I/O Unit Power-Saving Switching via Controller Process Data
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Solution Overview
Problem
Decentralized control units in programmable logic control devices have a high hardware footprint and inflexible energy-saving configurations that cannot be adjusted during operation, making it difficult to simplify the selection, grouping, and control of input/output units for energy-saving states.
Innovation Solution
The control device uses energy-saving process data to switch selected input/output units to a low power state, allowing for flexible and centralized or decentralized parameterization and switching by assigning energy-saving profiles to individual or grouped channels, which can be activated without specific knowledge of subordinate units, using a data transmission channel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If decentralized control units are used to manage energy-saving states, then energy management functionality is achieved, but device complexity and hardware footprint increase
Solution Approach 1:
The patent introduces an intermediary component (fieldbus coupler or higher-level controller) that manages energy-saving states for multiple input/output units. This intermediary consolidates the control logic, eliminating the need for each decentralized control unit to have full energy management functionality, thus reducing overall hardware complexity while maintaining energy management capabilities.
Solution Approach 2:
The fieldbus coupler or higher-level controller serves multiple functions: it manages energy-saving states, coordinates communication between input/output units, and handles process data exchange. By making this single component multi-functional, the system reduces the number of specialized hardware components needed, thereby reducing device complexity.
2Loss of energy
If energy-saving configurations are set during installation, then energy management is implemented, but adaptability during configuration and operation is lost
Solution Approach 1:
The patent implements dynamic energy-saving management where the fieldbus coupler or higher-level controller can adjust energy-saving states during configuration and operation based on actual system conditions. This dynamic approach allows the system to adapt to changing requirements while maintaining energy efficiency, replacing static installation-time configurations.
Solution Approach 2:
The system incorporates feedback mechanisms where the fieldbus coupler monitors the operational status of input/output units and adjusts energy-saving states accordingly. This feedback loop enables the system to respond to actual usage patterns and environmental conditions, providing adaptability during operation while maintaining energy management effectiveness.
3Reliability
If process data exchange is maintained for all input/output units, then real-time control is achieved, but energy consumption increases
Solution Approach 1:
The patent segments the data exchange approach by distinguishing between active and energy-saving states for different input/output units. The fieldbus coupler manages this segmentation by maintaining full process data exchange only for units that require real-time control, while reducing or suspending data exchange for units in energy-saving states, thereby optimizing the balance between reliability and energy consumption.
Solution Approach 2:
The system dynamically changes the parameter of data exchange frequency and completeness based on the operational state of each input/output unit. When units are in energy-saving states, the fieldbus coupler reduces data exchange parameters (frequency, detail level), while maintaining full parameters for units requiring real-time control, thus achieving energy savings without compromising critical real-time control capabilities.
Data Source
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AI summary
The invention relates to a controller (1) comprising a control unit (2), which communicates with at least one input and/or output unit (10) via a data transmission channel (3, 6) for exchange of process data (P). The controller (1) has predetermined power saving process data (V) for power-saving states (En), which are associated with the input/output units (10), and is designed to access the predetermined power-saving process data (V) instead the exchanged process data (P) when in the power saving state.