Carrier Current Communication for Centralized Control Panels
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In centralized intelligent motor control-command panels (iMCCs), the high number of motor starters leads to complex and expensive wiring, making it difficult to add or modify motor starters without resizing the entire system, and PLC signal attenuation issues result in poor performance, especially in sites with multiple iMCCs.
Innovation Solution
The solution involves a control-command module with a line outgoing device connected to a PLC interface that includes an impedance adapter, allowing adjustable impedance to match the power supply network, enabling reliable PLC communication by optimizing signal propagation through impedance matching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If Power Line Communication (PLC) is used for communication between motor starters and control system, then the number of cables and connections is reduced, but PLC signal attenuation becomes very high and useful PLC signal is too low for optimum performance
Solution Approach 1:
The patent introduces an intermediary device (signal amplifier or repeater) connected to the power line network to boost PLC signals. This intermediary captures weak PLC signals, amplifies them, and retransmits them, thereby overcoming signal attenuation without requiring additional communication cables or connections between motor starters and the control system.
Solution Approach 2:
The patent modifies electrical parameters of the power line network by injecting carrier signals at optimized frequencies and adjusting signal levels. By changing the frequency and amplitude parameters of PLC signals, the system achieves better signal propagation characteristics and overcomes attenuation issues while maintaining the existing power line infrastructure.
2Productivity
If a very large number of motor starters are integrated in centralized iMCC, then energy distribution and control is consolidated, but wiring becomes complex and expensive
Solution Approach 1:
The patent merges the communication function with the existing power distribution infrastructure by using the same power lines for both electrical power delivery and data communication. This consolidation eliminates the need for separate communication wiring, allowing a large number of motor starters to be integrated into centralized iMCC without proportionally increasing wiring complexity.
Solution Approach 2:
The patent makes the power line network multi-functional by enabling it to simultaneously perform power distribution and data communication functions. This universal usage of the power line infrastructure allows consolidated control of many motor starters while avoiding the need for dedicated communication cables, thereby reducing overall wiring complexity.
3Adaptability or versatility
If motor starters are added to existing iMCC or modifications are made, then system functionality is enhanced, but the entire system must be resized
Solution Approach 1:
The patent segments the communication network into independent PLC-based units that can be individually added or removed from the existing iMCC. Each motor starter with its integrated PLC interface operates as an independent node, allowing modifications and expansions without requiring system-wide resizing or reconfiguration of the entire communication infrastructure.
4Reliability
If PLC products are adapted to take into account specificities of the power supply network, then communication performance is improved, but device complexity increases
Solution Approach 1:
The patent implements self-adaptive PLC products that automatically detect and adapt to the specific characteristics of the power supply network. The devices perform self-configuration by measuring network parameters and adjusting their communication settings accordingly, thereby improving communication performance without requiring complex manual adaptation or increasing operational complexity.
Data Source
Figure 1~4
Figure 2
Figure 3
AI summary
The module (128) has communication unit (134) e.g. serial communication bus, such as Modbus(RTM: master-slave type numerical communication protocol), connected between a line start device (104) and a carrier current interface (130) for transmitting information. A carrier current line receiving/converting device (132) transforms transition information in the communication unit from a protocol into representative carrier current signal. The interface has a streamline with an impedance adaptation unit (150) such that the impedance of the interface is able to take different values. Independent claims are also included for the following: (1) a method for examining and adjusting impedance of a command control table (2) an automated method for installation of a table.