JP7732201B2 - Power supply control method, uninterruptible power supply, power supply, power supply system, and embedded software program - Google Patents

Description

The present invention relates to technology for updating embedded software programs (hereinafter also referred to as firmware) in power supply devices.

Patent document 1 discloses a method for reprogramming the control program of a vehicle control device.

Japanese Patent Application Laid-Open No. 2020-052960

Various power supply devices, such as uninterruptible power supplies, power conditioners, and electric vehicle chargers, are used as part of social infrastructure. Power supply devices are controlled by firmware stored in their built-in memory. Firmware updates for power supply devices have traditionally been performed by shutting down the power supply at a time when the impact is expected to be minimal.

Given the intended use of the power supply, it is not desirable to stop power input and output to the power supply for an extended period of time in order to update firmware.

The present invention aims to provide a power supply control method, an uninterruptible power supply, a power supply, a power supply system, and an embedded software program that properly execute firmware updates.

A power supply device control method according to one aspect of the present invention continues at least one of power output and power input by continuing operation of a power converter included in the power supply device, acquires update data for the power supply device's firmware while continuing at least one of power output and power input of the power supply device and stores it in a non-transitory storage medium included in the power supply device, and, after storage of the update data in the non-transitory storage medium is completed, causes a control unit included in the power supply device to start processing based on the updated firmware.

FIG. 2 is a block diagram showing the configuration of a power supply device. 10 is a flowchart illustrating an example of a firmware update procedure performed by a control unit. 4 is a timing chart showing the state of the power supply device. FIG. 10 is a block diagram showing the configuration of a power supply device according to a second embodiment. 10 is a flowchart illustrating another example of a firmware update procedure performed by the control unit. FIG. 1 is a schematic diagram of a system equipped with multiple power supply devices. FIG. 1 is a schematic diagram of a system equipped with multiple power supply devices.

A control method for a power supply device continues at least one of power output and power input by continuing operation of a power converter provided in the power supply device, acquires update data for the firmware of the power supply device while continuing at least one of power output and power input of the power supply device, stores the update data in a non-transitory storage medium provided in the power supply device, and, after storage of the update data in the non-transitory storage medium is completed, causes a control unit provided in the power supply device to start processing based on the updated firmware.

Here, the power supply device may be an uninterruptible power supply (hereinafter referred to as UPS), a power conditioner (hereinafter referred to as PCS), or a charger (or charger/discharger) for a storage element mounted on an electric vehicle or the like. The power supply device is not limited to these.
The power converter may be a so-called converter that converts AC power to DC power, or a so-called inverter that converts DC power to AC power. The power converter may be a converter that converts DC power into DC power of a different voltage value. The power supply device may include multiple power converters (e.g., converters and inverters).
The non-transitory storage medium may be part of the control unit.

When acquiring firmware update data, the power supply device may acquire firmware data divided into multiple parts in multiple installments.

The non-transitory storage medium on which the firmware update data is stored in the power supply device may be a storage medium built into the computer (e.g., a microcomputer) or an external storage medium.

When processing based on the updated firmware begins, for example, the CPU of the restarted computer accesses the area storing the code of the updated firmware that should be executed first. This corresponds to the process of making the updated firmware executable.

The power supply control method configured as described above allows the power converter (converter and/or inverter) to continue operating, and allows the power supply to continue outputting and/or inputting power while firmware update data is acquired and stored in the power supply's non-transitory storage medium. This reduces the possibility of the power supply to be shut down for an extended period of time.

Power supply devices such as UPSs and PCSs are used as infrastructure, and it is not desirable to stop the power input and output of the power supply devices for an extended period of time in order to update their firmware. If a power outage occurs during a firmware update, a conventional UPS cannot supply backup power to electrical loads and cannot perform its expected functions. A conventional PCS cannot convert or input/output power during a firmware update, resulting in opportunity losses (for example, the inability to sell or store electricity generated by solar cells, or the missed opportunity to respond to demand).

The power supply control method configured as described above allows the power supply to continue inputting and outputting power during the update data acquisition process, which takes a relatively long time (e.g., several minutes to several hours) during the entire firmware update period. The process of making the updated firmware executable after data acquisition is complete can be completed in a relatively short time (e.g., one second to several tens of seconds). This reduces the possibility of the power supply to stop inputting and outputting power for an extended period of time.

In the power supply device control method, after multiple power supply devices included in the system have completed obtaining the firmware update data and storing it in the non-temporary storage medium, the updated firmware in those multiple power supply devices may be made executable collectively.

