Embedded industrial computer for a long time after the operation, (long time refers to: including continuous work on a standard days / 24 hours a week or more), product set a lot of dust inside the case and case temperature is higher. Usually without shutdown of all work is normal, once the need because of the power supply or emergency stop, the control system is prone to disk cannot be started, the system can't load, such as long time in the login screen failure.

Failure analysis and elimination method:

The cause of magnetic disk failure very much, we are here to roughly divided into the quality problem of the industrial computer disk itself and work environment caused as a result of the problem.

Disk itself quality problem, we can't deeply fastidious, only in the start control system, choose to buy good quality, brand drive, also can use Scandisk, Norton Disk Doctor software such as a Disk surface defect detection. If we can predict the quality of the hard disk and health status, it will select the hard disk and backup important data for us to win time. The author found a called Drive Health software on the net, can detect the service life of the hard disk, can help you learn hard disk Health ahead of time.

Work environment caused as a result of the problem, common has the following several aspects:

1, the embedded industrial computer work long hours. Due to the needs of normal production, some factories of industrial control systems need to work long hours, to test industrial computer operating system is great. According to Microsoft's operating systems running time in the report shows that Microsoft has claimed the Windows 2000 operating system can support after long hours, but look from actual operation, running for more than a week later, the disk in the process of huge data exchange, will accumulate a large number of data fragments, easy to cause bad word, reading and writing disk logic errors and system running and start slowly. So industrial control in the production permission, can restart industrial PC and disk defragmenter regularly, in order to reduce the disk errors caused by working long hours. Restart time according to the size of the industrial computer processing data and production situation and decide, it is not hard, need to slowly to the reader. From the point of the author's practical experience, a standard month (30 days) to restart and finishing a industrial computer can reduce the chance of disk errors.

2, the embedded industrial control internal temperature is too high. In the environment of the need to run high temperature for a long time, the computer's components easily happened ageing, hard disk failure frequency is higher than. This will require a factory automation system maintenance personnel in the daily inspection, pay close attention to case temperature, try to keep the temperature of the industrial control between 10 to 30 degrees c, too high, too low temperature is not suitable for hard disk protection, if the case reach 30 degrees Celsius temperature, the temperature of the internal hard drive will reach 40 degrees or more. We can simple DIR your industrial control, reduce the role of the environment temperature in order to achieve.

A, replace the high power fan CPU, hard disk (hard disk fans to pay attention to the fixed, should not be installed on the hard drive firmware frame, just in case for fan rotation bring hard disk vibration) accelerated cooling;

Second, inside the chassis mounted to the chassis outside convulsions of the fans, increasing air convection;

Third, placed in the industrial control cabinet, install small axial flow fan;

Fourth, in the control room equipped with air conditioning, in order to reduce the space temperature.

3, environmental humidity is not appropriate. Embedded industrial computer is mainly made up of many electronic components integrated circuit, its insulation performance has a great relationship with environment humidity. Humidity is too big, easy to cause circuit short circuit and burned; Humidity is too small, easy to generate static electricity, also can breakdown of electronic components. Therefore, humidity is too big, too small, will bring industrial potential threat. Electrostatic protection issues on the industrial PC we must be good instrument grounding. Worth mentioning is that different from the civil industrial grounding lightning protection grounding, grounding pole location should be three meters away from the control room, 1700 mm under the outdoor floor vertical grounding electrodes for 30 20 galvanized Angle steel, grounding quantity meet the grounding resistance less than 1 ohm (backfill application of shaking table test), then USES 40 * 40 * 4 galvanized flat steel and reliable grounding body welding (each welding point to do careful antirust processing), points to a building and 25 mm copper cable to the site of the systematically terminals and industrial control. This can effectively reduce the electrostatic damage.

4, the ground was shaking. Many factories need motor drag, such as vibration displacement of physical movement, not only bring huge noise, the vibration of the machine is working to bring bring industrial computer disks, cd-rom, floppy drive huge damage. Disk production process more and more high, the current speed has reached 7200 or more per second. In automatic control system of a large number of data exchange, long operating time, high speed disk, easy for disk vibration, resulting in a decline in disk, speaking, reading and writing, head positioning is slow, and even damaged disk; Therefore reduce the aftershock, industrial environment is conducive to protect the disk. We can in the engineering design, as far as possible let industrial computer away from the source of job site; If the location cannot be changed, we can also in the industrial control cabinet, with the box body sponge, can buffer object to reduce vibration damage.

More than 5, the particulate matter in the air. A lot of the factory mostly need powder processing of raw materials, coupled with large outside air flow and a lot of dust, industrial PC within easy to accumulate a large amount of sticky dust, caused by industrial PC in the local temperature is too high, bring damage of hardware. This kind of situation happens in CPU, power supply, hard disk, video card, such as a cooling fan around. Dust is lighter, in normal production permission, can use timing blowing dust. Can place with severe dust, industrial PC box placed drafty place strainer gauze, regular cleaning.

