Programmable Network Data Filtering for PLC Error Diagnosis
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Solution Overview
Problem
In factory automation manufacturing sites, the limited memory capacity of control devices hinders the collection of all communication data required to identify causal factors during high-speed network communications, as the volume of data exceeds the devices' storage capabilities.
Innovation Solution
A control device with a program execution module, communication unit, and collection module that allows the filtering condition for data collection to be dynamically changed based on user-program instructions, including IP addresses, protocols, and port numbers, enabling efficient data collection by adjusting the timing and content of data capture according to the current working process status.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If all communication data is collected to identify causal factors, then measurement precision is improved, but the device complexity increases due to insufficient memory capacity
Solution Approach 1:
The patent extracts only the necessary communication data by implementing a collection module that selectively captures data based on filtering conditions. Instead of collecting all communication data, the system extracts only those packets that match specific criteria (such as source/destination IP addresses, port numbers, or protocol types), thereby reducing memory requirements while maintaining the ability to identify causal factors of communication errors.
Solution Approach 2:
The patent applies local quality by making different parts of the data collection process have different characteristics. The filtering mechanism applies different selection criteria to different types of communication data based on the error type being investigated. For example, when investigating connection establishment errors, the system selectively collects data with specific TCP flag patterns, while for data transfer errors, it collects different types of packets, optimizing memory usage for each specific diagnostic scenario.
2Adaptability or versatility
If filtering conditions are made flexible to adapt to different working process statuses, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent implements dynamics by making the filtering conditions changeable and adaptable during operation. The collection module can dynamically adjust its filtering criteria based on the current working process status, error types detected, or diagnostic needs. This allows the system to adapt to different scenarios (such as different communication protocols, error types, or network conditions) without requiring hardware changes, while the programmable nature keeps the implementation complexity manageable.
Data Source
AI summary
A control device includes a program execution module, a communication unit, and a collection module connected to the communication unit. The program execution module generates control instructions for a control target in accordance with a user program that is freely created. The communication unit transmits and/or receives communication data to and/or from an external device through a network. The collection module collects data satisfying a filtering condition from among the communication data that is transferred on the network. The collection module changes the filtering condition in accordance with an instruction included in the user program.