Multi-Machine Trace Data Capture for Alarm Cause Analysis
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Solution Overview
Problem
In industrial settings, analyzing the cause of alarms in machines is challenging because the influence of one machine on others cannot be identified solely by referencing trace data from the machine that satisfied a specific condition, as the operations of multiple machines are closely related, and acquiring trace data from all relevant machines is necessary for comprehensive analysis.
Innovation Solution
A trace data acquisition system that includes a data collection apparatus and controllers, where when an alarm is generated in one machine, the system requests and acquires trace data from all machines involved in the process, including those that have not generated an alarm, to provide comprehensive data for analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If trace data is acquired only from the machine that generated the alarm, then memory consumption is reduced, but the accuracy of alarm cause analysis deteriorates because the influence of other machines cannot be identified
Solution Approach 1:
The system pre-configures trace data acquisition settings and establishes the framework for multi-machine data collection before alarms occur. When an alarm is generated, the pre-established system automatically requests trace data from relevant machines, enabling rapid response without manual intervention while maintaining analysis accuracy.
Solution Approach 2:
Instead of uniformly acquiring trace data from all machines regardless of situation, the system selectively requests data only from machines that are locally relevant to the alarm source. This targeted approach maintains high analysis accuracy by including potentially influential machines while avoiding unnecessary data collection from unrelated machines, thus optimizing memory usage.
2Reliability
If trace data is acquired from all machines when an alarm occurs, then the accuracy of analyzing machine states improves, but the system complexity increases
Solution Approach 1:
The system introduces a central management apparatus that acts as an intermediary between the alarm-generating machine and other machines. This mediator coordinates trace data acquisition requests, manages data collection from multiple sources, and organizes the data for analysis, thereby simplifying the overall system architecture while enabling comprehensive multi-machine data collection.
3Loss of information
If trace data is continuously collected from all machines, then complete data availability is achieved, but energy consumption and storage requirements increase
Solution Approach 1:
Instead of continuous data collection, the system implements periodic trace data acquisition triggered by specific events (alarms). Trace data is collected at discrete intervals only when alarms occur, ensuring that complete data is available for analysis while minimizing unnecessary energy consumption and storage requirements during normal operation.
Data Source
AI summary
A trace data acquisition system, comprising: a plurality of industrial machines configured to sequentially process an object; and circuitry configured to: determine whether one of the plurality of industrial machines has satisfied a specific condition; and request another industrial machine to acquire trace data when the one of the plurality of industrial machines is determined to have satisfied the specific condition.