Industrial Controller Power Switching for Wake-On-LAN Sleep Mode
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Solution Overview
Problem
Existing industrial controllers with wake-on-LAN functionality are not compatible with centralized safety chains, leading to energy wastage and structural complexity due to the use of batteries and capacitors.
Innovation Solution
An industrial controller with a power switch that selectively supplies the network interface in sleep mode while powering off the drive module, eliminating the need for alternative power sources and reducing energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the industrial controller is powered off to save energy during temporary shutdown, then energy consumption is reduced, but the controller cannot be monitored by the centralized safety chain
Solution Approach 1:
The controller segments power supply to different modules: the network interface module remains powered while the drive module is powered off during temporary shutdown. This allows the safety chain to monitor the controller via the network interface without requiring the entire controller to remain powered.
Solution Approach 2:
Different parts of the controller have different power states: the network interface module maintains power for monitoring purposes while the drive module enters low-power state. This local differentiation of power quality enables selective monitoring without full system operation.
2Ease of operation
If alternative power sources (batteries or capacitors) are used to power the network interface in sleep mode, then wake-on-LAN functionality is achieved, but structural complexity increases and harmful materials are used
Solution Approach 1:
The invention extracts and removes the alternative power source components (batteries and capacitors) from the controller. Instead, it uses the existing power supply circuitry to selectively power the network interface module, eliminating the need for separate energy storage devices while maintaining wake-on-LAN functionality.
Solution Approach 2:
The power supply circuitry serves multiple functions: it powers the drive module during normal operation, selectively powers the network interface module during sleep mode for wake-on-LAN, and eliminates the need for dedicated alternative power sources. This multi-functionality reduces overall system complexity.
3Loss of energy
If the power module is completely powered off in sleep mode, then energy saving is maximized, but the controller cannot receive wakeup signals
Solution Approach 1:
The controller segments the power module into distinct functional blocks: the network interface module remains powered to receive wakeup signals, while the drive module is completely powered off for maximum energy saving. This segmentation enables selective power management.
Solution Approach 2:
The network interface module acts as an intermediary between the external wake-up signal and the powered-off drive module. It receives the wakeup signal during sleep mode and triggers the power module to restore power to the drive module, enabling wake-up functionality without keeping the entire system powered.
Data Source
AI summary
An industrial controller operable in a work mode and a sleep mode, the industrial controller having: a drive module configured to drive an industrial appliance; a network interface configured to communicate with an external network; and a power module configured to directly supply the drive module in the work mode. The industrial controller further includes a power switch connected to an input power source and configured to supply the power module in the work mode, and to supply the network interface but not the power module in the sleep mode. In the work mode, the network interface may be supplied either by the power module or the power switch. There is further provided a method of operating the industrial controller.