PLC (Programmable Logic Controller) power load dynamic shunting method, device and equipment and storage medium

Abstract

The invention discloses a PLC power load dynamic shunting method, device and equipment and a storage medium, and relates to the technical field of electrical engineering, and the PLC power load dynamic shunting method comprises the steps: monitoring the output current of a target power module; generating an overload risk mark according to the output current and a preset current threshold value; in response to the overload risk mark, obtaining available power supply capacity from a newly added power supply module; and according to the available power supply capacity and a preset shunting strategy, switching a power supply link of target switching equipment in an equipment group connected with the target power supply module to the newly added power supply module to complete dynamic shunting. According to the invention, the dynamic adjustment of the load is realized, the overload risk of the PLC power supply module caused by the increase of the load is effectively avoided, the stability and reliability of the system are improved, the use efficiency of the power supply module is optimized, and the service life of equipment is prolonged.

Description

Technical Field

[0001] This application relates to the field of electrical engineering technology, and in particular to a method, device, equipment and storage medium for dynamic load shunting of PLC power supply. Background Technology

[0002] In the water distribution room on the second floor of the continuous casting machine, the 24V DC power supply of all cooling water flow meters must be uniformly supplied by the PLC03 cabinet (PLC control cabinet No. 3). The production line is required to replace imported flow meters that have been in service for more than 20 years with domestic ones without interrupting monitoring. Even after the power consumption of the new meter increases, the 24V bus voltage must still be kept stable within ±5% to ensure that the cooling flow signal is uploaded to the process control system in real time and accurately, and to prevent uneven cooling of billets or steel leakage accidents caused by power failure.

[0003] Currently, the PLC03 cabinet is equipped with only one 24V / 10A output. The power cords of all flow meters are connected in parallel to the same terminal of this output. No redundant power modules or graded circuit breakers are added to the cabinet. The load current is directly supplied to more than twenty flow meters after passing through a single 10A glass tube fuse. The system's power-on, power-off, and normal operation all rely on this single circuit.

[0004] However, when domestically produced flow meters replaced more than half of the total, the increased power consumption per unit raised the total operating current from 7A to over 9.5A. The peak current during probe heating could reach 11A, and the 10A fuse continuously operated at the edge of its rated value and frequently blew, causing momentary power loss for the entire floor's water distribution flow meters, interruption of the cooling water flow signal, and channel errors in the PLC (Programmable Logic Controller) analog module due to a sudden drop in busbar voltage. Power-on recovery took more than 15 minutes, directly disrupting the continuous casting rhythm and increasing the billet scrap rate. Simultaneously, the fuse holder overheated for extended periods, raising the cabinet temperature by approximately 8°C, and halving the lifespan of the electrolytic capacitors in the adjacent 24V power module, further reducing system reliability. Therefore, how to avoid the overload risk of the PLC power module due to increased load has become an urgent problem to solve.

[0005] The above content is only used to help understand the technical solution of this application and does not represent an admission that the above content is prior art. Summary of the Invention

[0006] The purpose of this application is to provide a method, device, equipment and storage medium for dynamic load shunting of PLC power supply, which aims to solve the technical problem of how to avoid the overload risk of PLC power supply module due to increased load.

[0007] To achieve the above objectives, this application proposes a dynamic load balancing method for PLC power supplies, the method comprising:

[0008] Monitor the output current of the target power module;

[0009] An overload risk marker is generated based on the output current and a preset current threshold.

[0010] In response to the overload risk flag, obtain the available power capacity from the newly added power module;

[0011] Based on the available power capacity and the preset power distribution strategy, the power supply link of the target switching device in the device group connected to the target power module is switched to the newly added power module to complete the dynamic power distribution.

[0012] In one embodiment, the step of switching the power supply link of the target switching device in the device group connected to the target power module to the newly added power module according to the available power capacity and the preset power distribution strategy, thereby completing the dynamic power distribution, includes:

[0013] A set of candidate devices is generated based on the device priority rules in the preset traffic splitting strategy;

[0014] Based on the capacity allocation rules in the preset power distribution strategy and the available power capacity, target switching devices are selected from the candidate device set;

[0015] The control relay control unit disconnects the target power module from the target switching device;

[0016] The relay control unit is controlled to establish a connection between the newly added power module and the target switching device, thereby completing dynamic power distribution.

[0017] In one embodiment, the step of generating a candidate device set according to the device priority rules in a preset traffic splitting strategy includes:

[0018] Obtain real-time power consumption data and criticality level markers for each device;

[0019] Excluding the devices marked as Level 1 protection devices for critical operation, an initial set of devices is obtained;

[0020] The initial set of devices is sorted in descending order by power consumption per unit time.

[0021] A predetermined number of devices ranked at the top of the initial device set are selected as the candidate device set.

[0022] In one embodiment, the step of selecting target switching devices from the candidate device set based on the capacity allocation rules in the preset power distribution strategy and the available power capacity includes:

[0023] The capacity allocation rules in the preset traffic splitting strategy are parsed to obtain the minimum capacity limit for a single device and the threshold for the proportion of total capacity.

