PLC Remote Diagnostics via Reasoning Engine and Segmented Protocol
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Solution Overview
Problem
Monitoring and Diagnostics systems face challenges in response time due to reliance on human operator availability and the use of static communication protocols that are inflexible and degrade performance by mixing raw data and information in the same channel.
Innovation Solution
A Monitoring and Diagnostics system incorporating a reasoning engine with diagnostics knowledge for automated fault handling, combined with a communication method that uses a separate description file to differentiate between raw data and information, allowing for flexible and efficient data transmission between Programmable Logic Controllers and central units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a human operator is used to analyze fault data and take actions, then the system can handle complex diagnostic situations, but the response time increases and operational costs increase
Solution Approach 1:
The monitoring unit is equipped with a reasoning engine that enables it to automatically analyze fault data, diagnose problems, and initiate corrective actions without human intervention. The system serves itself by performing diagnostic functions that were previously requiring human operators, thereby reducing response time while maintaining reliable fault handling through automated expert systems
Solution Approach 2:
The patent replaces the mechanical system of human operators physically analyzing fault data with an automated reasoning engine that processes fault data electronically. This substitution eliminates the time delay associated with human availability while maintaining diagnostic capability through computer-based expert systems and knowledge bases
2Stability of the object's composition
If static communication protocols are used between PLC and central unit, then the communication structure is simple and stable, but the protocol performance degrades and flexibility is reduced
Solution Approach 1:
The communication protocol is segmented into separate functional components: a stable structural framework that ensures reliability and a flexible data representation layer that enables efficient information exchange. This segmentation allows the protocol to maintain structural stability while improving communication performance through optimized data handling
Solution Approach 2:
The patent introduces dynamic elements to the communication protocol by enabling flexible data representation and adaptive information exchange mechanisms. The protocol can dynamically adjust data formatting and transmission methods based on the specific communication needs, thereby improving performance while maintaining structural stability through its core framework
3Device complexity
If data and information are transmitted in the same communication channel, then the protocol structure is simple, but the communication performance is degraded
Solution Approach 1:
The communication channel is segmented into distinct functional streams: one for transmitting raw data and another for transmitting information about the data structure and meaning. This segmentation prevents data from information overhead, improving communication performance by reducing parsing complexity and enabling parallel processing of data and metadata
Solution Approach 2:
The patent introduces an intermediary layer in the communication protocol that separates raw data transmission from information transmission. This intermediary structure acts as a mediator that organizes and manages the flow of data and information separately, thereby improving communication performance without significantly increasing overall protocol complexity through standardized interfacing
Data Source
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AI summary
A Monitoring and Diagnostics System (110) is provided, which includes a monitoring unit (100) and a monitored unit (104) remotely located from the monitoring unit. The System also includes communication means (102) between the monitoring unit and the monitored unit. The monitored unit includes data acquisition means for providing fault data of the monitored unit and the communication means are adapted to communicate the fault data from the monitored unit to the monitoring unit. The monitoring unit includes a rules engine (124) having a set of expert rules for analyzing the information contained in the fault data and being adapted to deduce diagnostics information (126) from the rules and from the information. In addition, a communication method for communicating between a first Programmable Logic Controller and a second Programmable Logic Controller or a central unit (118) is provided, in which a description file (142) is provided.