PLC control module with price profile logic

Abstract

PLC control module (20) for the demand-oriented connection of a consumer depending on a received price / cost time series, comprising: (a) a communication / acquisition unit for receiving and buffering the time series; (b) a computing unit with decision logic that evaluates hysteresis thresholds, minimum on / off times, and time windows / calendar rules and generates an enable / disable signal therefrom; (c) a fallback / safety mechanism with at least one of the Safe-OFF, Safe-ON, and Hold modes, as well as optional profile bridging; and (d) a galvanically isolated output stage for providing a PLC-compatible 24 V digital signal for a PLC digital input (DI).

Description

Technical field

[0001] The invention relates to industrial automation technology, in particular control modules that switch consumers on or off as required depending on a received price / cost time series and provide a PLC-compatible 24 V digital signal for this purpose. State of the art

[0002] Time- or threshold-controlled switching modules are known. However, a decision logic that takes into account the rules of hysteresis, minimum on / off times, and time windows / calendars in combination, while ensuring robust fallback operation, is not satisfactorily solved in the current state of the art. Object of the invention

[0003] The task is to provide a control module that receives and buffers price / tariff time series, performs a combined evaluation of several rules (hysteresis, minimum on / off times, time window / calendar), derives a release / block signal from this, and ensures a safe state in case of data / communication problems. Summary of the invention

[0004] The problem is solved by a PLC control module (20) comprising: (a) a communication / acquisition unit for receiving and buffering a price / cost time series; (b) a processing unit with decision logic that considers hysteresis thresholds, minimum on / off times, and time windows / calendar rules and generates an enable / disable signal; (c) a fallback / safety mechanism with at least one of the modes Safe-OFF, Safe-ON, and Hold, as well as optional profile override; (d) a galvanically isolated output stage for providing a PLC-compatible 24 V digital signal for a PLC DI; (e) an optional real-time clock (RTC) for mains-independent implementation of time windows; and (f) a display / diagnostics and override control element. In preferred embodiments, the aforementioned rules are evaluated simultaneously or in parallel / sequentially, taking into account each other with weighting / prioritization. Advantages

[0005] Demand-oriented, cost-efficient activation through combined consideration of multiple boundary conditions; high operational reliability through fallback modes and buffering; PLC compatibility and easy integration; diagnostic and override functions for commissioning and service. Example of implementation

[0006] One embodiment includes an Ethernet / serial interface for receiving dynamic tariff time series, a buffer memory, a microcontroller (MCU) with decision logic (considering hysteresis, minimum times, and time windows), and a galvanically isolated 24 V output stage according to IEC 61131-2. In case of communication errors, the fallback mechanism forces safe-OFF or optionally retains the last valid state. An override button allows temporary override with automatic fallback; LEDs indicate operating and fault states; an RTC implements time windows even without a network connection. Reference symbol list 20 PLC control modules 30 System 40 PLCs / control units 50 Electrical consumers

Claims

[1] PLC control module (20) for the demand-oriented activation of a consumer depending on a received price / cost time series, comprising: (a) a communication / acquisition unit for receiving and buffering the time series; (b) a computing unit with decision logic that evaluates hysteresis thresholds, minimum on / off times and time windows / calendar rules and generates an enable / disable signal from this; (c) a fallback / safety mechanism with at least one of the modes Safe-OFF, Safe-ON and Hold as well as optional profile bridging; and (d) a galvanically isolated output stage for providing a PLC-compatible 24 V digital signal for a PLC digital input (DI). [2] Module according to claim 1, with galvanically isolated output stage. [3] Module according to claim 1, wherein the decision logic evaluates the aforementioned rules simultaneously. [4] Module according to claim 1 or 3, wherein the decision logic evaluates the aforementioned rules in parallel or sequentially taking common consideration and resolves conflicts by means of weighting or prioritization. [5] Module according to any one of claims 1 to 4, wherein the output stage complies with switching thresholds according to IEC 61131-2 (Type 1 / 2 / 3). [6] Module according to one of claims 1 to 5, wherein the computing unit implements the decision logic parameterizable via thresholds, hysteresis, minimum on / off times and time windows. [7] Module according to one of claims 1 to 6, comprising a parameterization interface via which thresholds, hysteresis, minimum on / off times and time windows can be set via a web interface and / or a cloud service. [8] Module according to one of claims 1 to 7, comprising a communication interface for receiving external price / tariff time series (market prices, dynamic tariffs) and a buffer memory for local intermediate storage. [9] Module according to any one of claims 1 to 8, wherein the fallback / safety mechanism enforces a safe state in the event of data or communication errors and optionally continues to use the last valid parameterization. [10] Module according to one of claims 1 to 9, with real-time clock / calendar function for implementing time windows independently of a network connection. [11] Module according to any one of claims 1 to 10, with display / diagnostic means (LED status, log, interface) for signaling operating and fault conditions. [12] Module according to one of claims 1 to 11, comprising a manual override control element (button / switch) with time-controlled automatic return to normal operation. [13] System (30) comprising a module according to one of claims 1 to 12, a PLC (40) with a digital input (DI) and an electrical load (50), wherein the 24 V digital signal provided by the output stage serves as an enable / disable signal.