[0024] Calculate the real-time power consumption value of each device in the candidate device set;

[0025] In the candidate device set, devices whose real-time power consumption value is lower than the minimum capacity limit of a single device are excluded, and a subset of candidate devices is generated;

[0026] The subset of candidate devices is sorted in descending order of power consumption value to obtain the device selection sequence;

[0027] Starting from the top of the device screening sequence, the power consumption value is accumulated until the accumulated value reaches the product of the available power capacity and the total capacity percentage threshold. Devices within the accumulated range are then identified as target switching devices.

[0028] In one embodiment, the step of monitoring the output current of the target power module includes:

[0029] Acquire the current signal of the target power module;

[0030] The current signal is filtered to obtain the output current;

[0031] The output current is stored in the current monitoring log.

[0032] In one embodiment, the step of generating an overload risk marker based on the output current and a preset current threshold includes:

[0033] Calculate the difference between the output current and the preset current threshold;

[0034] When the difference is lower than a preset safety margin and the duration exceeds a preset duration, the peak current in a preset future period is predicted based on historical current data.

[0035] When the peak current exceeds the preset current threshold, an overload risk flag is generated.

[0036] In one embodiment, the step of obtaining available power capacity from the newly added power module in response to the overload risk marker includes:

[0037] In response to the overload risk marker, a capacity query command is sent to the newly added power module;

[0038] Receive the remaining capacity reported by the newly added power module;

[0039] Calculate the required capacity based on the total power consumption requirements of the equipment to be transferred;

[0040] When the remaining capacity is greater than the required capacity, the remaining capacity is used as the available power capacity.

[0041] Furthermore, to achieve the above objectives, this application also proposes a dynamic load shunting device for PLC power supplies, the device comprising:

[0042] The detection module is used to monitor the output current of the target power module;

[0043] The overload analysis module is used to generate an overload risk marker based on the output current and a preset current threshold.

[0044] A capacity acquisition module is used to acquire the available power capacity from the newly added power module in response to the overload risk marker.

[0045] The power distribution module is used to switch the power supply link of the target switching device in the device group connected to the target power module to the newly added power module according to the available power capacity and the preset power distribution strategy, thereby completing dynamic power distribution.

[0046] In addition, to achieve the above objectives, this application also proposes a PLC power load dynamic shunting device, the device comprising: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the PLC power load dynamic shunting method described above.

[0047] In addition, to achieve the above objectives, this application also proposes a storage medium, which is a computer-readable storage medium, on which a computer program is stored, and when the computer program is executed by a processor, it implements the steps of the PLC power load dynamic shunting method described above.

[0048] In addition, to achieve the above objectives, this application also provides a computer program product, which includes a computer program that, when executed by a processor, implements the steps of the PLC power load dynamic shunting method described above.

[0049] One or more technical solutions proposed in this application have at least the following technical effects:

[0050] First, the power control system continuously monitors the output current of the target power module, obtaining a stable current value through real-time sampling and filtering to provide data support for subsequent decisions. Next, the system compares the monitored output current with a preset current threshold. When the output current approaches the threshold, an overload risk flag is generated to detect potential overload risks in advance, preventing problems such as fuse blowouts due to excessive current. Then, in response to the overload risk flag, the system obtains the available power capacity from the newly added power module. By sending a capacity query command and receiving feedback, it determines the remaining capacity of the newly added power module, ensuring that there is a power module with sufficient capacity available for switching. Finally, based on the available power capacity and the preset current sharing strategy, the system switches the power supply link of the target switching device in the equipment group connected to the target power module to the newly added power module, completing dynamic current sharing. This process achieves dynamic load adjustment, effectively avoiding the overload risk of the PLC power module due to increased load, improving system stability and reliability, optimizing the utilization efficiency of the power module, and extending the service life of the equipment. Attached Figure Description

[0051] The accompanying drawings, which are incorporated in and form part of this specification, illustrate embodiments consistent with this application and, together with the description, serve to explain the principles of this application.

[0052] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0053] Figure 1 This is a flowchart illustrating an embodiment of the PLC power load dynamic shunting method of this application.

[0054] Figure 2 This is a flowchart illustrating Embodiment 2 of the PLC power load dynamic current sharing method of this application;

[0055] Figure 3 This is a schematic diagram of the module structure of the PLC power load dynamic shunt device in an embodiment of this application;

[0056] Figure 4 This is a schematic diagram of the equipment structure of the hardware operating environment involved in the PLC power load dynamic shunting method in the embodiments of this application.

[0057] The purpose, features, and advantages of this application will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0058] It should be understood that the specific embodiments described herein are merely illustrative of the technical solutions of this application and are not intended to limit this application.

[0059] To better understand the technical solution of this application, a detailed description will be provided below in conjunction with the accompanying drawings and specific implementation methods.

[0060] It should be noted that the executing entity of this application embodiment can be a computing service device with data processing, network communication, and program execution functions, such as a tablet computer, personal computer, or mobile phone, or an electronic device or power control system capable of realizing the above functions. The following description uses a power control system as an example to illustrate this embodiment and the subsequent embodiments.