For example, in situations where a large capacity (high VA) power output is required, a system is configured by connecting multiple power supply devices in parallel. Firmware updates must be performed on each of the multiple power supply devices. When multiple power supply devices sequentially receive firmware update data from a higher-level control device (e.g., a network interface card) via communication, it takes a long time for all of the multiple power supply devices to complete the acquisition and storage of the data.
According to the power supply device control method having the above configuration, power input/output to each power supply device continues during data acquisition and storage processes in the multiple power supply devices, which takes a long time, thereby minimizing the period during which power input/output is stopped.

In the power supply device, the update data may be stored in a storage area of the non-transitory storage medium that is different from the area in which the firmware is stored. After the update data has been stored in the non-transitory storage medium, the control unit sets the storage area in which the update data has been stored as an operating area.
This allows the power supply device to operate with the updated firmware after the update data has been stored, while minimizing the period during which power input and output is stopped.

The control unit may copy at least a part of the firmware to a temporary storage medium to continue at least one of power output and power input. Update data may be stored in a non-temporary storage medium while the control unit is performing control based on the firmware on the temporary storage medium.
With the above configuration, even if the non-temporary storage medium does not have sufficient storage capacity to simultaneously store both the update data and the firmware currently being executed, the power supply device can continue to input and output power. By storing the minimum code for power input and output within the firmware in the temporary storage medium and temporarily setting it as an active area, the power supply device can continue to input and output power.

The UPS includes a power converter, a non-temporary storage medium, and a control unit that executes control based on firmware. The control unit continues operation of the power converter to continue power output, acquires firmware update data while continuing power output and stores it in the non-temporary storage medium, and after the update data has been stored in the non-temporary storage medium, switches to bypass power supply and starts processing based on the updated firmware. The non-temporary storage medium may be part of the control unit.

For example, a continuous inverter power supply UPS converts AC power supplied from a grid power source such as a commercial power supply into DC power using a converter. The converter supplies the DC power to a storage element such as a storage battery (charging the storage battery) and also supplies it to an inverter. The inverter converts the DC power into AC power, rectifies it, and supplies it to an electrical load. Alternatively, the UPS may be a parallel processing type or a continuous commercial power supply type.
With a UPS configured as described above, the power converter continues to operate during the update data acquisition process, which takes a relatively long time during the entire firmware update process, and the UPS can supply backup power to the electrical load even if a power outage occurs, thereby fulfilling the functions expected of a UPS.

The power supply device includes a power converter, a non-transitory storage medium, and a control unit that executes control based on firmware, wherein the control unit continues operation of the power converter to continue at least one of power output and power input, acquires update data for the firmware while continuing at least one of power output and power input, stores the update data in the non-transitory storage medium, and starts processing based on the updated firmware after storage of the update data in the non-transitory storage medium is completed. The non-transitory storage medium may be part of the control unit.
The power supply system is configured by connecting a plurality of the power supply devices described above. The plurality of power supply devices may be electrically connected in parallel or in series for power input and/or power output.
The embedded software program causes a control unit provided in the power supply device to continue operating a power converter provided in the power supply device, acquire update data for the firmware of the power supply device and store it in a non-temporary storage medium, and start processing based on the updated firmware after storage of the update data in the non-temporary storage medium is completed.

The present invention will now be described in detail with reference to drawings showing embodiments thereof.

(First embodiment)
1 is a block diagram showing the configuration of a power supply device 1. The power supply device 1 includes a control unit 10, a power storage unit 11, a charge/discharge circuit 12, and a communication unit 13.

The control unit 10 is a microcontroller. The control unit 10 includes a CPU (Central Processing Unit) 100, a ROM (Read Only Memory) 101, a RAM (Random Access Memory) 102, and an I/O (Input/Output) 103.

CPU 100 is an execution unit that sequentially reads firmware stored in ROM 101 and executes control processing according to the control procedures defined in the firmware. ROM 101 is, in principle, a non-temporary memory that is read-only by CPU 100. The operating area of ROM 101 is rewritable. ROM 101 has a temporary storage area outside the operating area. ROM 101 is used in a read mode, in which only reading is permitted, and an erase/rewrite mode, in which rewriting is permitted but reading is not. ROM 101 is, for example, a flash memory. As described above, ROM 101 stores firmware read by CPU 100. The firmware read by CPU 100 is stored in the operating area within ROM 101. ROM 101 stores control firmware 2P for charge/discharge control and rewrite firmware 1P for executing the update process described below while power supply device 1 is operating.

RAM 102 is temporary memory used by CPU 100 for calculations. CPU 100 writes the results of calculations to RAM 102 and reads them as it proceeds with processing. Data stored in RAM 102 is volatilized when control unit 10 is restarted.

