I/O Unit Energy-Saving Switching with Substitute Process Data
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Solution Overview
Problem
Decentralized control units in programmable logic control systems have a high hardware footprint and fixed energy-saving settings that cannot be flexibly adjusted during configuration or operation, making it difficult to simplify the selection, grouping, and activation of input/output units for energy-saving states.
Innovation Solution
Assigning energy-saving process data to input/output units, which can be used as substitute values for process data during energy-saving states, allowing for flexible and centralized or decentralized switching to energy-saving modes without requiring specific knowledge of subordinate units or higher-level controller intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If decentralized control units are used to control input/output units, then control functionality is distributed and autonomous, but the hardware footprint increases and device complexity increases
Solution Approach 1:
The patent extracts the energy-saving control logic from the higher-level controller and embeds it directly into the input/output units as autonomous energy-saving controllers. This allows the I/O units to independently determine and switch to energy-saving states based on predefined criteria, eliminating the need for complex centralized control hardware while maintaining autonomous functionality.
Solution Approach 2:
The input/output units are equipped with autonomous energy-saving controllers that enable them to self-determine whether to switch to energy-saving states based on process data and predefined switching criteria. This self-service capability allows the units to autonomously manage their own energy consumption without requiring additional complex control hardware or continuous intervention from higher-level controllers.
2Device complexity
If fixed energy-saving settings are predefined during installation, then device complexity is reduced, but adaptability during configuration and operation is limited
Solution Approach 1:
The patent implements dynamic energy-saving switching criteria that can be flexibly configured and adjusted during operation. The switching criteria include adjustable parameters such as process data thresholds, time intervals, and state transition conditions that can be modified without changing the hardware structure. This allows the system to adapt to different operational requirements while maintaining a relatively simple control structure.
Solution Approach 2:
The energy-saving controller uses configurable parameters such as process data thresholds, time intervals, and switching criteria that can be adjusted during configuration and operation. By changing these parameters rather than the underlying control structure, the system achieves high adaptability while keeping the device complexity low. The parameters can be modified through software configuration rather than hardware changes.
3Reliability
If process data exchange continues for all input/output units, then real-time control accuracy is maintained, but energy consumption increases
Solution Approach 1:
The patent implements periodic switching between normal operation mode and energy-saving mode based on predefined criteria. During energy-saving periods, process data exchange is reduced or suspended while maintaining the ability to quickly resume normal operation when needed. This periodic switching allows the system to balance real-time control accuracy requirements with energy consumption reduction by alternating between full data exchange and reduced data exchange states.
4Extent of automation
If higher-level controllers directly manage energy-saving states of subordinate units, then centralized control is maintained, but device complexity and communication overhead increase
Solution Approach 1:
The patent segments the energy-saving control function into independent modules within each input/output unit. Each unit has its own energy-saving controller that autonomously evaluates switching criteria and determines energy-saving states based on locally available process data. This segmentation eliminates the need for complex centralized control logic while maintaining coordinated energy management across the system through standardized communication interfaces.
Data Source
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AI summary
A control device 1 with a control unit 2, 5, which is in communication connection with at least one input and/or output unit 10 via a data transmission channel 3, 6 for the exchange of process data P, characterized in that the control device 1 has predefined energy-saving process data V assigned to the input/output units 10 for energy-saving states En of the input/output units 10, wherein the input and/or output unit 10 accesses the predefined energy-saving process data V instead of the exchanged process data P in the energy-saving state if a switching criterion C parameterized in the input and/or output unit 10 is fulfilled. Furthermore, a method for switching input and/or output units 10 of a control device 1 into an energy-saving state is claimed.