PLC Power Supply Monitoring for Predictive RUL Diagnostics
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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
Incorporating analytics circuitry within the programmable logic controller (PLC) to monitor diagnostic parameters of internal and external power supplies without external communication devices, enabling predictive analysis of RUL through field programmable gate array (FPGA) communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If external communication devices are used to monitor power supply parameters, then measurement precision is improved, but device complexity and costs increase
Solution Approach 1:
The patent combines the monitoring function with the existing PLC by integrating an analog-to-digital converter and processing circuitry into the PLC's internal architecture. This allows the PLC to directly receive and process analog power supply parameters without requiring separate external communication devices, thereby maintaining measurement precision while reducing system complexity and costs.
Solution Approach 2:
The PLC is designed to perform multiple functions including both its primary control operations and power supply parameter monitoring. By making the PLC universal, the system eliminates the need for dedicated external monitoring devices, as the PLC can handle both control logic and diagnostic measurements through its integrated analog-to-digital conversion capabilities.
2Reliability
If power supplies are replaced based on fixed schedules, then reliability is improved, but loss of time and costs increase due to premature replacement
Solution Approach 1:
The system implements continuous feedback monitoring of power supply parameters such as voltage, current, and temperature through the integrated analog-to-digital converter. This real-time feedback enables the detection of degradation trends and predictive maintenance scheduling, allowing power supplies to be replaced only when actually needed rather than following fixed schedules, thus reducing premature replacements and associated downtime.
Solution Approach 2:
The monitoring system performs preliminary detection of power supply degradation by continuously analyzing parameter trends before actual failure occurs. This preliminary action enables proactive maintenance planning and avoids sudden failures, allowing scheduled maintenance to be optimized based on actual condition rather than conservative time-based intervals.
Data Source
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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.