Central control room computer crashes

In the case of our factory, we can analyze the reasons in detail and then deal with them. 1) Hardware reasons. In the early days of the factory's establishment in 1997, the central control system had two Siemens industrial computers configured as: The central processor is Pentium200MHz, the memory is 32M, and the hard disk is 1G. This configuration was relatively advanced at the time. Because the Windows95 operating system is used and the WinCC control software system is run, the speed of the industrial computer processing S7-400PLC information is relatively slow. During the debugging and operation of the cement plant, the industrial computer often "crash". When the industrial computer processes more than 100 on-site signals transmitted through the PLC, the industrial computer's CPU frequency is low and the memory is small. It cannot recognize and process so many signals at the same time, causing these signals to "crash" and causing the industrial computer to "crash". 　　Countermeasures: Due to the limitation of the memory slot on the industrial computer motherboard, the memory can only be expanded to 64M. The main solution is to reduce the frequency of industrial computer processing and identification of on-site signals to avoid signal "crash". The specific plan is: When the industrial computer is connected to on-site signals through PLC, the signal sampling period is set to more than 2s. For analog signals that change little, such as temperature, it can be set to more than 10s. During the WinCC programming process, after setting the sampling period of all analog signals to more than 2s, the "crash" phenomenon of the industrial computer rarely occurs. 　　2) Ambient temperature The raw material and cement batching station uses the 486 industrial computer, which is relatively sensitive to the ambient temperature. When the summer is hot and the air conditioner is damaged, the industrial computer is prone to "crash". 　　Countermeasures: Repair the air conditioner and lower the ambient temperature of the industrial computer to ensure normal operation of the industrial computer. 　　3) Poor internal heat dissipation of industrial computers. The environment in which industrial computers are located is harsh. In addition to high temperatures, there is also a lot of dust. When dust enters the industrial computer, the heat dissipation effect of various boards, CPUs and other electronic components is poor, causing the industrial computer to "crash". 　　Countermeasures: Regularly remove dust inside the industrial computer and maintain good ventilation. 　　4) Check the CPU fan and host power supply fan. The heat dissipation of the industrial computer is mainly carried out through the CPU fan and power supply fan. When the CPU fan is damaged, the temperature of the CPU will rise, which can easily cause the industrial computer to "crash". This phenomenon happened at the raw material batching station. 　　Countermeasures: Check the fan of the industrial computer frequently and replace damaged fans in time. When the industrial computer in the central control room leaves the factory, the CPU is only equipped with a heat sink and no fan. After installing a special cooling fan, the CPU temperature dropped by nearly 5℃. 　　5) Frequently clean up temporarily generated files. When the industrial computer is running, a large number of temporary files such as Temp files will be generated. These files occupy the hard disk and system resources and affect the speed of the industrial computer processing information. Regularly check the hard disk and delete temporary files to improve the speed of industrial computer processing information. 　　6) Regular maintenance of the system. Due to editing control programs and other reasons, other application software is installed in the system. Too many application software will make the industrial computer run slower and slower. Therefore, every once in a while, perform a comprehensive maintenance on the industrial computer. Click "Start" → "Programs" → "Accessories" → "System Tools" → "Maintenance Wizard", and then click the "OK" button to perform comprehensive maintenance on the industrial computer. This can keep the industrial computer in the best condition. It is best to "defragment" the hard disk every one month. After defragmentation, the program can run faster. 　　7) The industrial computer "crash" caused by information blocking. The industrial computer (host computer) in the central control room monitors and controls the S7-400PLC (slave computer). The fault phenomenon when information is blocked is:: A "shadow" appears at the monitoring signal on the industrial computer screen and the signal values ​​are all zero. The upper computer cannot monitor and control the lower computer. This fault is different from the "crash" phenomenon mentioned above. The cause of this failure is caused by information blocking. The host computer cannot receive signals due to the "crash" of the lower computer or the failure of the transmission signal network cable and network card. In fact, the host computer does not "crash". This kind of failure occurred in early November 2001. Due to poor contact between the network cable and the network card, the upper computer was unable to monitor and control the lower computer. 　　Countermeasures: When a "shadow" appears on the upper computer screen, first check the working status of the lower computer. There are various error indicators on the CPU template of S7-400PLC, and you can operate according to the status of the indicator lights. If the PLC "crash", use the key to restart the PLC CPU to return to normal. If there is a problem with the network cable or network card, the operator (or notify the electrician or factory technician) should immediately check whether the signal cable plugs of the upper and lower computers have poor contact. Press or swing each plug gently with your hands. It is very likely to find the fault point and create conditions for factory technicians to arrive on site for diagnosis and treatment. 　　8) It is recommended to upgrade the industrial computer. At present, through the above measures, the number of "crash" of the industrial computer has been reduced. * * reduce. However, since the hardware configuration of the host computer is low, the software operation and control system versions are also low, and the host computer's information processing speed is still slow. It is recommended to upgrade the industrial computer to increase the CPU frequency, memory capacity and hard disk capacity. In order to better meet production needs, it is recommended that the CPU of the industrial computer in the central control room be upgraded to Pentium 41.5GHz or above, the memory to 256M, and the hard disk to 20G or above. At the same time, the operating software was upgraded to Windows2000 system, and the control software was upgraded to WinCC5.0 version. This can greatly improve the speed of industrial computer processing information and avoid "crash".

The CPU is bad, replace the CPU, or the fan is dusty and the heat dissipation is not good. This post was last edited by wopale3 on 2009-4-16 11:41 ]

How is the environment in the control room? Is there dust? Machine CPU fan

I'm a layman, I have a few ideas: 1) Why not adopt a one-use-one-standby system for such important operating equipment? It seems that the investment is not high, right? 2) Does the slave computer have autonomous control capabilities?

It’s not a layman’s question! It’s feasible to build an operator station for many wealthy people, and the cost of domestic production is not high. The DPU is basically autonomously controlled. Let’s talk about the reasons: 1. The machine is aging (especially the hard disk and memory), and the PC always has greater component loss than the overall one, because it is assembled. 2. Clear the system garbage. 3. Anti-virus. If it doesn’t work, buy a new one and import the operator station software.

The DCS microcomputer of a certain installation in my unit once had such a phenomenon. We searched for the cause but failed. Later, the hard drive was replaced due to other reasons, and the fault disappeared. The replaced hard drive was tested and found to have bad sectors. you can take a look

1 Whether the CPU fan is running normally 2 Graphics card fan 3 Format the hard disk and repartition it

The site runs continuously for 24 hours. This situation here is generally caused by too much dust on the CPU fan or heat sink.

Just treat it like a normal computer and take it out for repair: lol

Dear brothers. It's most likely a memory issue. It is recommended to change the memory stick.

The first possibility is that the hard disk has bad sectors. The second possibility is that the fan is not spinning and the temperature is too high.

Check if there is a problem with the software? If the system record file is too large, the hard disk space is insufficient.