6, the power supply voltage fluctuation, easy to power outages. Industry and the rapid development of life, the demand for electricity is growing, many areas have the power supply, voltage instability, easy to power outages. Voltage instability and a sudden power outage, causing frequent restart system, system files are easy to happen lost and can't be started normally; Is do read/write head, sometimes because of power failure caused by head return is allowed to bring industrial computer disk failure. Therefore industrial work environment, the stability of the power supply is related to industrial computer working properly or not. We can use the regulated power supply and UPS uninterruptible power supply, equipment selection, in accordance with the size of the load power, how much need to keep working time.

Fault emergency strategies:

Most of the time, we have done a lot of engineering personnel protection work, there is still a industrial computer disk failure occurs, the readers and let's discuss how to take remedial action before failure. Recommended readers to learn how to use GHOST (famous disk cloning software), object version as far as possible the latest, it will help the implementation of the solution of the following.

No capital investment plan: GHOST cloning mirror.

Solution premise: only system disk failure, the system tray can be normal FORMAT software FORMAT. (the author has encountered two unable to properly use the FORMAT software formatting system disk, master-slave mode, access to the bad disk system disk, prompt error parameters, with low recovery) after

Package material: GHOST software, DOS system boot disk (CD, software, U disk)

Scheme: a disk failure occurs mostly in the system tray (C), after the automation system put into operation, first using GHOST software, the system disk image, put to the image files (*. GHO) under the FAT32 format disk backup (for single disk case, for restoring the GHOST system disk, generally under DOS, DOS can only be run under the FAT32, FAT16 disk format, under the NTFS points disc format cannot be run.) , once the system disk fails, the fastest way to system disk formatting, using GHOST software available in 5 minutes to the original image files back to the system tray.

Solution conclusion: without equipment investment, without capital spending; Fast recovery. This solution can only be for operating system destruction rather than disk occurs under the condition of physical damage using; Once the disk physical damage, this plan will not be able to. This can also be extended to the entire disk image.

Solution premise: the embedded industrial computer disk failure (system failure or disk physical damage)

Package material: the target within the industrial PC is the disk a piece, GHOST software, DOS system boot disk (CD, software, USB drive)

Implementation plan: before the industrial computer system in operation, using GHOST software will have first control system disk system disk (C) image to the disk of system disk FAT32 partition the disk format, complete the whole content of hard disk cloning to the same model within the alternate disk. Once appear, damage of the operating system, operating system image files can be recovered; In the event of the entire disk failure, can remove the bad disk, change to backup the same content of the spare hard disk.

Plan conclusion: just a disk money (about 400-800 yuan between, depending on the size of disk, different vendors), easy replacement, fast recovery, can eliminate all of the disk.

Security investment plan (budget) : the Windows 2000 double hard disk raid 1 or 3 hard disk RAID5 means software disk array

Solution premise: this plan the implementation of the time, had better be in industrial computer before put into operation

Package material: Windows 2000 system disk or higher, disk two pieces (the same type as appropriate)

Scheme: first installation Windows 2000 or later (because in Microsoft Windows NT after the disk array is better), the boot disk array function support. Disk array to the way in which industrial computer run time of write operation, to two pieces of the disk write the same content at the same time, if there is a piece of two pieces of disk failure, another disk for it is written to the same content at the same time, the undisturbed switching to normal working condition. That is to say, the disk array mode of two pieces of hard disk as long as there is no damage in a disk, important data is not lost. Afterwards to replace or repair the bad disk, the biggest advantage is that will not affect the loss of production data, change quickly.

Plan conclusion: investment is small, high safety, stability and system installation beginners set good or bad, but technology is not easy to master.

Security investment scheme (stable) : the low end of the server hardware disk array way (in the face of low technical requirements, high and stable production, the data is quite important place in use)

Material: support hardware disk array functions of low-end server a about 25000 RMB

Approach: because is using hardware disk array, all of the low noise, low failure rate. In the event of a disk failure, only to dismantle bad hard disk, supplement the same model new hard drive. Specific measures for implementation, for details please consult the low-end server providers.

Conclusion scheme: invested relatively large, high safety, good stability, low technical requirements.

Embedded industrial computer disk failure damage is self-evident, ensure that its security is an issue we should focus on industrial control personnel, only we do detailed preventive measures in advance, and industrial computer to stable and efficient operation. The author adopts the method in the practical work, and effectively avoid the industrial computer disk failure, failure can be from a few hours, the repair time shortened to a few minutes, to provide guarantee for normal production.