PLC Power Supply with Super Capacitor Backup
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Solution Overview
Problem
Existing power supply systems for programmable logic controllers (PLCs) face issues with data loss and frequent battery replacements due to limited battery lifetime and slow data write times in flash memories, and the need for continuous power backup for SRAM and RTC operations.
Innovation Solution
A power supply apparatus utilizing a battery module and a super capacitor module to provide auxiliary power during power interruptions, with the super capacitor offering high charge/discharge cycles and reducing battery usage, ensuring stable power for memory backup and RTC operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If a battery is used for power backup, then power supply duration is extended, but battery lifetime is limited requiring periodic replacement
Solution Approach 1:
The power backup system is segmented into two distinct modules: a battery module for long-term energy storage and a super capacitor module for short-term high-power delivery. This segmentation allows each component to operate within its optimal performance range, with the battery providing sustained power over years and the super capacitor providing immediate power during sudden outages, thereby extending the overall system lifetime while maintaining adequate power supply duration.
2Reliability
If a super capacitor module is added to the power supply system, then charge/discharge cycle reliability is improved, but device complexity increases
Solution Approach 1:
The battery module and super capacitor module are merged into a single integrated power supply apparatus with shared control circuitry and a unified output interface. The control unit intelligently manages power flow between the two modules based on real-time conditions, selecting the appropriate power source or combining them. This merging approach achieves high reliability through the super capacitor's superior cycle life while minimizing complexity by using common control and output infrastructure rather than completely separate systems.
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
The solution prevents data loss and reduces battery replacement costs by extending battery life and providing stable power backup, improving data storage stability and reducing maintenance expenses.
Implementation Method 1
a second power storing module (200) comprising a second auxiliary power source (210). An output voltage from the second power storing module (200) is larger than an output voltage from the first power storing module (100). The second auxiliary power source (210) may be a super capacitor
Implementation Method 2
a first power storing module (100) comprising a first auxiliary power source (110). The first auxiliary power source (110) may be a battery
Data Source
AI summary
Disclosed herein are embodiments of a power supply apparatus. In some embodiments, the power supply apparatus supplies power to a load including a programmable logic controller (PLC) and includes: a first power storing module comprising a first auxiliary power source; and a second power storing module including a second auxiliary power source. An output voltage from the second power storing module may be larger than an output voltage from the first power storing module. It is possible to prevent an accident such as memory data loss possibly occurring in the event of sudden power-off by way of reducing usage of a battery that has limited lifetime while utilizing the advantage of super capacitor that has a very high number of charge/discharge cycles.