[0061] Based on this, the embodiments of this application provide a method for dynamic load balancing of PLC power supply, referring to... Figure 1 , Figure 1 This is a flowchart illustrating the first embodiment of the PLC power load dynamic shunting method of this application.

[0062] In this embodiment, the PLC power load dynamic shunting method includes steps S10 to S40:

[0063] Step S10: Monitor the output current of the target power module.

[0064] It should be noted that the target power module refers to the 24V DC output unit with a rated capacity of 10A that originally powered all the cooling water flow meters in the PLC03 cabinet, and it is also the object that needs to be monitored in real time to see if it is overloaded.

[0065] As an example, the step of monitoring the output current of the target power module includes: acquiring the current signal of the target power module; filtering the current signal to obtain the output current; and storing the output current in the current monitoring log.

[0066] The current signal refers to a millivolt-level analog voltage signal induced by a through-hole Hall sensor on the positive bus of the target power module, which is proportional to the instantaneous load current. Its amplitude directly reflects the magnitude of the total current of each flowmeter in the 24V circuit. The current monitoring log refers to a set of register files continuously recorded in chronological order in the memory of the PLC or host computer. Each record contains the output current value with a timestamp, which is used for post-event traceability, trend analysis, and overload alarm criteria.

[0067] First, the power control system uses Hall effect sensors to sample the positive bus of the target power module in real time, and connects the sensed millivolt-level voltage signal to a high-speed analog input channel (e.g., reading the original AD code value (analog-to-digital conversion value) every 10ms) to capture transient changes in current. Then, in the PLC cyclic interrupt, the 20 consecutive sampled values ​​are filtered by moving average to remove glitches introduced by inverter harmonics or relay actions, resulting in a smooth instantaneous value of "output current" (e.g., the resolution after filtering can reach 0.01A). Finally, this instantaneous value, along with the timestamp provided by the system clock, is written to the power-off retained data block to generate a current monitoring log record (e.g., adding one record every 1 second, with a storage depth of the most recent 7 days), ensuring that the background trend analysis is verifiable and providing a real-time data basis for subsequent overload threshold comparisons.

[0068] Step S20: Generate an overload risk marker based on the output current and a preset current threshold.

[0069] It should be noted that the preset current threshold refers to the boundary current value written to the power-down retention register during parameter initialization by the power control system. If the output current of the target power module consistently exceeds this value, it is considered an overload risk. Its value is typically set as a percentage of the fuse's rated current with a certain margin. The overload risk flag is a Boolean variable within the PLC. When the real-time output current exceeds the preset current threshold and remains in this state for several consecutive scan cycles, it is set to TRUE. This flag is used to immediately trigger an alarm, record an event, or initiate a subsequent unloading process. If the current drops, it automatically resets to FALSE.

[0070] As an example, the step of generating an overload risk marker based on the output current and a preset current threshold includes: calculating the difference between the output current and the preset current threshold; predicting the peak current in a preset future period based on historical current data when the difference is lower than a preset safety margin and the duration exceeds a preset duration; and generating an overload risk marker when the peak current exceeds the preset current threshold.

[0071] The preset safety margin refers to the current buffer value pre-written in the parameter table by the power supply control system. It is used to determine how close the output current is to the preset current threshold. Its value is usually set as a certain proportion of the threshold. When the difference is less than this margin, it is considered to have entered the warning range. The preset duration refers to the delay in seconds set in the register by the power supply control system. It is used to confirm that the current remains within the warning range rather than being a momentary spike. Only after this delay will subsequent prediction calculations be triggered. Historical current data refers to the output current sampling values ​​of the most recent continuous period extracted by the power supply control system from the current monitoring log, serving as the basis for the prediction model to estimate trends. The preset future time period refers to the length of the time window that the power supply control system sets in the prediction algorithm to extrapolate forward, used to assess in advance whether the current will exceed the limit. Peak current refers to the maximum instantaneous current value that may occur within the preset future time period, calculated by the power supply control system based on historical current data using linear extrapolation or gradient boosting algorithms.

[0072] The power control system subtracts a preset current threshold from the filtered output current in each scan cycle to obtain the difference. Once the difference is less than the preset safety margin, a timer is started. If the timer accumulates to the preset duration and the condition is still maintained, the historical current data in the sliding window is immediately called for linear extrapolation to calculate the peak current that may be reached in the preset future time period. If the peak current is greater than the preset current threshold, the overload risk flag is immediately set to TRUE; otherwise, the flag remains FALSE and the monitoring continues in a loop.

[0073] Step S30: In response to the overload risk marker, obtain the available power capacity from the newly added power module.

[0074] It should be noted that the newly added power module refers to a second 24V DC power supply unit, independently of the original 10A circuit, installed later in the PLC03 cabinet. Its output terminals are isolated from the cabinet bus and can be controlled to operate via a MOS (Metal-Oxide-Semiconductor) array. The available power capacity refers to the remaining current capacity of the newly added power module, after deducting its current load, that can still be safely used by the equipment to be transferred, and which has been verified and confirmed by the power control system.

