I. Rapid Troubleshooting of the Basis Physical Network (Completion in Five Minutes)
Initial Evaluation Based on Network Port Indicator Lights: Monitor the industrial switch, SCADA industrial control computer, and MES server for the Link/Act indicator status. Locate the physical link interruption directly if the Link light is not illuminated. Prioritise the examination of network cables, RJ45 connectors, and network port hardware faults.
Accurate Connectivity Test: Access the switch's backend to verify that the MAC addresses of MES and SCADA are learning in a normal manner by reviewing the ARP table. A failed ping does not necessarily indicate a link abnormality when the ICMP protocol is disabled in the industrial field; therefore, it is crucial to prioritise the verification of security policy configurations.
Efficient Network Environment Verification: Verify that there are no broadcast storms or network loops, that power lines and communication network cables are routed separately, and that there is no link packet loss caused by intense electromagnetic interference.
II. Rapid Communication Protocol Layer Troubleshooting (Completed in 10 minutes)
Verification of Protocol Compatibility: To prevent communication failures caused by version incompatibility, verify that the MES and SCADA interfacing protocols are entirely consistent and that the OPC UA/MQTT driver version is compatible with the system firmware version.
Port Status Verification: Ensure that the industrial firewalls are not obstructing the dedicated communication ports for RC calibration data on both sides and that no other processes are occupying the ports.
Verification of Security Mode: To prevent connection rejection as a result of inconsistent security configurations, ensure that the security policies and encryption levels of both endpoints of the OPC UA protocol are identical.
III. Data Mapping Layer Quick Troubleshooting (Completed in 10 minutes)
Verification of Point Mapping: Verify that the RC parameter register addresses and point IDs on both the MES and SCADA sides are fully aligned, with no address misalignment issues.
Verification of Data Format: To prevent data parsing failures and garbled characters as a result of format mismatches, ensure that the numerical type, unit, and decimal places of the RC calibration data on both sides are perfectly consistent.
IV. Rapid Troubleshooting of the Service and Application Layers (Completion in 10 minutes)
Check Service Status:
Status Check of Database: Verify that there are no synchronisation timeouts, slow query backlogs, or connection pool exhaustion that are the result of lock contention.
The RC calibration data synchronisation link can be rapidly restored by avoiding ineffective operations such as blindly restarting devices and unplugging and plugging network cables, and the entire troubleshooting process can complete 99% of synchronisation fault location within 40 minutes.
