I. Rapid Resolution of Physical Network Faults
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 light on the network port is illuminated.
In the event of a malfunctioning port, promptly transfer the communication network cable to a spare, inactive port, reconfigure the port's VLAN, and bypass the faulty port to re-establish connections.
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 Resolution of Communication Protocol Defects
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 allow the dedicated port for RC calibration data in the industrial firewall; communication can be restored without restarting the firewall.
IP address conflict: Immediately modify the IP address of one end to an inactive network segment, reconfigure the routing rules, and prevent IP address contention from resulting in communication interruption.
III. Rapid Rehabilitation of Data Mapping Errors
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 Repair of Service Operation Faults
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, bypassing the faulty node and achieving a seamless, rapid recovery.
Data Transmission Resume: The system automatically compares the timestamps of the data on both sides and retransmits all missing RC calibration data during the interruption, eliminating the need for manual data entry, following link 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.
The average recovery time can be reduced to less than 15 minutes by the entire recovery process, thereby reducing the impact of RC calibration data synchronisation interruptions on production.