[0075] As an example, the step of obtaining available power capacity from the new power module in response to the overload risk marker includes: sending a capacity query instruction to the new power module in response to the overload risk marker; receiving the remaining capacity fed back by the new power module; calculating the required capacity based on the total power consumption requirement of the device to be transferred; and using the remaining capacity as the available power capacity when the remaining capacity is greater than the required capacity.

[0076] The capacity query command refers to a remote frame sent by the power control system to the new power module via the CAN bus, requesting it to return the current remaining output current value. The equipment to be transferred refers to several domestically produced flow meters and their associated heating components that were originally connected to the target power module and are about to be transferred to the new power module. The total power consumption requirement is the maximum continuous current value obtained by adding the rated currents of the aforementioned equipment to be transferred. The required capacity is this total power consumption requirement, used to determine whether the new power module is sufficient to handle it.

[0077] Step S40: Based on the available power capacity and the preset power distribution strategy, switch the power supply link of the target switching device in the device group connected to the target power module to the newly added power module to complete the dynamic power distribution.

[0078] It should be noted that the preset power diversion strategy refers to the power control system pre-writing a switching rule table into the controller. This table follows the principle of "available power capacity ≥ total power consumption of the target device + redundancy coefficient," prioritizing the device with the highest power consumption as the first batch of switching targets. Simultaneously, it limits the number of switching operations to no more than the number of channels that the new power module can handle, ensuring no overload or instantaneous voltage drop during the switching process. The target switching device refers to one or more flow meters and their associated loads in the device group that are triggered by the current overload risk flag and, according to the strategy, need to be immediately switched from the target power module to the new power module. The power supply link refers to the complete DC loop from the positive / negative terminals of the target power module through terminal blocks, aviation plugs, and field junction boxes to the power input of the target switching device, including the positive wire, negative wire, and shielded ground wire.

[0079] Understandably, the power control system first selects several target switching devices with the highest power consumption and total current not exceeding the available power capacity from the equipment group according to the preset current shunting strategy. It immediately disconnects the output of the MOSFET corresponding to the target power module, and simultaneously closes the redundant MOSFET pre-built on the side of the new power module. The original power supply link is switched to the new bus at the terminal block. The current distribution and bus voltage after switching are detected in real time. After confirming that there is no voltage drop and overshoot, the dynamic current shunting is marked as complete, and the monitoring continues in a loop.

[0080] This embodiment provides a dynamic load balancing method for PLC power supplies. First, the power control system continuously monitors the output current of the target power module, obtaining a stable current value through real-time sampling and filtering to support subsequent decision-making. Next, the system compares the monitored output current with a preset current threshold. When the output current approaches the threshold, an overload risk flag is generated to detect potential overload risks in advance, preventing problems such as fuse blowouts due to excessive current. Then, in response to the overload risk flag, the system obtains the available power capacity from the newly added power module. By sending a capacity query command and receiving feedback, the remaining capacity of the newly added power module is determined, ensuring that a power module with sufficient capacity is available for switching. Finally, based on the available power capacity and the preset load balancing strategy, the system switches the power supply link of the target switching device in the device group connected to the target power module to the newly added power module, completing the dynamic load balancing. This process achieves dynamic load adjustment, effectively avoiding overload risks to the PLC power module caused by increased load, improving system stability and reliability, optimizing power module utilization efficiency, and extending equipment lifespan.

[0081] Based on the first embodiment of this application, in the second embodiment of this application, the content that is the same as or similar to that in Embodiment 1 above can be referred to the above description, and will not be repeated hereafter. Based on this, please refer to... Figure 2 , Figure 2 This is a flowchart illustrating the second embodiment of the PLC power load dynamic shunting method of this application. Step S40 of the PLC power load dynamic shunting method includes steps S41 to S44:

[0082] Step S41: Generate a set of candidate devices according to the device priority rules in the preset traffic splitting strategy.

[0083] It should be noted that the equipment priority rule refers to a judgment table written by the power control system before power diversion, based on a three-level ranking: "highest power consumption first, lowest process criticality second, and closest to the new bus last." This table determines which equipment should be removed from the target power module first. The candidate equipment set refers to a group of target switching equipment that, after being screened by the above rules, have a total power consumption not exceeding the available power capacity and can be switched immediately. These devices serve as the actual targets for dynamic power diversion operations.

[0084] As an example, the step of generating a candidate device set according to the device priority rules in the preset traffic diversion strategy includes: obtaining real-time power consumption data and criticality level markers for each device; excluding devices whose criticality level markers are level 1 protection devices to obtain an initial device set; sorting the initial device set in descending order by power consumption value per unit time; and selecting a preset number of devices that rank highest in the initial device set as a candidate device set.

