PLC Switcher Power Converter Slope Elimination
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Solution Overview
Problem
The existing switching regulators in Programmable Logic Controller (PLC) power modules exhibit a slope phenomenon in output voltage during gradual input voltage changes, leading to unstable voltage levels and timing, causing malfunctions in analog input/output modules and affecting product quality and performance.
Innovation Solution
A switcher power converter with an input voltage correction unit that includes an input stage distribution unit, a constant voltage generation unit, and a voltage comparison unit, which corrects the external input voltage to ensure a stable output voltage by only outputting the voltage when it exceeds a reference value, thereby eliminating the slope phenomenon.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a conventional switching regulator is used to convert DC 24V to DC 5V, then the regulator can drive the required load current, but the output voltage exhibits a slope phenomenon during gradual input voltage changes, causing unstable voltage levels and timing
Solution Approach 1:
The patent applies preliminary action by detecting the input voltage before it is gradually applied and generating a corrected input voltage in advance. The correction unit pre-processes the gradual voltage change by comparing it with a reference voltage and outputting a corrected voltage that eliminates the slope phenomenon, ensuring stable output voltage from the start without affecting the regulator's load driving capability.
2Reliability
If the external input voltage is gradually increased from 0V to 24V, then the system can power up safely, but the output voltage slope causes rising time delays and timing instability in the PLC internal circuits
Solution Approach 1:
The patent introduces an intermediary component (the correction unit) between the gradual input voltage and the switching regulator. This intermediary detects the gradual voltage change, compares it with a reference voltage, and generates a corrected input voltage that eliminates the slope. The regulator then receives this corrected voltage and produces stable output voltage without timing delays, thus resolving the contradiction between safe gradual power-up and fast stable voltage establishment.
3Ease of operation
If the regulator outputs voltage during gradual input voltage increase, then the analog input/output modules can operate, but the slope phenomenon causes voltage level instability and potential malfunctions
Solution Approach 1:
The patent implements feedback by using a correction unit that continuously monitors the gradual input voltage and compares it with a stable reference voltage. Based on this feedback comparison, the correction unit generates a corrected input voltage that eliminates the slope phenomenon. This feedback mechanism ensures that the regulator receives a stable input voltage, thereby maintaining accurate voltage levels for analog input/output module operation without malfunctions.
Data Source
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AI summary
The present disclosure provides a device for eliminating a slope in an output voltage of a switcher power converter of a PLC module, by which a power supply timing of an internal regulator circuit applied to a PLC power supply is secured and an initial start condition (specification) required by the circuit element is satisfied by eliminating a slope phenomenon occurring in an output voltage from the internal regulator circuit when an external input voltage to the PLC module increases or decreases gradually. The present disclosure provides a switcher power converter for a programmable logic controller (PLC) module, characterized in that the power converter has an output voltage without a slope, the converter comprising: an input voltage correction unit configured to correct a gradually increasing external input voltage such that the gradually increasing external input voltage is output only when the gradually increasing external input voltage is greater than or equal to a reference voltage; and a regulator configured to receive the corrected external input voltage output from the input voltage correction unit and to supply a fixed output voltage to an internal circuit in the PLC module.