Intelligent verification of industrial control systems

Synostik, an IT service provider based in Oebisfelde, Germany, introduces new inspection algorithms developed for industrial IoT systems to complement its diagnostic software tools for IIoT systems. These enable the testing and monitoring of functionality, safety and quality of technical systems.

"Inspection algorithms can be used primarily to make the guided inspection of a system possible. And this is done in a standardized way that is defined and specified in advance by the customer himself," explains Heino Brose, Managing Director of Synostik GmbH.

Inspection in today's IIoT systems is used to check complex machine systems. In the process, the actual condition of the machine is determined and documented. Furthermore, the functioning of the entire plant as well as all plant components, settings and values are checked. In addition, the necessary adjustments for future use are derived. This means that a fault is detected in advance and a solution is derived that saves time and costs. In themselves, these are complex processes for which Synostik has developed algorithms to simplify these operations.

From the concept to algorithms

In detail, the procedure is as follows: Suitable strategies, processes and algorithms for inspecting the systems are defined at an early stage of development. For this purpose, an inspection concept is created in which all components are included. The inspection algorithms are created with the Synostik tool using the diagnostic design methodology and can be individually adapted to customer requirements for their systems and devices. The tool provides a graphical system visualization, based on which potential wear and its possible causes are fully detected at an early stage. An example from the shoring and load test: During the shoring test, part numbers, software and hardware versions are compared with the technical specifications. The analysis of deviations and discrepancies is also included. In the load test, on the other hand, load, service life, working hours, their consumption and remaining parameters are examined in detail. Everything together leads to a result that can be worked with to predict possible failures and exclude them from the outset.

Further processing into individual formats

If the inspection appointment by an inspector is due, the plant and its components are checked in the following. The test algorithms created in advance are also used there and significantly shorten the duration of the inspection, as the downtime is reduced and the operation of the plant can continue quickly. Test algorithms also help to test equipment functionally. An additional advantage: the algorithms are available as XML files and can be converted very easily for further processing and transferred into any customer-specific format.

Mobile app provides even more transparency

With the help of Synostik's smartphone app Diana, instructions for repairing a machine after inspection can also be reliably identified and troubleshooting instructions retrieved. With the help of an AI-supported chatbot, symptoms are evaluated in dialog with the user. This allows possible causes of faults to be identified and further narrowed down in the exclusion process.