[0085] Real-time power consumption data refers to the instantaneous operating current and voltage product of each flow meter and its heating component, periodically read by the power control system via the fieldbus, reflecting the current actual power consumption level of the equipment. Criticality level markers are enumerated values ​​assigned to each piece of equipment by the control system in the equipment ledger, indicating the degree of impact of power loss on the safety of billet cooling. These are divided into multiple levels, with smaller values ​​indicating greater indispensability in the process. Level 1 protection equipment refers to the highest level of criticality level markers, designated as "absolutely prohibited from power failure," and must not be included in the switching targets under any current diversion strategy. The initial equipment set is a temporary list of all remaining equipment that can be switched after excluding Level 1 protection equipment. The preset quantity refers to the "maximum number of devices to switch at a time," pre-written in the parameter table by the power control system based on the number of channels and current margin that the new power module can handle. This quantity is used to extract the first entries from the sorted initial equipment set to generate the final candidate equipment set.

[0086] First, the power control system polls the lower-level registers of each flowmeter via Modbus (fieldbus) to read its current current and voltage values ​​in real time, multiplying them to obtain real-time power consumption data. Simultaneously, it extracts the criticality level markers of the devices for subsequent screening of switchable equipment. Second, devices marked as Level 1 protection are removed, retaining only those allowed to be powered off, generating an initial device set to ensure that critical equipment will not malfunction and shut down due to current diversion. Then, the initial device set is sorted from highest to lowest power consumption per unit time, prioritizing devices with high power consumption for diverting high-load devices to quickly reduce the current pressure on the target power module. Finally, a predetermined number of devices are selected from the sorted list to form a candidate device set, which serves as the actual switching targets for this dynamic current diversion operation, ensuring that the newly added power module can safely take over the load within its capacity range and achieve smooth current diversion.

[0087] Step S42: Based on the capacity allocation rules in the preset power distribution strategy and the available power capacity, select target switching devices from the candidate device set.

[0088] It should be noted that the capacity allocation rule refers to the power control system selecting devices one by one from the candidate device set according to the principle of "high power consumption priority and cumulative current not exceeding 90% of available power capacity" until the remaining capacity of the newly added power module is fully utilized and the necessary margin is left, thereby determining the target switching device that needs to be switched.

[0089] As an example, the step of selecting target switching devices from the candidate device set based on the capacity allocation rules in the preset power distribution strategy and the available power capacity includes: parsing the capacity allocation rules in the preset power distribution strategy to obtain the minimum capacity limit for a single device and the total capacity percentage threshold; calculating the real-time power consumption value of each device in the candidate device set; excluding devices in the candidate device set whose real-time power consumption value is lower than the minimum capacity limit for a single device, generating a subset of candidate devices; sorting the subset of candidate devices in descending order of power consumption value to obtain a device selection sequence; accumulating the power consumption value from the top of the device selection sequence until the accumulated value reaches the product of the available power capacity and the total capacity percentage threshold, and determining the devices within the accumulated range as target switching devices.

[0090] The minimum capacity limit for a single device refers to the "minimum power consumption current of switchable devices" pre-written in the parameter table by the power control system. Devices below this value are directly eliminated due to insufficient current diversion benefits. The total capacity percentage threshold is the upper limit set by the control system to reserve a safety margin for new power modules, limiting the actual accumulated power consumption to not exceed the available power capacity multiplied by this percentage. The real-time power consumption value is the product of current and voltage obtained by the system based on the latest sampling, representing the device's current instantaneous power demand. The candidate device subset is the list of remaining devices after removing those below the minimum capacity limit for a single device from the candidate device set. The device screening sequence is a queue formed by sorting the candidate device subset according to real-time power consumption values ​​from high to low, used to sequentially accumulate power consumption and determine the final switching range.

[0091] First, the power control system reads the capacity allocation rules from the register area of ​​the preset current distribution strategy, extracting the minimum capacity limit for a single device and the total capacity percentage threshold (e.g., minimum capacity limit for a single device = 0.3A, total capacity percentage threshold = 0.8A) for subsequent screening. Second, the system polls the lower-level machine of each flowmeter in the candidate device set via Modbus RTU (Remote Terminal Unit), instantly reading and multiplying the current and voltage registers to obtain their respective real-time power consumption values. Devices with power consumption below the minimum capacity limit for a single device are then eliminated, generating a subset of candidate devices to exclude small loads with little switching significance. Then, the subset of candidate devices is sorted in descending order of real-time power consumption values ​​to obtain a device screening sequence, placing devices with high power consumption at the top for priority accumulation. Finally, starting from the top of the sequence, the power consumption value is gradually accumulated until the total accumulated value reaches the product of the available power capacity and the total capacity percentage threshold (e.g., available power capacity = 5A, product = 5A × 0.8 = 4A). The accumulation is stopped immediately, and the devices within the accumulation range are locked as the target switching devices. This fully utilizes the capacity of the newly added power modules while retaining a 20% safety margin to ensure a smooth and unloaded switching process.

[0092] Step S43: Control the relay control unit to disconnect the target power module from the target switching device.

[0093] It should be noted that the relay control unit refers to the programmable relay module installed in the PLC03 cabinet. Its coil is driven by the PLC digital output point, and its normally closed contact is connected in series between the positive bus of the target power module and the target switching equipment. It can instantly disconnect the original power supply circuit after receiving the switching command, realizing automatic isolation without manual intervention.

