Improper Cabling Detection in Redundant Communication Networks

Solution Overview

Problem

Existing industrial communication networks with redundant configurations face challenges in accurately identifying improper cabling, which can lead to system failures and require additional engineering effort and costs, especially in high-availability systems like substation automation.

Innovation Solution

A method and device that establish connect statuses and error events by receiving messages with identifiers to determine if ports are correctly connected to their intended networks, using standard protocols like IEC 62439 PRP, allowing for automated diagnosis of improper cabling without hardware modifications.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If dedicated designs of plugs or color-coding of cables are used to prevent wrong cabling, then cabling accuracy is improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improvecabling accuracyVSAvoidplug design complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system automatically detects improper cabling by monitoring network messages and comparing port identifiers with network identifiers. When a mismatch is detected, an error event is generated and reported, providing feedback about the cabling status without requiring physical modifications to plugs or cables.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical prevention methods (dedicated plug designs, color-coding) with an electronic/software-based identification and detection system. Instead of modifying physical connectors, the system uses message analysis and identifier comparison to detect cabling errors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If dedicated designs of plugs or color-coding are used to prevent wrong cabling, then cabling accuracy is improved, but manufacturing cost increases

Engineering Contradiction:

Improvecabling accuracyVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The system automatically detects improper cabling by monitoring network messages and comparing port identifiers with network identifiers. When a mismatch is detected, an error event is generated and reported, providing feedback about the cabling status without requiring physical modifications to plugs or cables.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces mechanical prevention methods (dedicated plug designs, color-coding) with an electronic/software-based identification and detection system. Instead of modifying physical connectors, the system uses message analysis and identifier comparison to detect cabling errors.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Difficulty of detecting and measuring

If user intervention is used to investigate wrong cabling, then identification capability is improved, but time consumption increases

Engineering Contradiction:

Improvewrong cabling identification capabilityVSAvoidinvestigation time

Core Design Contradiction:

Difficulty of detecting and measuringVSLoss of time

Solution Approach 1:

The system performs self-diagnosis by automatically monitoring network messages and detecting cabling errors. The receiving device independently compares identifiers and generates error events without requiring user intervention, enabling the system to identify and report improper cabling autonomously.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The system automatically detects improper cabling by monitoring network messages and comparing port identifiers with network identifiers. When a mismatch is detected, an error event is generated and reported, providing feedback about the cabling status without requiring physical modifications to plugs or cables.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS8344736B2Identifying improper cabling of devices

Publication Date: 2013.01.01 HITACHI ENERGY LTD

AI summary

Systems and methods are disclosed for identifying improper cabling of control system devices connected to redundant communication networks of distributed control systems. In an embodiment, a receiving device receives messages including a sender identification or source address, and a network or associated device port identification, from sending devices, over redundant networks. The receiving device determines a connect status indicating whether a message was received on a particular device port, and an error event indicating whether the port is associated with the network identified in the message. A system diagnoses an improper communication path between devices and produces an indication of a location and/or type of improper cabling. A method supplants error events with error rates calculated as a probability of receiving messages on a device port not associated with the network identified in a received message. The method compares the error rates to error thresholds to identify improper cabling.