Patent Grant
9368306
The present invention is directed to powering electrical devices and more particularly relates to a configurable multi-pole relay system.
The installation of electrical wiring and equipment may involve installing electromechanical relays in a building or other structure. Electromechanical relays are used to switch electrical circuits between different states. For example, an electromechanical relay may include a switch in an electrical circuit that is used to switch the electrical circuit between an “ON” state in which current flows through the electrical circuit and an “OFF” state in which no current flows through the electrical circuit.
Multi-pole electromechanical relays may be used to simultaneously (or near simultaneously) change the respective states of multiple electrical circuits in an electrical system. For example, a multi-pole relay can have multiple switches that are electrically connected to different electrical circuits. The switches of the multi-pole relay may be actuated simultaneously (or near simultaneously) such that the different electrical circuits switch between states at or near the same time.
Prior solutions for providing multi-pole relays for use in a field environment present disadvantages. For example, a technician may not know the appropriate number of poles for a multi-pole relay in advance or may be tasked with modifying the electrical system to include additional electrical circuits for simultaneous actuation. In one example, a technician may mistakenly bring a two-pole relay to a job requiring a three-pole relay. In another example, modifying an electrical system that currently uses a two-pole relay such that the electrical system uses a three-pole relay may require removing an existing two-pole relay. These disadvantages associated with current multi-pole relays can increase the time and complexity involved in installing or modifying electrical systems.
It is therefore desirable to provide a configurable multi-pole relay system for installation in electrical systems.
In some aspects, a configurable multi-pole relay system is provided. The configurable multi-pole relay system can include at least two relay modules and a connecting structure for connecting the relay modules together. The first relay module can include a first switch that can be electrically connected to a first electrical circuit. The second relay module can include a second switch that can be electrically connected to a second electrical circuit. The connecting structure can include first and second physical connectors. The first physical connector can be attached to a first interlocking portion of the first relay module. The second physical connector can be attached to a second interlocking portion of the second relay module.
These and other aspects, features and advantages of the present invention may be more clearly understood and appreciated from a review of the following detailed description and by reference to the appended drawings and claims.
Certain aspects of the invention provide a configurable multi-pole relay system. The configurable multi-pole relay system can include multiple relay modules, such as electromechanical relays. A connecting structure can physically connect or otherwise couple the relay modules together. For example, the connecting structure can include multiple physical connectors suitable for attachment to various interlocking portions of respective relay modules (e.g., manual switches for actuating the relay modules). A non-limiting example of a connecting structure can include a tie-bar or other connecting member. Connecting multiple relay modules to provide a configurable multi-pole relay system can accommodate the multi-pole specifications of particular installations.
In some aspects, the portions of the relay modules that interlock with the connecting structure can include actuating levers or other actuation mechanisms for the relay modules. In one non-limiting example, the physical connectors of the connecting structure may be receptacles into which corresponding actuating levers or other interlocking portions of the relay modules can be inserted. The receptacles can be sized such that inserting multiple actuating levers into respective receptacles of the connecting structure can allow the actuating levers of different relay modules to be moved together in a single physical motion. In other aspects, the physical connectors of the connecting structure can be protrusions that can be inserted into corresponding interlocking portions of the relay modules. For example, the connecting structure can include locking tabs that can be inserted into receptacles on the relay modules (e.g., portions of the actuating levers defining grooves that can receive the locking tabs).
In some aspects, a configurable multi-pole relay system can be installed in a control panel for a lighting system or another electrical system. A control panel can include slots for multiple single-pole modular relays. The multiple single-pole relay modules of the multi-pole relay system can be positioned in adjacent slots of the control panel. An installer can physically connect or couple (i.e., “link”) adjacent single-pole relay modules with a tie-bar or other connecting structure. Physically connecting or otherwise coupling adjacent single-pole relay modules with a tie-bar or other connecting structure can provide a multi-pole relay system that can function as a multi-pole relay, such as (but not limited to) a two-pole relay or a three-pole relay. The multi-pole relay configuration can be selected by an installer in the field in accordance with lighting specifications or other electrical specifications for a building or other structure.
Detailed descriptions of certain aspects and examples are discussed below. These illustrative examples are given to introduce the reader to the general subject matter discussed here and are not intended to limit the scope of the disclosed concepts. The following sections describe various additional aspects and examples with reference to the drawings in which like numerals indicate like elements, and directional descriptions are used to describe the illustrative examples but, like the illustrative aspect examples, should not be used to limit the present invention.
