PLC Backup Power Circuit Using Ultra-Capacitor Memory Switching

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional PLC systems face limitations with secondary batteries used as auxiliary power supplies, including long charging times, short lifetimes, difficulty in powering high-speed memories, and the risk of explosion during charging and discharging, which hinder efficient and safe data backup during power module interruptions.

Innovation Solution

A PLC system utilizing an ultra-capacitor as an auxiliary power supply, charged by the power module, with a variable resistor to manage current flow and a switching unit to alternate power sources, along with a voltage transform unit to ensure stable power delivery to high-speed memory units, allowing for quick and safe data backup.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a secondary battery is used as an auxiliary power supply, then power can be supplied during power module interruption, but the charging period is long and lifetime is short

Engineering Contradiction:

Improveauxiliary power supply reliabilityVSAvoidcharging period

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent changes the fundamental parameter of the auxiliary power supply from a secondary battery to a capacitor. This parameter change transforms the energy storage mechanism from electrochemical to electrostatic, enabling much faster charging times (from hours to seconds) while maintaining the ability to provide power during interruptions.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent accepts that capacitors have shorter operational lifetimes compared to secondary batteries, but compensates by making the capacitor replaceable and inexpensive. This allows the system to use a short-living component that can be quickly replaced, achieving both fast charging and acceptable overall system reliability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If a secondary battery is used as an auxiliary power supply, then power can be supplied during power module interruption, but the risk of explosion increases

Engineering Contradiction:

Improveauxiliary power supply reliabilityVSAvoidexplosion risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the secondary battery with a capacitor that is inherently safer and can be disposed of or replaced more frequently. Capacitors do not have the chemical reactions that can lead to explosion, thus eliminating this harmful factor while maintaining the backup power function.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The patent converts the limitation of capacitors (shorter lifetime) into a benefit by making them replaceable and inexpensive, thereby eliminating the explosion risk associated with secondary batteries. The short lifetime becomes acceptable because the component can be easily replaced without significant cost or complexity.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Productivity

If high-speed memory is used for data backup, then backup speed is improved, but power consumption increases

Engineering Contradiction:

Improvedata backup speedVSAvoidmemory power consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the power supply parameter from a secondary battery with limited capacity to a capacitor that can deliver high power bursts. This parameter change enables the system to power high-speed memory during the brief backup operation without the capacity limitations of a secondary battery.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The capacitor is pre-charged during normal operation when power is abundant, storing energy specifically for the backup operation. This preliminary action ensures that when power interruption occurs, the capacitor can immediately provide the high power needed for fast memory backup without drawing from limited battery capacity.

Inventive Principle:

Principle #10Preliminary action

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 system provides more power efficiently, reduces the risk of accidents, extends the auxiliary power supply's lifetime, and enables faster and safer data backup during power module abnormalities.

Implementation Method 1

a capacitor configured to be charged by the power module and supply accumulated power to the memory unit when the power from the power module to the MCU is interrupted

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentEP3159755B1PLC system

Publication Date: 2021.03.10 LSIS CO LTD

Figure 1~2
Figure 3

AI summary

A PLC system (30) according to the present disclosure includes a memory unit (318) configured to back up user data stored in a MCU thereto when the power supply from the power module is interrupted, a capacitor (308) configured to be charged by the power module and supply accumulated power to the memory unit when the power from the power module to the MCU is interrupted, a variable resistor unit (314) configured to be coupled between the power module and the capacitor, and a switching unit (316) configured to alternatively couple either the power module or the capacitor to the memory unit depending on a state of power being supplied from the power module. The present disclosure has advantages that it can supply much more power while reducing a charging period of time of an auxiliary power supply for supplying power with urgency when an abnormality occurs in a power module of the PLC system.