[0094] Understandably, the power control system first sends a disconnect command to the relay control unit, causing its coil to lose power. The normally closed contact immediately pops open, and the positive bus of the target power module is instantly disconnected from the target switching device, the current returns to zero, and the isolation of the original power supply side is completed.

[0095] Step S44: Control the relay control unit to establish a connection between the newly added power module and the target switching device to complete dynamic power distribution.

[0096] Understandably, firstly, after confirming that the target power module has been completely disconnected, the power control system immediately sends a "closing" command to the relay control unit, energizing the corresponding coil and causing the normally open contacts to close rapidly. This establishes a forward conduction path between the new power module and the target switching device, ensuring a delay-free switching of the current path. Then, the system monitors the current rise rate of the new circuit in real time via high-speed analog input. If the inrush current exceeds a set threshold, the system immediately triggers the current limiting function to slow down the MOSFET's conduction speed, preventing hot-plugging sparks or voltage drops from affecting other online devices. Finally, the power control system writes the current current distribution result to the log and updates the load distribution table of the two power modules, marking the completion of this dynamic current distribution. This provides real-time data for the next round of load balancing, ensuring that the entire PLC power supply network remains in a safe and efficient operating range.

[0097] In this embodiment, devices with high power consumption and not under Level 1 protection are first arranged into a candidate device set according to the device priority rules in the preset current shunting strategy, so as to maximize the reduction of the original circuit current. Then, the power consumption of the devices is accumulated according to the capacity allocation rules and compared with the available power supply capacity to screen out the target switching device, ensuring that the load of the new power module is reasonable. Then, the relay control unit is controlled to disconnect the connection between the target power module and the target switching device, so that the original side current instantly returns to zero, avoiding arcing under load. Finally, the contacts on the side of the new power module are closed to establish a power supply path for the new load, completing the dynamic current shunting, thereby avoiding the overload risk of the PLC power module due to the increase in load.

[0098] It should be noted that the above examples are only for understanding this application and do not constitute a limitation on the PLC power load dynamic shunting method of this application. Any simple modifications based on this technical concept are within the protection scope of this application.

[0099] This application also provides a dynamic load shunting device for PLC power supplies; please refer to [reference needed]. Figure 3 The PLC power load dynamic shunt device includes:

[0100] Detection module 10 is used to monitor the output current of the target power module;

[0101] Overload analysis module 20 is used to generate an overload risk marker based on the output current and a preset current threshold.

[0102] The capacity acquisition module 30 is used to acquire the available power capacity from the newly added power module in response to the overload risk marker.

[0103] The power distribution module 40 is used to switch the power supply link of the target switching device in the device group connected to the target power module to the newly added power module according to the available power capacity and the preset power distribution strategy, thereby completing dynamic power distribution.

[0104] The PLC power load dynamic shunting device provided in this application, employing the PLC power load dynamic shunting method in the above embodiments, can solve the technical problem of how to avoid the overload risk of the PLC power module due to increased load. Compared with the prior art, the beneficial effects of the PLC power load dynamic shunting device provided in this application are the same as those of the PLC power load dynamic shunting method provided in the above embodiments, and other technical features in the PLC power load dynamic shunting device are the same as those disclosed in the methods of the above embodiments, and will not be repeated here.

[0105] This application provides a PLC power load dynamic shunting device, which includes: at least one processor; and a memory communicatively connected to the at least one processor; wherein the memory stores instructions executable by the at least one processor, and the instructions are executed by the at least one processor to enable the at least one processor to execute the PLC power load dynamic shunting method in the above embodiment 1.

[0106] The following is for reference. Figure 4This document illustrates a structural schematic diagram suitable for implementing a dynamic power load shunting device for PLCs in the embodiments of this application. The dynamic power load shunting device for PLCs in the embodiments of this application may include, but is not limited to, mobile terminals such as mobile phones, laptops, digital radio receivers, PDAs (Personal Digital Assistants), PADs (Portable Application Description), PMPs (Portable Media Players), vehicle terminals (e.g., vehicle navigation terminals), and fixed terminals such as digital TVs and desktop computers. Figure 4 The PLC power load dynamic shunting device shown is merely an example and should not impose any limitations on the functionality and scope of use of the embodiments of this application.

[0107] like Figure 4 As shown, the PLC power load dynamic shunting device may include a processing unit 1001 (e.g., a central processing unit, a graphics processor, etc.), which can perform various appropriate actions and processes according to the program stored in ROM (Read Only Memory) 1002 or the program loaded from storage device 1003 into RAM (Random Access Memory) 1004. RAM 1004 also stores various programs and data required for the operation of the PLC power load dynamic shunting device. The processing unit 1001, ROM 1002, and RAM 1004 are interconnected via bus 1005. Input / output (I / O) interface 1006 is also connected to the bus. Typically, the following systems can be connected to I / O interface 1006: input devices 1007 including, for example, touchscreens, touchpads, keyboards, mice, image sensors, microphones, accelerometers, gyroscopes, etc.; output devices 1008 including, for example, LCDs (Liquid Crystal Displays), speakers, vibrators, etc.; storage devices 1003 including, for example, magnetic tapes, hard disks, etc.; and communication devices 1009. Communication device 1009 allows the PLC power load dynamic shunt device to exchange data with other devices wirelessly or via wired communication. Although the figure shows a PLC power load dynamic shunt device with various systems, it should be understood that it is not required to implement or have all the systems shown. More or fewer systems can be implemented alternatively.

