Controller-Based Communication Failure Detection for Industrial Networks
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Solution Overview
Problem
Current industrial process control and automation systems lack effective methods to detect and pinpoint the root causes of communication failures due to mis-connected wiring, connector/extender shorting, and unsupported local network loops, leading to network instability and device failures.
Innovation Solution
A fault detection tool implemented in the controller of the system that diagnoses network instabilities by monitoring and analyzing communication data, such as UDP packets, to identify faulty local loops, wiring issues, and momentary network problems, generating alarms and notifications to operators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional communication monitoring methods are used in industrial networks, then network communication can be maintained, but communication failures caused by mis-connected wiring, connector shorting, and local network loops cannot be detected or diagnosed
Solution Approach 1:
The patent introduces a diagnostic message (intermediary) that is inserted into the communication data stream to act as a probe for detecting network faults. This diagnostic message carries identification information that allows the system to trace and identify the specific location and cause of communication failures, such as mis-connected wiring, connector shorting, and local network loops, without disrupting normal communication operations.
Solution Approach 2:
The system implements a feedback mechanism where communication data including diagnostic responses is continuously monitored and analyzed. When a communication failure is detected, the system provides feedback about the fault condition, enabling automatic or assisted diagnosis of the root cause. This feedback loop allows the network to self-diagnose issues and provide information about the location and nature of failures.
2Device complexity
If no active fault detection mechanism is implemented, then the system structure remains simple, but network instabilities and failures cannot be proactively detected or diagnosed
Solution Approach 1:
The patent implements preliminary action by proactively injecting diagnostic messages into the communication stream before actual failures occur. These diagnostic messages are sent at predetermined intervals or under specific conditions to preemptively detect potential network issues. This allows the system to identify problems early, such as developing wiring issues or forming network loops, before they cause complete communication breakdowns.
3Difficulty of detecting and measuring
If communication data is continuously monitored for fault detection, then root causes of failures can be identified, but additional processing overhead and system complexity are introduced
Solution Approach 1:
The patent segments the fault detection function into separate components: a diagnostic message generation module, a communication data collection module, and an analysis module. This segmentation allows each component to perform its specific function efficiently without requiring the entire system to be complex. The diagnostic messages are segmented with specific identification information that enables targeted analysis rather than requiring comprehensive monitoring of all communication data.
Data Source
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AI summary
An apparatus and method is disclosed for identifying the root cause of device communication failures in a communication network comprising collecting communication data transmitted and received on the communication network from a controller and one or more devices operably connected to the communication network and analyzing the collected communication data to diagnose if communication data is local looping or has been lost between the controller and the one or more devices and the location of the fault in the communication network.