I. Rapid Recovery from Physical Network Failures
Loose network cable/oxidized RJ45 connector: Replace immediately with a spare shielded industrial network cable, re-crimp the RJ45 connector, and verify that the Link indicator light on the network port is illuminated.
In the event of a port failure, it is imperative to promptly transfer the communication network cable to a spare, unused port, reconfigure the port's VLAN, and bypass the faulty port in order to re-establish connectivity.
Packet loss and electromagnetic interference: Temporarily replace the interfered communication network cable with a higher shielding level industrial network cable, adjust the cable routing to avoid power lines, and promptly decrease the packet loss rate.
II. Rapid Recovery from Communication Protocol Failures
Protocol version incompatibility: Temporarily upgrade or downgrade the OPC UA/MQTT driver version on one end to align with the firmware version on the other end, and immediately re-establish the handshake connection.
Port obstructed by firewall: Temporarily add a rule to permit access to the dedicated port for RC calibration data in the industrial firewall; communication can be re-established without the need to restart the firewall.
IP address conflict: Immediately modify the IP address of one end to an unused network segment, reconfigure routing rules, and prevent IP address contention from causing communication interruption.
III. Rapid Recovery from Data Mapping Failures
Misalignment of Point Addresses: Import the pre-backed-up RC parameter point mapping configuration file directly to overwrite incorrect configurations with a single click, thereby eradicating the necessity for manual modification of register addresses.
Data Format Mismatch: Resolve data muddled issues quickly by calling the system's preset RC calibration data format conversion script to automatically align the numerical types and decimal places on both sides.
Benchmark File Version Deviation: Utilise a one-click synchronisation script to transfer the most recent RC calibration benchmark parameters from the MES to the SCADA, ensuring that the version alignment is completed within one minute.
IV. Rapid Recovery from Service Operation Failures
Synchronisation Service Process Crash: Restart the SCADA data acquisition service and MES synchronisation scheduling service with a single click, without restarting the entire machine, thereby restoring service operation within 30 seconds.
Message Queue Accumulation: Temporarily clear non-core historical production data messages, prioritising the consumption channel for RC calibration data to rapidly alleviate queue congestion.
Database Connection Pool Exhaustion: Restart the database connection pool service, release idle connections, and immediately recommence synchronous data write operations.
V. Mechanism for Rapid Recovery of Backup Data
Activate Backup Synchronisation Link: In the event of a primary link failure, the system will automatically transition to the backup MQTT synchronisation channel, circumventing the failed node and achieving a seamless, rapid recovery.
Rapid Fault Verification: Three full-process RC calibration data synchronisation tests are conducted following recovery to verify the successful bidirectional synchronisation of all data, thereby preventing the recurrence of the fault.