[0108] Specifically, according to the embodiments disclosed in this application, the processes described above with reference to the flowcharts can be implemented as computer software programs. For example, embodiments disclosed in this application include a computer program product comprising a computer program carried on a computer-readable medium, the computer program containing program code for performing the methods shown in the flowcharts. In such embodiments, the computer program can be downloaded and installed from a network via a communication device, or installed from storage device 1003, or installed from ROM 1002. When the computer program is executed by processing device 1001, it performs the functions defined in the methods of the embodiments disclosed in this application.

[0109] The PLC power load dynamic shunting device provided in this application, employing the PLC power load dynamic shunting method in the above embodiments, can solve the technical problem of how to avoid the overload risk of the PLC power module due to increased load. Compared with the prior art, the beneficial effects of the PLC power load dynamic shunting device provided in this application are the same as those of the PLC power load dynamic shunting method provided in the above embodiments, and other technical features in this PLC power load dynamic shunting device are the same as those disclosed in the previous embodiment method, and will not be repeated here.

[0110] It should be understood that the various parts disclosed in this application can be implemented using hardware, software, firmware, or a combination thereof. In the description of the above embodiments, specific features, structures, materials, or characteristics can be combined in any suitable manner in one or more embodiments or examples.

[0111] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope of the claims.

[0112] This application provides a computer-readable storage medium having computer-readable program instructions (i.e., a computer program) stored thereon, the computer-readable program instructions being used to execute the PLC power load dynamic shunting method in the above embodiments.

[0113] The computer-readable storage medium provided in this application may be, for example, a USB flash drive, but is not limited to, electrical, magnetic, optical, electromagnetic, infrared, or semiconductor systems, devices, or any combination thereof. More specific examples of computer-readable storage media may include, but are not limited to: electrical connections having one or more wires, portable computer disks, hard disks, RAM (Random Access Memory), ROM (Read Only Memory), EPROM (Erasable Programmable Read Only Memory or Flash Memory), optical fibers, CD-ROM (CD-Read Only Memory), optical storage devices, magnetic storage devices, or any suitable combination thereof. In this embodiment, the computer-readable storage medium may be any tangible medium containing or storing a program that can be used by or in conjunction with an instruction execution system, system, or device. The program code contained on the computer-readable storage medium may be transmitted using any suitable medium, including but not limited to: wires, optical cables, RF (Radio Frequency), etc., or any suitable combination thereof.

[0114] The aforementioned computer-readable storage medium may be included in the PLC power load dynamic shunt device; or it may exist independently and not be assembled into the PLC power load dynamic shunt device.

[0115] The aforementioned computer-readable storage medium carries one or more programs. When these programs are executed by the PLC power load dynamic shunting device, the PLC power load dynamic shunting device: monitors the output current of the target power module; generates an overload risk flag based on the output current and a preset current threshold; in response to the overload risk flag, obtains available power capacity from the newly added power module; and, based on the available power capacity and a preset shunting strategy, switches the power supply link of the target switching device in the device group connected to the target power module to the newly added power module, thereby completing the dynamic shunting.

[0116] Computer program code for performing the operations of this application can be written in one or more programming languages ​​or a combination thereof, including object-oriented programming languages ​​such as Java, Smalltalk, and C++, as well as conventional procedural programming languages ​​such as "C" or similar programming languages. The program code can be executed entirely on the user's computer, partially on the user's computer, as a standalone software package, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In cases involving remote computers, the remote computer can be connected to the user's computer via any type of network—including LAN (Local Area Network) or WAN (Wide Area Network)—or can be connected to an external computer (e.g., via the Internet using an Internet service provider).

[0117] The flowcharts and block diagrams in the accompanying drawings illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of this application. In this regard, each block in a flowchart or block diagram may represent a module, segment, or portion of code containing one or more executable instructions for implementing a specified logical function. It should also be noted that in some alternative implementations, the functions indicated in the blocks may occur in a different order than those indicated in the drawings. For example, two consecutively indicated blocks may actually be executed substantially in parallel, and they may sometimes be executed in reverse order, depending on the functions involved. It should also be noted that each block in the block diagrams and / or flowcharts, and combinations of blocks in the block diagrams and / or flowcharts, can be implemented using a dedicated hardware-based system that performs the specified function or operation, or using a combination of dedicated hardware and computer instructions.

[0118] The modules described in the embodiments of this application can be implemented in software or hardware. The names of the modules do not necessarily limit the functionality of the unit itself.

[0119] The readable storage medium provided in this application is a computer-readable storage medium that stores computer-readable program instructions (i.e., a computer program) for executing the above-described PLC power load dynamic shunting method, thereby solving the technical problem of how to avoid the overload risk of the PLC power module due to increased load. Compared with the prior art, the beneficial effects of the computer-readable storage medium provided in this application are the same as those of the PLC power load dynamic shunting method provided in the above embodiments, and will not be repeated here.

