variables to actuators. In normal operation, the control device stores the history of at least some of the measurement variables at least for a limited time and monitors the measurement variables for the occurrence of a fault. If a fault occurs, the control device transmits a fault message identifying the fault and the history to a knowledge base. In response to the fault message and the histories, the control device receives a reply from the knowledge base and outputs the reply to an operator. Before the normal operation is performed, the control device receives from the operator specifications which allow the control device to defines the histories. In the event of a fault, the control device determines, in dependence on the specifications, which histories to transmit to the knowledge base.