PLC Power Supply Analytics for Remaining Useful Life Monitoring
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Solution Overview
Problem
Predicting the remaining useful life (RUL) of power supplies in process control systems is challenging due to varying factors like operating temperature and load, leading to premature replacement and increased costs, and existing communication methods for monitoring power supplies increase system complexity and costs.
Innovation Solution
Implementing analytics circuitry within the programmable logic controller (PLC) to monitor diagnostic parameters of internal and external power supplies without external communication devices, using field programmable gate array (FPGA) for data communication, enabling predictive analysis of RUL.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If regular scheduled maintenance is performed on power supplies, then reliability is maintained, but productivity decreases due to downtime and premature replacement
Solution Approach 1:
The analytics circuitry performs preliminary monitoring and analysis of power supply diagnostic parameters (voltage, current, temperature, load) to predict remaining useful life before actual failure occurs. This enables maintenance to be scheduled based on actual condition rather than fixed schedules, preventing premature replacement and avoiding unplanned downtime.
2Measurement precision
If external communication devices are used to monitor power supplies, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The monitoring and analytics circuitry is merged directly into the power supply unit itself. The analytics circuitry receives diagnostic parameters from the power supply and performs on-board analysis, eliminating the need for separate external communication devices and reducing overall system complexity while maintaining measurement precision.
3Ease of operation
If analytics circuitry is implemented within the PLC, then ease of operation is improved, but device complexity increases
Solution Approach 1:
The power supply performs self-diagnosis through the analytics circuitry that continuously monitors its own diagnostic parameters and calculates remaining useful life. This self-service capability provides maintenance information directly within the PLC without requiring external analysis systems, making operation easier despite the added internal circuitry.
Data Source
AI summary
Methods and apparatus to monitor a power supply are disclosed. An example apparatus includes a first power supply included in a programmable logic controller (PLC), the first power supply to receive input power from a second power supply external to the PLC, and analytics circuitry included in the first power supply, the analytics circuitry to determine, based on the input power, a diagnostic parameter associated with the second power supply.