[0120] This application also provides a computer program product, including a computer program that, when executed by a processor, implements the steps of the PLC power load dynamic shunting method described above.

[0121] The computer program product provided in this application can solve the technical problem of how to avoid the overload risk of PLC power modules due to increased load. Compared with the prior art, the beneficial effects of the computer program product provided in this application are the same as the beneficial effects of the PLC power load dynamic current distribution method provided in the above embodiments, and will not be repeated here.

[0122] The above description is only a part of the embodiments of this application and does not limit the patent scope of this application. All equivalent structural transformations made under the technical concept of this application and using the contents of the specification and drawings of this application, or direct / indirect applications in other related technical fields, are included in the patent protection scope of this application.

Claims

1. A method for dynamic load balancing of a PLC power supply, characterized in that, The method includes: Monitor the output current of the target power module; An overload risk marker is generated based on the output current and a preset current threshold. In response to the overload risk flag, obtain the available power capacity from the newly added power module; Based on the available power capacity and the preset power distribution strategy, the power supply link of the target switching device in the device group connected to the target power module is switched to the newly added power module to complete the dynamic power distribution.

2. The method as described in claim 1, characterized in that, The step of switching the power supply link of the target switching device in the device group connected to the target power module to the newly added power module, based on the available power capacity and the preset power distribution strategy, to complete the dynamic power distribution includes: A set of candidate devices is generated based on the device priority rules in the preset traffic splitting strategy; Based on the capacity allocation rules in the preset power distribution strategy and the available power capacity, target switching devices are selected from the candidate device set; The control relay control unit disconnects the target power module from the target switching device; The relay control unit is controlled to establish a connection between the newly added power module and the target switching device, thereby completing dynamic power distribution.

3. The method as described in claim 2, characterized in that, The step of generating a candidate device set based on the device priority rules in the preset traffic splitting strategy includes: Obtain real-time power consumption data and criticality level markers for each device; Excluding the devices marked as Level 1 protection devices for critical operation, an initial set of devices is obtained; The initial set of devices is sorted in descending order by power consumption per unit time. A predetermined number of devices ranked at the top of the initial device set are selected as the candidate device set.

4. The method as described in claim 2, characterized in that, The step of selecting target switching devices from the candidate device set based on the capacity allocation rules in the preset power distribution strategy and the available power capacity includes: The capacity allocation rules in the preset traffic splitting strategy are parsed to obtain the minimum capacity limit for a single device and the threshold for the proportion of total capacity. Calculate the real-time power consumption value of each device in the candidate device set; In the candidate device set, devices whose real-time power consumption value is lower than the minimum capacity limit of a single device are excluded, and a subset of candidate devices is generated; The subset of candidate devices is sorted in descending order of power consumption value to obtain the device selection sequence; Starting from the top of the device screening sequence, the power consumption value is accumulated until the accumulated value reaches the product of the available power capacity and the total capacity percentage threshold. Devices within the accumulated range are then identified as target switching devices.

5. The method as described in claim 1, characterized in that, The step of monitoring the output current of the target power module includes: Acquire the current signal of the target power module; The current signal is filtered to obtain the output current; The output current is stored in the current monitoring log.

6. The method as described in claim 1, characterized in that, The step of generating an overload risk marker based on the output current and a preset current threshold includes: Calculate the difference between the output current and the preset current threshold; When the difference is lower than a preset safety margin and the duration exceeds a preset duration, the peak current in a preset future period is predicted based on historical current data. When the peak current exceeds the preset current threshold, an overload risk flag is generated.

7. The method according to any one of claims 1 to 6, characterized in that, The step of obtaining available power capacity from the newly added power module in response to the overload risk marker includes: In response to the overload risk marker, a capacity query command is sent to the newly added power module; Receive the remaining capacity reported by the newly added power module; Calculate the required capacity based on the total power consumption requirements of the equipment to be transferred; When the remaining capacity is greater than the required capacity, the remaining capacity is used as the available power capacity.

8. A dynamic load shunting device for PLC power supply, characterized in that, The device includes: The detection module is used to monitor the output current of the target power module; The overload analysis module is used to generate an overload risk marker based on the output current and a preset current threshold. A capacity acquisition module is used to acquire the available power capacity from the newly added power module in response to the overload risk marker. The power distribution module is used to switch the power supply link of the target switching device in the device group connected to the target power module to the newly added power module according to the available power capacity and the preset power distribution strategy, thereby completing dynamic power distribution.

9. A dynamic load shunting device for PLC power supply, characterized in that, The device includes: a memory, a processor, and a computer program stored in the memory and executable on the processor, the computer program being configured to implement the steps of the PLC power load dynamic shunting method as described in any one of claims 1 to 7.

10. A storage medium, characterized in that, The storage medium is a computer-readable storage medium, and a computer program is stored on the storage medium. When the computer program is executed by a processor, it implements the steps of the PLC power load dynamic shunting method as described in any one of claims 1 to 7.

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