The power storage unit 11 includes a power storage element. The power storage unit 11 is connected to the power grid E directly or via a charge/discharge circuit 12. The control unit 10 may receive power from the power storage unit 11.

The charge/discharge circuit 12 includes an inverter and/or converter. The charge/discharge circuit 12 is connected to an electrical load. In response to commands from the control unit 10, the charge/discharge circuit 12 supplies power from the system power supply E to the electrical load, charges the storage element from the system power supply E, or supplies power from the storage element to the electrical load. The configuration of the charge/discharge circuit 12 varies depending on the type of power supply device 1 (UPS, PCS, or DC power supply device).

The communication unit 13 is a communication device for communicating with the higher-level device 2 or an external storage medium (e.g., USB memory) not shown. The communication unit 13 may be, for example, a network interface card, or may be configured to allow attachment of an external storage medium. For example, the control unit 10 receives instructions from the higher-level device 2 via the communication unit 13. The control unit 10 receives firmware update data via the communication unit 13. The higher-level device 2 may be a maintenance terminal device that transmits update data for control firmware 2P to the power supply device 1 via a local network, or may be a network interface card connected to multiple power supply devices 1. The higher-level device 2 may be a server device that issues instructions to the power supply device 1 or collects data from the power supply device 1 via a communication network including the Internet.

Figure 2 is a flowchart showing an example of the firmware update processing procedure performed by the control unit 10. The CPU 100 of the control unit 10 copies a portion of the rewrite firmware 1P and the control firmware 2P to the RAM 102 and executes the following processing. The portion of the control firmware 2P copied to the RAM 102 corresponds to the minimum functions such as control of the charge/discharge circuit 12 and power outage/abnormality detection.

The CPU 100 determines whether firmware update data has been received via the communication unit 13 (step S101). If it determines that firmware update data has not been received (S101: NO), the CPU 100 returns to step S101 and repeats the process until it determines that firmware update data has been received. In this case, the control unit 10 continues charge/discharge control using the control firmware 2P in the ROM 101. The ROM 101 is in read mode.

If it is determined that firmware update data has been received (S101: YES), the CPU 100 analyzes the received data (step S102). The CPU 100 determines whether the received data has reached a specified number of bytes (step S103). If it is determined that the received data has not reached the specified number of bytes (S103: NO), the CPU 100 returns to step S101. If it is determined that the received data has reached the specified number of bytes (S103: YES), the CPU 100 switches the ROM 101 to erase/rewrite mode (step S104) and writes the received update data directly to the ROM 101 (step S105). During this time, the CPU 100 continues to control charging and discharging on the RAM 102, for example, to maintain power supply to an electrical load. After writing is complete, the CPU 100 switches the ROM 101 to read mode (step S106).

In step S105, the CPU 100 may store the firmware update data in a temporary storage area of the ROM 101. In this case, the data of the control firmware 2P before the update remains in the operation area of the ROM 101, so even if an error occurs during writing, operation with the control firmware 2P before the update can be started.
While the writing is being performed, the CPU 100 continues to control charging and discharging on the RAM 102, for example, to maintain the power supply to the electric load.

The CPU 100 determines whether data reception is complete (step S107). If it determines that data reception is not complete (S107: NO), the CPU 100 returns to step S101 and continues the reception and writing process.

If it is determined in step S107 that data reception has been completed (S107: YES), the CPU 100 temporarily stops operation of the charge/discharge circuit 12 (step S108). If the power supply device 1 is a UPS, the CPU 100 switches the power supply method to the electrical load to bypass power supply.

The CPU 100 restarts the power supply device 1 using an internal reset or the like (step S109). The restart resets the update process, and the power supply device 1 resumes normal operation. The restart also resets a portion of the rewrite firmware and control firmware that had been copied to RAM 102.

If the control firmware 2P data is stored in the temporary storage area of the ROM 101, the CPU 100 temporarily stops the operation of the charge/discharge circuit 12 in step S108, and then restarts it in step S109, moving the updated control firmware 2P data to the operating area of the ROM 101. The movement of the control firmware 2P data is completed in less than one second or approximately one second.

This allows the power supply device 1 to continue functioning even while receiving and storing firmware update data, which can take a long time. Receiving firmware update data can take anywhere from several minutes to several hours. The power supply device 1 only stops its functions (power input/output) during restart, which includes the time it takes to copy (move) the updated control firmware 2P from the temporary storage area of ROM 101 to the operating area, and lasts for no more than a few tens of seconds.

