Distributed Controller Diagnostics for Remote Service and Monitoring

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Solution Overview

Problem

Current methods for diagnosing and servicing controllers are manual, time-consuming, and costly, requiring on-site visits by service engineers, which limits efficiency and productivity.

Innovation Solution

A distributed control system with a diagnostic engine that collects and evaluates diagnostic parameters from multiple computing resources, enabling remote diagnosis and service through a network of distributed controllers and a remote support platform.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual inspection by service engineers is used, then diagnostic accuracy can be achieved, but time consumption and cost increase significantly

Engineering Contradiction:

Improvediagnostic accuracyVSAvoidtime consumption

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The controller performs self-diagnosis by automatically collecting and analyzing its own operational data through embedded sensors and diagnostic software, eliminating the need for manual inspection while maintaining diagnostic accuracy

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Physical manual inspection by service engineers is replaced with automated electronic monitoring systems that continuously collect and analyze operational parameters, achieving both speed and accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Loss of information

If manual inspection by service engineers is used, then comprehensive data collection is possible, but cost and productivity are negatively affected

Engineering Contradiction:

Improvedata collection completenessVSAvoidservice productivity

Core Design Contradiction:

Loss of informationVSProductivity

Solution Approach 1:

The diagnostic system operates continuously, constantly monitoring operational parameters and collecting data without interruption, ensuring comprehensive information gathering while maintaining high service productivity

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

Manual data collection processes are replaced with automated electronic sensors and software that continuously gather operational data, achieving complete data collection without reducing productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If on-site visits by service engineers are required, then direct observation and measurement can be performed, but efficiency and productivity decrease

Engineering Contradiction:

Improvedirect measurement accuracyVSAvoidservice efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The controller autonomously performs measurements and diagnostics of its own components using integrated sensors and analysis algorithms, eliminating the need for service engineer visits while maintaining measurement accuracy

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Physical presence and manual measurement tools are replaced with electronic sensors and automated diagnostic software that perform measurements remotely and continuously, improving service efficiency without sacrificing accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If remote diagnosis is implemented, then productivity and efficiency improve, but system complexity increases

Engineering Contradiction:

Improvediagnostic productivityVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The controller integrates multiple functions including operation control, self-diagnosis, data collection, and communication capabilities into a single unified system, improving productivity while managing complexity through functional integration

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

A standardized communication interface and data protocol act as intermediaries between the controller's internal systems and external diagnostic tools, simplifying the overall system architecture while enabling remote diagnosis

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS12276970B2Systems and methods for controller diagnostics and service

Publication Date: 2025.04.15 ABB (SCHWEIZ) AG

AI summary

According to one aspect of this disclosure, a distributed control system may include a diagnostic engine, a plurality of computing resources generating diagnostic parameters for transmission to the diagnostic engine, a first communication link operatively coupling the plurality of computing resources to one another, a second communication link operatively coupling the plurality of computing resources to the diagnostic engine, and a remote connection operatively coupling the diagnostic engine to a remote computing resource. The diagnostic parameters may indicate one or more conditions for at least one of the plurality of computing resources. The diagnostic engine locally observes the diagnostic parameters of the plurality of computing resources via the first communication link, and the remote computing resource initiates operation of the diagnostic engine via the remote connection and evaluates the diagnostic parameters remotely.