Industrial Trace Data Collection for Cross-Machine Fault Analysis
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Solution Overview
Problem
Existing trace data acquisition systems are insufficient in analyzing the state of industrial machines, as they only collect data from the machine that generated an alarm, failing to identify causes that may originate from other interconnected machines.
Innovation Solution
A trace data acquisition system that requests and collects trace data from all controllers in a network when an alarm is generated, including both the controller that triggered the alarm and others, to provide comprehensive data for analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If trace data is collected only from the machine that generated an alarm, then data collection is simple and fast, but the accuracy of fault analysis is insufficient because causes may originate from other interconnected machines
Solution Approach 1:
The system segments the data collection process by identifying and collecting trace data from specific controllers based on alarm information. Instead of collecting from all machines, it segments collection to only those machines relevant to the alarm (the alarming machine and its connected machines), thus improving analysis accuracy while controlling complexity
Solution Approach 2:
The server performs multiple functions: it collects alarm information, identifies related controllers, requests trace data, and stores data. This multi-functionality allows the system to achieve comprehensive fault analysis without adding separate dedicated components for each function, balancing accuracy with system simplicity
2Loss of information
If trace data is collected from all controllers in the network, then comprehensive data for analysis is obtained, but memory consumption and data collection time increase
Solution Approach 1:
The system applies local quality by collecting trace data selectively from specific controllers rather than uniformly from all controllers. The data collection is localized to controllers that are relevant to the alarm (identified through alarm information and connection relationships), ensuring information completeness for fault analysis while minimizing unnecessary data volume
Solution Approach 2:
The system takes partial action by collecting data from a subset of controllers (those involved in or affected by the alarm) rather than all controllers. This partial collection is sufficient to identify fault causes while avoiding the excessive data volume and memory consumption that would result from collecting from every controller in the network
Data Source
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AI summary
A plurality of industrial machines (20) of a trace data acquisition system (1) are configured to sequentially process an object. A determination module (201) is configured to determine whether or not one of the plurality of industrial machines (20) has satisfied a specific condition. A request module (101) is configured to request another industrial machine (20) to acquire trace data when the one of the plurality of industrial machines (20) is determined to have satisfied the specific condition.