Figure 3 is a timing chart of the state of the power supply device 1. Figure 3 shows the passage of time from the top to the bottom of the vertical axis. Figure 3 shows the progression of states when the power supply device 1 is a UPS and when it is a PCS.

If the power supply device 1 is a UPS with a continuous inverter power supply system, after receiving an update request (update data) from the higher-level device 2, it maintains power supply from the inverter to the electrical load until the update data for the control firmware 2P has been received. After the update data for the control firmware 2P has been received, the UPS maintains bypass power supply while stopping the charge/discharge circuit 12 (inverter). After copying the updated control firmware 2P data to the operating area has been completed, the UPS begins control of the charge/discharge circuit 12, including the inverter, and can begin supplying power from the inverter. In this way, the time that the UPS stops supplying power to the inverter can be minimized.

When the power supply device 1 is a PCS, downtime can be minimized after receiving an update request (update data) from the higher-level device 2. The PCS can continue operating until it has completely received the update data for the control firmware 2P. After it has completely received the update data for the control firmware 2P, the PCS quickly restarts, including transferring data. During this time, the PCS stops functioning, but the downtime is shorter than with conventional update methods.

With the conventional update method shown in Figure 3, the firmware becomes unreadable from ROM 101 upon receiving an update request (update data), and operation of the UPS or PCS stops. After receiving the firmware update data and copying it to the operating area of ROM 101 is complete, the UPS or PCS resumes operation. If it takes several minutes to several hours to receive the data, the UPS or PCS will not be able to perform its expected functions during that time.

In contrast, if the power supply unit 1 updates the control firmware 2P using the processing procedure in Figure 2, the time during which the power supply unit 1 functions can be minimized.

Second Embodiment
4 is a block diagram showing the configuration of the power supply device 1 in the second embodiment. The control unit 10 has a plurality of (two) ROMs 101 that can be read by the CPU 100. The configuration of the power supply device 1 is the same as that of the power supply device 1 in the first embodiment, except for the number of ROMs 101 and the following processing procedure. The same reference numerals are used for common components, and detailed explanations will be omitted.

Figure 5 is a flowchart showing another example of the firmware update processing procedure performed by the control unit 10. Among the processing procedures shown in Figure 5, steps common to those in Figure 2 are assigned the same step numbers and detailed descriptions are omitted.

If the CPU 100 determines that the received update data has reached the specified number of bytes (S103: YES), it places the other ROM 101, which is different from the one ROM 101 used in read mode as the operating area, in erase/rewrite mode (step S124) and writes the data (step S125).

The CPU 100 determines whether data reception is complete (S107), and if it determines that data reception is not complete (S107: NO), the CPU 100 returns the process to step S101 and continues receiving and writing.

If it is determined that data reception is complete (S107: YES), the CPU 100 temporarily suspends operation of the charge/discharge circuit 12 (S108) and restarts it using an internal reset or the like (step S109). Upon restarting, the ROM 101 storing the updated control firmware 2P becomes the active area of the CPU 100, and the ROM 101 that was in use becomes the next target for updating the control firmware 2P.

The configuration of the power supply device 1 in the second embodiment allows the charge/discharge circuit 12 to continue operating even while firmware update data is being received and stored, which takes a long time. In the second embodiment, the power supply device 1 also stops functioning only during the restart period.

By updating the control firmware 2P in the power supply device 1 using the processing procedure shown in the first or second embodiment, the amount of time that power supply to the electrical load is stopped can be minimized throughout the entire system, including the power supply device 1, as described below.

6 and 7 are schematic diagrams of systems 200 and 300 equipped with multiple power supply devices 1. System 200 in FIG. 6 includes multiple UPSs 1. The multiple UPSs 1 are connected in parallel. System 200 also includes a router 3 on a local network LN. In system 200, a maintenance terminal device (host device) 2 carried by a maintenance technician connects to the router 3 and causes multiple UPSs 1 to perform update processing via the router 3. The host device 2 stores update data for the control firmware 2P in each UPS 1. Receiving and storing the update data takes several minutes to several hours per UPS 1. While each UPS 1 receives and stores the update data, each UPS 1 can continue to supply power to the electrical load by using the firmware update method of the first or second embodiment. After the update data has been stored in ROM 101 (see FIGS. 1 and 4) in the multiple UPSs 1, the updated firmware in those multiple UPSs 1 can be executed collectively.

