PLC Energy Harvesting from Measurement Inputs
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Solution Overview
Problem
Programmable logic controllers (PLCs) face issues with high power loss and heating due to the conversion of electrical input signals into heat, leading to derating and reduced service life, especially at higher environmental temperatures, and sensitivity to electromagnetic disturbances.
Innovation Solution
The PLC incorporates separate converter units connected to each measurement input, allowing the reuse of some electric energy from input signals to power the PLC, reducing power loss and heating, and increasing robustness against electromagnetic interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If measurement inputs are used to detect electrical input signals, then the PLC can monitor and control industrial processes, but the electrical input signals generate substantial heat that must be dissipated
Solution Approach 1:
The patent converts the harmful electrical energy from input signals into useful energy by harvesting it through converter units. The converter units transform the electrical energy that would otherwise be dissipated as heat into usable power for the PLC, turning a harmful thermal effect into a beneficial energy source.
Solution Approach 2:
The PLC system serves itself by using its own input signals to power its operation. The converter units enable the PLC to draw energy from its measurement inputs, making the system self-sufficient and reducing the need for external power sources.
2Productivity
If multiple measurement inputs are used, then the PLC can handle more monitoring tasks, but the total power loss and heat generation increases
Solution Approach 1:
The patent combines multiple converter units into a unified energy harvesting system. Each converter unit processes energy from its associated measurement input, and all converter units work together to supply power to common PLC consumers, merging individual energy sources into a collective power solution.
Solution Approach 2:
The patent converts the previously wasted energy from multiple measurement inputs into useful power. By harvesting energy from each input signal through converter units, the system transforms what would have been pure heat loss into valuable electrical energy for operating the PLC.
3Reliability
If high currents are conducted through measurement inputs, then more robust signal detection is achieved, but electromagnetic disturbances become more sensitive
Solution Approach 1:
The converter units act as intermediary devices between the measurement inputs and the PLC internal circuitry. They provide galvanic isolation and controlled energy transfer, mediating the interaction between high-current input signals and the PLC's sensitive electronic components, thereby reducing electromagnetic interference.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution reduces power loss and heating, extends the PLC's service life, allows for smaller and more densely packed designs, and prevents measurement inputs from being switched off at high temperatures, while enhancing signal detection robustness and reducing electromagnetic sensitivity.
Implementation Method 1
Each converter unit is electrically connected to the energy supply and supplies at least some of the electric energy of the respective input signals to the energy supply
Data Source
AI summary
The invention relates to a programmable logic controller having an energy supply that provides electric energy to operate the unit and having at least one measurement input, with the measurement input being configured to measure and/or detect an electrical input signal. The programmable logic controller is characterized in that at least some of the electric energy of the input signal is supplied to the energy supply.