Industrial Automation Troubleshooter

Stop guessing. Start diagnosing.

Industrial Automation Troubleshooter guides technicians, maintenance teams and automation engineers through a structured, evidence-based fault diagnosis process for industrial machinery.

Instead of generating a generic list of possible causes, the Agent analyzes the available evidence, identifies the most relevant hypotheses and guides you toward the next highest-value diagnostic test.

What it can troubleshoot

• PLC and control logic faults
• VFD / inverter alarms and trips
• Motors and actuators
• Sensors and feedback devices
• Industrial communication problems
• Modbus TCP / RTU
• PROFINET, PROFIBUS and EtherCAT
• Remote I/O
• Electrical faults
• Intermittent machine stops
• Process-related problems
• Difficult or recurring machine faults

How it works

1. Describe the problem

Tell the Agent what the machine is doing, what it should be doing and any alarms or symptoms you have observed.

2. Build the diagnosis

The Agent separates confirmed facts from assumptions and evaluates possible causes across:

• Software / PLC
• Communication
• Electrical
• Drive / motion
• Sensors
• Mechanical systems
• Process conditions

3. Test intelligently

Instead of telling you to replace components at random, the Agent selects diagnostic checks based on their ability to confirm or eliminate possible causes.

For each important test it explains:

CHECK — What to verify
WHY — Why the test matters
EXPECTED — What normal behavior should look like
IF YES — What the result suggests
IF NO — What the result suggests

4. Update the diagnosis

Send the test result back to the Agent.

It maintains the diagnostic context, updates the active hypotheses and selects the next most useful test.

5. Identify the root cause

Conclusions are classified as:

SUSPECTED — Evidence is still limited
PROBABLE — Multiple observations support the diagnosis
CONFIRMED — Testing demonstrates the causal relationship

Quick or Deep Diagnosis

⚡ QUICK

Designed for clearly defined faults where fast troubleshooting is the priority.

Examples:

• Motor does not start
• Known VFD alarm
• Sensor permanently active
• Device offline after replacement
• Communication fault after maintenance

🔬 DEEP

Designed for complex and intermittent problems.

Examples:

• Machine randomly stops
• Fault appears only after several hours
• Multiple systems may be involved
• Previous repairs did not solve the problem
• No clear alarm identifies the cause

The Agent can automatically select the most appropriate approach.

Example

Input

A conveyor stops after approximately 20 minutes of operation.
The VFD reports an overcurrent fault.
Resetting the drive allows the machine to restart.

Typical diagnostic approach

The Agent will not immediately conclude that the VFD or motor is defective.

It may investigate:

• whether the PLC RUN command remains active;
• motor current before the trip;
• mechanical load;
• drive temperature;
• acceleration parameters;
• motor data configuration;
• whether the fault correlates with temperature or operating time.

Each result is used to narrow the diagnosis.

Built for real troubleshooting

The core philosophy is simple:

Diagnose before replacing.

The Agent prioritizes evidence, measurements and high-information tests over random component replacement.

Technical Diagnostic Report

At the end of the troubleshooting process, the Agent can generate a structured report containing:

• Reported fault
• Operating conditions
• Recent changes
• Evidence collected
• Tests performed
• Root cause
• Confidence level
• Corrective action
• Preventive recommendations
• Open items

Useful for maintenance records, service departments and customer reports.

Designed for

• Industrial maintenance technicians
• Automation engineers
• Field service engineers
• Electricians
• Machine builders
• System integrators
• Technical support teams

Important

This Agent is a diagnostic support tool. It does not replace qualified personnel, manufacturer documentation, applicable safety procedures or professional engineering judgment.

Never bypass machine safety systems or perform hazardous electrical or mechanical work without appropriate qualifications and procedures.