In some aspects, software configuration can be performed on control electronics to which the multi-pole relay system 100 can be electrically connected. A respective driving circuit or other device in the control electronics can be configured to output a driving signal to one or more of the relay modules 102a-c. The driving circuits or other devices can be configured via software to provide a synchronized driving circuit to all of the relay modules 102a-c. Providing a synchronized driving circuit to all of the relay modules 102a-c can allow the relay modules 102a-c to be cycled or otherwise actuated simultaneously as a single multi-pole relay system.
A connecting structure 108 can be used to physically connect or otherwise couple the relay modules 102a-c to form the multi-pole relay system 100. The connecting structure 108 can be formed from any suitable rigid or semi-rigid material, such as (but not limited to) rubber or plastic. A non-limiting example of a connecting structure 108 is a snap-on bridging connector.
The connecting structure 108 can include three receptacles 112a-c. Each of the receptacles 112a-c can be formed to surround (in whole or in part) and engage a respective one of the actuating levers 104a-c. Each of the receptacles 112a-c can be formed to have a sufficient size that the receptacle contacts one or more edges of a corresponding actuating lever. The receptacles 112a-c contacting one or more edges of each of the actuating levers 104a-c can exert sufficient force to cause the connecting structure 108 to be retained in place.
In some aspects, the connecting structure 108 can be formed such that the receptacles 112a-c are integral with the connecting structure 108. In other aspects, the receptacles 112a-c can be separate structures that can be connected or otherwise coupled to the connecting structure 108. In some aspects, the receptacles 112a-c can have a fixed position along the length of the connecting structure 108. In other aspects, one or more of the receptacles 112a-c can have a movable position along the length of the connecting structure 108. A connecting structure 108 having movable receptacles can be configured for differently sized or differently spaced relay modules in the configurable multi-pole relay system 100.
The connecting structure 108 can be removed from the relay modules 102a-c by applying a force to the connecting structure 108 in a direction away from the relay modules 102a-c. Removing the connecting structure 108 can allow the relay modules 102a-c to be re-configured into a different multi-pole relay system, such as a relay system greater than or fewer than three poles, using a different connecting member with greater than or fewer than three receptacles. The connecting structure 108 being removable allows the connecting structure 108 to be removed and re-applied in the multi-pole relay system 100.
In additional or alternative aspects, the configurable multi-pole relay can include an additional connecting structure for connecting the relay modules 102a-c to on another. For example,
Differently sized connecting structures can be selected for multi-pole relay systems having different numbers of relay modules. For example,
Although
The configurable multi-pole relay system 100 allows multiple single-pole relays to be connected to form a multi-pole relay. For example,
Using individual relay modules 102a-c to provide a configurable multi-pole relay system 100 can provide improved flexibility over a relay system having a fixed number of switches. In one example, although
Although
The connecting structure 108′ and the protrusions 502a-c can be formed from any suitable rigid or semi-rigid material, such as (but not limited to) rubber or plastic. In some aspects, the protrusions 502a-c can be integral with the connecting structure 108′. In other aspects, the protrusions 502a-c can be separate structures that are attached to the connecting structure 108′. In some aspects, the protrusions 502a-c can have a fixed position with respect to one another. For example, the connecting structure 108′ can be manufactured with the protrusions 502a-c in fixed positions for connecting relay modules 102a-c having specific widths. In other aspects, one or more of the protrusions 502a-c can be movable along a longitudinal axis or other length of the connecting structure 108′. Such movable protrusions can be used to use relay modules 102a-c having different widths in the same multi-pole relay system 100.
Each of the receptacles 504a-c can be formed to surround (in whole or in part) and engage a respective one of the protrusions 502a-c. Each of the receptacles 504a-c can be formed with a sufficient size that the receptacle contacts one or more edges of a corresponding protrusion. In some aspects, the receptacles 504a-c contacting one or more edges of the corresponding protrusions 502a-c can exert sufficient force to cause the connecting structure 108′ to be retained in place. In other aspects, the protrusions 502a-c and/or the receptacles 504a-c can include additional structures, such as retaining or locking tabs, that can maintain each of the protrusions 502a-c in a fixed position within a respective one of the receptacles 504a-c.
In some aspects, the receptacles 504a-c can be integral with the actuating levers 104a′-c′. In other aspects, the receptacles 504a-c can be separate structures that are attached to the actuating levers 104a′-c′ via any suitable process, such as applying an adhesive to the actuating lever or the structure defining the receptacle. In additional or alternative aspects, the receptacles 504a-c can be separate structures that are attached to the portions of the relay modules 102a-c other than the actuating levers 104a′-c′.
The exemplary method 600 involves providing first and second relay modules having respective first and second switches that are electrically connectable to respective first and second electrical circuits, as depicted in block 610. For example, relay modules 102a, 102b can be selected for an electrical system by a technician. The relay modules 102a, 102b can be attached to a rail 110 at appropriate positions (e.g., adjacent to one another).
