I. Phase of Pre-fault Confirmation (0-5 minutes)
Access the SCADA system synchronisation monitoring interface and document the error code of the most recent unsuccessful synchronisation and the time of the most recent successful synchronisation.
Confirm the extent of the issue: Verify whether the malfunctioning of a single Husky injection moulding machine or a synchronisation failure that affects all equipment on the entire production line is the cause.
Perform a Ping test: To locate the defective link, ping the MES server IP from the SCADA gateway side and the SCADA gateway IP from the device side.
To ensure that the data backup is completed prior to the fault, export a snapshot of the local RC calibration cache on the SCADA side and a snapshot of the synchronised RC parameters on the MES side.
II. Physical Network Layer Troubleshooting and Recovery (5-15 minutes)
On-site, verify the status of the Link indicator on the communication ports at both endpoints. If the indicator is not illuminated, disconnect and reconnect the network cable, and replace it with a spare shielded industrial network cable.
Access the industrial switch backend and verify the present port packet loss rate. Switch the network cable to a spare, inactive port if the packet loss rate is ≥10%.
Check the routing of the communication network cable to ensure that it is not placed in the same cable receptacle as the power lines. To mitigate electromagnetic interference, adjust the cable routing distance from the power lines to a minimum of 30cm.
Enable the switch loop detection function to identify and disconnect redundant links, thereby releasing saturated network bandwidth.
Confirm the recovery effect: Conduct another ping test to verify that the network connectivity is normal and the link packet loss rate is ≤0.1%.
III. Troubleshooting and Recovery of the Communication Protocol Layer (15–30 minutes)
Verify the MES system protocol version, upgrade or downgrade the OPC UA/MQTT driver on the SCADA side, and ensure that the versions match.
Incorporate any omitted port allow configurations.
