CN-122001741-A - Communication link health state diagnosis and alarm system based on bistable state monitoring

Abstract

The invention relates to the technical field of industrial automation and intelligent manufacturing, in particular to a communication link health state diagnosis and alarm system based on bistable state monitoring. The system comprises a first monitoring agent module deployed on an MES side, a second monitoring function module deployed on a PLC side and an alarm module. The monitoring logic is respectively arranged in the first monitoring agent module and the second monitoring function module so as to continuously monitor whether the content of the key communication signal from the other party changes or not as a criterion of link health, and the physical connectivity is not only detected. When any monitoring party does not detect the updating of the signal content of the other party within the continuous preset time, the communication silence fault is judged to occur and the specific alarm is triggered. The invention creatively changes the detection of signal existence into the detection of signal activity, can timely find out the communication interruption of a logic layer caused by software deadlock, program crash and the like, and realizes the real-time finding, accurate source determination and quick response of faults.

Inventors

• WANG NING
• LI XIUDONG
• WU QINGLEI
• ZHENG JINDONG

Assignees

• 赛轮集团股份有限公司

Dates

Publication Date

20260508

Application Date

20260312

Claims (10)

1. 1. A bi-stable monitoring based communication link health status diagnostic and alarm system, comprising: the system comprises a first monitoring agent module arranged on an MES side, a second monitoring function module arranged on a PLC side and an alarm module; The first monitoring agent module is configured to continuously monitor a feedback signal from the PLC side, and when the content of the feedback signal is unchanged within a continuous preset time period, the first monitoring agent module judges that the communication silence fault occurs on the PLC side and triggers a first alarm signal; the second monitoring function module is configured to continuously monitor command signals from the MES side, judge that communication silence faults occur on the MES side when the content of the command signals is unchanged within a continuous preset time period, and trigger a second alarm signal; The alarm module is configured to generate and output alarm information containing fault side identification according to the first alarm signal or the second alarm signal.
2. 2. The system of claim 1, wherein said command signal and said feedback signal each include a dynamic field for identifying changes in signal content.
3. 3. The system of claim 2, wherein the dynamic field is a sequence number or a timestamp.
4. 4. The system of claim 1, wherein the first monitoring agent module comprises a first timing unit configured to: resetting when the content of the feedback signal is monitored to change, accumulating when the content of the feedback signal is unchanged, and triggering the first alarm signal when the accumulated value reaches the preset duration.
5. 5. The system of claim 4, wherein the second monitoring function comprises a second timing unit configured to: resetting when the content of the command signal is monitored to change, accumulating when the content of the command signal is unchanged, and triggering the second alarm signal when the accumulated value reaches the preset duration.
6. 6. The system of claim 1, wherein the alarm module includes a human interface for displaying the alarm information including the fault side identification.
7. 7. The system of claim 6, wherein the alarm information displayed by the human interface indicates that the source of the fault is PLC-side communication silence when the first alarm signal is triggered.
8. 8. The system of claim 6, wherein when the second alarm signal is triggered, the alarm information displayed by the human machine interface indicates that the source of the fault is MES-side communication silence, and/or the second monitoring function is further configured to control the PLC to switch to a safe state.
9. 9. The system of claim 1, further comprising a radio frequency identification RFID read-write device for reading material information and triggering the MES to generate control instructions containing the command signals.
10. 10. The system of any one of claims 1-9, wherein a monitoring flow of the command signal and the feedback signal is independent of a normal business data interaction flow between the MES and the PLC.

Description

Communication link health state diagnosis and alarm system based on bistable state monitoring Technical Field The invention relates to the technical field of industrial automation and intelligent manufacturing, in particular to a communication link health state diagnosis and alarm system based on bistable state monitoring. Background In the field of intelligent manufacturing and industrial automation, reliable communication between a manufacturing execution system and a programmable logic controller is a cornerstone for guaranteeing production continuity and product quality. Traditional communication state monitoring methods focus mainly on connectivity detection at the physical link layer, such as checking whether network cables are connected, switch port indicator light status, or verifying underlying IP reachability through network ping tests. However, this level of monitoring has significant limitations in that it cannot effectively detect a more concealed and compromised failure mode, a logical link silence failure. Such failures appear as normal physical network connections, but one end of the communication has stopped sending or updating application layer data signals that should be exchanged periodically or event-driven due to deep causes such as software getting stuck in a dead loop, an application crash, buffer overflows, resource deadlocks, or process suspension. This "silent failure" causes a series of serious drawbacks to the prior art solutions. First, the fault discovers a severe hysteresis. When the logic communication is interrupted and the physical link is still smooth, the whole control system cannot sense the abnormality, the production line can continue to operate in an error or stagnation state until the product is scrapped in batches, the equipment idles, the materials are blocked or a safety event is caused, the product is not discovered accidentally by field operators, the fault response time can be as long as minutes or even hours, and huge economic loss is caused. Second, problem localization is extremely difficult. Once the production abnormality occurs, maintenance personnel need to spend a large amount of time to check network equipment, a server, a controller and a terminal executing mechanism one by one, and the problem root is difficult to quickly lock on a logic layer of a communication link, so that the maintenance efficiency is low. Furthermore, the health of the system is overly dependent on manual work. Whether the communication state is normal often requires an operator to continuously monitor a human-computer interface, and in a complex production environment with fast rhythm and multiple production lines, the mode relying on manual alertness is extremely easy to generate omission, and the reliability is insufficient. More troublesome is that there is also a dead zone of "signal false on line". Under certain communication protocols or configurations, the receiver may continue to read the last valid value of the signal in the local cache even if the counterpart device has been down, thus presenting all normal artifacts, with great fraud. The above-mentioned drawbacks together lead to the deficiencies of the conventional communication monitoring method in ensuring high availability and maintainability of the modern intelligent manufacturing system, and a technical scheme capable of deeply detecting communication activity, early warning in real time and accurately positioning a fault source is needed. Thus, the prior art is still to be further developed. Disclosure of Invention The invention aims to overcome the technical defects and provide a communication link health state diagnosis and alarm system based on bistable state monitoring so as to solve the problems in the prior art. To achieve the above technical object, the present invention provides a communication link health status diagnosis and alarm system based on bistable monitoring, comprising: the system comprises a first monitoring agent module arranged on an MES side, a second monitoring function module arranged on a PLC side and an alarm module; The first monitoring agent module is configured to continuously monitor a feedback signal from the PLC side, and when the content of the feedback signal is unchanged within a continuous preset time period, the first monitoring agent module judges that the communication silence fault occurs on the PLC side and triggers a first alarm signal; the second monitoring function module is configured to continuously monitor command signals from the MES side, judge that communication silence faults occur on the MES side when the content of the command signals is unchanged within a continuous preset time period, and trigger a second alarm signal; The alarm module is configured to generate and output alarm information containing fault side identification according to the first alarm signal or the second alarm signal. Specifically, the command signal and the feedback signal each inc