I. Troubleshooting of the Physical Link and Network Layer (Layer 1)
Verification of Network Port Status: Monitor the Link/Act indicator LEDs on the MES server, SCADA industrial control computer, and industrial switch. Check the network cable continuity, RJ45 crimping quality, and if the network port is loose or damaged if the Link light is off.
Connectivity Test: Verify that the MAC addresses of MES and SCADA are learning normally by logging into the switch's backend and reviewing the ARP table. A failed ping does not inherently indicate a link abnormality when the ICMP protocol is disabled in the industrial field; security policy configuration should be reviewed first.
Network Environment Compliance Check: Verify that the office network and production equipment network are logically isolated, with no network loops or broadcast storms. The shielding layer should be grounded at one end to prevent electromagnetic interference, and power lines and communication network cables should be routed separately.
II. Troubleshooting the Communication Protocol Layer (Layer 2)
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.
RC Calibration Data Port Status Verification: Ensure that the communication ports on both sides are unobstructed by industrial firewalls and that the dedicated communication port is not occupied by other processes.
Security Policy Verification: Verify that the EndpointDescription for the OPC UA protocol includes the Signing/Encrypting identifier, the Basic256 security policy is enabled, and it fully aligns with the security modes of both ends.
III. Third Layer Data Mapping Layer Check
Verification of Point Mapping: Ensure that the RC parameter register addresses and point IDs on both the MES and SCADA sides are fully aligned, and that there are no address misalignments for core data points, including RC capacitance, temperature fluctuation, and calibration status.
Data Format Verification: Ensure that the numerical type, unit, and decimal places of the RC calibration data on both parties are entirely consistent to prevent data parsing failures, garbled characters, and packet loss caused by format mismatches.
Verification of Benchmark File Consistency: Compare the RC calibration benchmark parameter versions on the MES and SCADA sides to verify that the judgement rules and pass thresholds on both sides are fully synchronised, with no version deviation.
IV. Inspection of the Service Operation Layer (Layer 4)
Service Status Check: Verify that the SCADA-side data acquisition service and the MES-side synchronisation scheduling service are functioning properly, with no process failures or frequent restarts.
Message Queue Status Check: Confirm that there are no queue congestion or message loss issues for RC calibration data by verifying the message backlog lag metric in Kafka/RabbitMQ.
Database Status Check: Verify that there are no synchronisation timeouts caused by connection pool exhaustion or lock contention by conducting a check of the number of active connections, sluggish queries, and lock waits between the MES and SCADA databases.
V. Inspection of the Application Logic Layer (Layer 5)
Synchronisation Script Verification: Confirm that the RC calibration data synchronisation triggers and custom script logic are functioning properly and that there are no syntax errors or missing condition checks by verifying that synchronisation actions are triggered as expected when data changes.
Verification of Breakpoint Resumption Mechanism: The system's ability to automatically compare timestamps and retransmit missing data after network recovery, without the use of synchronisation breakpoints, is verified by simulating a network interruption scenario.
Cross-system reconciliation logic verification: Ensure that the execution logs of daily automatic reconciliation tasks are verified to ensure that alarms are triggered accurately when data inconsistencies occur, and that there are no silent failures.
VI. Troubleshooting the Concurrency Timing Layer (Layer Six)
Synchronisation Task Priority Configuration: Ensure that the RC calibration data synchronisation task is prioritised over the standard production data acquisition task to prevent other tasks from preempting system resources in high-throughput scenarios.
Concurrency Conflict Troubleshooting: Determine whether there are timing conflicts resulting from the simultaneous upload of RC calibration data by multiple devices, and establish a reasonable polling interval to prevent synchronisation request congestion.
Verification of Fault Reproduction: Conduct a full-process simulation test following the completion of troubleshooting. A complete resolution is confirmed and repeated recurrence is prevented by ten consecutive successful RC calibration data synchronisations.