The system 300 in Figure 7 includes multiple PCSs 1 connected via serial communication. The system 300 also includes a router 3 that connects the local network LN to an external network. The PCSs 1 can communicate with the power server 4 via the public communication network N using a communication unit 13 (see Figures 1 and 4). In the system 300, the communication unit 13 of a specific PCS 1 among the multiple PCSs 1 connects via the router 3 to a maintenance terminal device (host device) 2 carried by a maintenance technician. The other PCSs 1 are communicatively connected via serial communication cables. The host device 2 transmits update data for the control firmware 2P to each PCS 1 in turn. After the update data has been stored in each PCS 1 using the firmware update method of the first or second embodiment, the updated firmware in the multiple UPSs 1 can be executed collectively.

Although not shown, the power supply device 1 may be equipped with multiple control units 10 (CPUs 100). In this case, the higher-level device 2 may request a firmware update from each control unit 10, or may request a firmware update for all multiple control units 10, with the updates being performed in parallel.

The embodiments disclosed above are illustrative in all respects and are not restrictive. The scope of the present invention is defined by the claims, and includes all modifications that are equivalent to and within the scope of the claims.

1 Power supply device 10 Control unit 100 CPU (execution unit)
101 ROM (non-temporary storage medium)
102 RAM (temporary storage medium)
1P Rewrite firmware 2P Control firmware 12 Charging/discharging circuit 13 Communication unit 2 Upper device

Claims (8)

a control unit provided in the power supply device, when starting to receive update data for the firmware of the power supply device, copies a portion of the firmware before the update to a temporary storage medium, the portion being used to continue at least one of the power output and the power input of the power supply device;
the control unit continues operation of a power converter included in the power supply device by executing the part copied to the temporary storage medium, thereby continuing at least one of power output and power input;
the control unit acquires update data for the firmware of the power supply device while at least one of the power output and the power input is continuing , and stores the update data in a non-transitory storage medium provided in the power supply device;
the control unit, after completing the storage of the update data in the non-temporary storage medium, starts processing based on the updated firmware without waiting to determine an operating status of a system including the power supply device .
A method for controlling a power supply. After the acquisition of the firmware update data and the storage of the firmware update data in the non-temporary storage medium are completed in the plurality of power supply devices included in the system,
The power supply device control method according to claim 1 , wherein updated firmware can be executed collectively in a plurality of the power supply devices. storing the update data in a storage area in the non-transitory storage medium that is different from an area in which the firmware is stored;
After the storage of the update data in the non-transitory storage medium is completed,
The method for controlling a power supply device according to claim 1 or 2, wherein the control unit sets the storage area in which the update data is stored as an operating area. The part corresponds to a function of rewriting the firmware, controlling a charge/discharge circuit of the power supply device, and detecting a power outage or an abnormality.
3. A method for controlling the power supply device according to claim 1. a power converter;
a non-transitory storage medium;
a control unit that executes control based on firmware,
The control unit
When reception of update data for the firmware of the power converter is started, a part of the firmware before the update is stored in a temporary storage medium for continuing power output of the power converter;
Executing the part copied to the temporary storage medium to continue operation of the power converter and continue power output;
acquiring update data for the firmware while the power output is continuing and storing the data in the non-transitory storage medium;
after completing the storage of the update data in the non-temporary storage medium, switching to bypass power supply without waiting to determine an operating state of a system including the power converter ;
Start processing based on the updated firmware,
Uninterruptible power supply. a power converter;
a non-transitory storage medium;
a control unit that executes control based on firmware,
The control unit
When reception of update data for the firmware of the power converter is started, a part of the firmware before the update is stored in a temporary storage medium in order to continue at least one of the power output and the power input of the power converter;
Executing the part copied to the temporary storage medium to continue operation of the power converter and continue at least one of power output and power input;
acquiring update data for the firmware while at least one of the power output and the power input is continuing and storing the data in the non-transitory storage medium;
after completing the storage of the update data in the non-temporary storage medium , starting processing based on the updated firmware without waiting to determine an operating status of a system including the power converter.
power supply. A power supply system comprising multiple power supply devices according to claim 6. The control unit of the power supply device includes:
When the power supply device starts receiving update data for the embedded software program, copying a portion of the embedded software program before the update to a temporary storage medium, the portion being used to continue at least one of the power output and the power input of the power supply device;
By executing the part copied to the temporary storage medium, the operation of the power converter provided in the power supply device is continued, thereby continuing at least one of power output and power input;
acquiring update data for the embedded software program of the power supply device while the power output and/or the power input of the power supply device is being continuously acquired and stored in a non-transitory storage medium;
after completing the storage of the update data in the non-transitory storage medium, starting processing based on the updated embedded software program without waiting to determine the operating status of the system including the power supply device ;
An embedded software program that performs processing.