The exemplary method 600 further involves attaching a first physical connector of a connecting structure to a first interlocking portion of the first relay module, as depicted in block 620. In one non-limiting example, physical connectors of a connecting structure 108 can include receptacles 112a-c. An interlocking portion of a relay module 102a can be the actuating lever 104a. The connecting structure 108 can be attached to the relay module 102a by inserting the actuating lever 104a into one of the receptacles 112a-c. In another non-limiting example, a connecting structure 108′ can include physical connectors such as protrusions 502a-c. An interlocking portion of a relay module 102a can be a receptacle 504a that is attached to or integral with the actuating lever 104a. The connecting structure 108 can be attached to the relay module 102a by inserting one of the protrusions 502a-c into the receptacle 504a.
The exemplary method 600 further involves attaching a second physical connector of the connecting structure to a second interlocking portion of the second relay module, as depicted in block 630. For example, an actuating lever 104b of a relay module 102b can be inserted into another one of the receptacles 112a-c of a connecting structure 108 or another one of the protrusions 502a-c of a connecting structure 108′ can be inserted into a receptacle 504b of the actuating lever 104b.
The exemplary method 600 further involves simultaneously actuating the first and second relay modules using the connecting structure attached to the first and second interlocking portions, as depicted in block 640. For example, the connecting structure 108 being attached to actuating levers 104a, 104b can cause the relay modules 102a, 102b to be actuated simultaneously or near simultaneously.
In one non-limiting example, an electrical current can be provided to a coil or other actuating mechanism of a switch 402a of the relay module 102a. The switch 402a can be physically connected to the actuating lever 104a. The current provided to the coil or other actuating mechanism of a switch 402a can move the switch 402a between an “ON” position and an “OFF” position. The switch 402a being moved between the “ON” position and the “OFF” position can cause the actuating lever 104a to move between the “ON” position and the “OFF” position. The actuating lever 104a moving between the “ON” position and the “OFF” position can apply a force to the connecting structure 108 that is attached to the actuating lever 104b of the relay module 102a. The force applied to the connecting structure 108 can move the connecting structure 108. A physical connector of the connecting structure 108 being attached to the actuating lever 104b can cause a corresponding force to be applied to the actuating lever 104b. The force applied to the actuating lever 104b can cause the actuating lever 104b to move between an “ON” and an “OFF” position. The actuating lever 104b moving between an “ON” and an “OFF” position can cause a switch 402b of the relay module 102b to move between the “ON” position and the “OFF” position simultaneously (or near simultaneously) with the movement of the switch 402a.
In another non-limiting example, a force can be applied to a point along a connecting structure 108 that is attached to actuating levers 104a, 104b. The force applied to the connecting structure 108 can move the connecting structure 108. The physical connectors of the connecting structure 108 can cause a corresponding force to be applied to the actuating levers 104a, 104b such that the actuating levers 104a, 104b simultaneously (or near simultaneously) move between an “ON” and an “OFF” position.
In some aspects, the connecting structure 108 can have physical connectors (e.g., receptacles 112a-c, protrusions 502a-c) in fixed positions with respect to one another. A suitable connecting structure 108 for coupling the relay modules 102a, 102b together can be selected based on the positions of the physical connectors along the connecting structure 108. For example, a connecting structure can be selected based on the positions of the physical connectors corresponding to a distance between interlocking portions of the respective relay modules 102a, 102b, such as (but not limited to) the distance between the actuating levers 104a, 104b when the relay modules 102a, 102b are attached to a rail 110.
In other aspects, the connecting structure 108 can have physical connectors (e.g., receptacles 112a-c, protrusions 502a-c) that are movable along a length of the connecting structure 108. One or more of the physical connectors can be moved into an appropriate position such that the connecting structure 108 can couple the relay modules 102a, 102b together. For example, one or more of the physical connectors can be moved to positions along the connecting structure 108 such that a distance between the physical connectors corresponds to a distance between interlocking portions of the respective relay modules 102a, 102b (e.g., the distance between the actuating levers 104a, 104b when the relay modules 102a, 102b are attached to a rail 110).
The foregoing description of the examples, including illustrated examples, of the invention has been presented only for the purpose of illustration and description and is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Numerous modifications, adaptations, and uses thereof will be apparent to those skilled in the art without departing from the scope of this invention. The illustrative examples described above are given to introduce the reader to the general subject matter discussed here and are not intended to limit the scope of the disclosed concepts. The terms “invention,” “the invention,” “this invention” and “the present invention” used in this patent are intended to refer broadly to all of the subject matter of this patent and the patent claims below. Statements containing these terms should not be understood to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.
This application claims priority to U.S. Provisional Application Ser. No. 61/762,134 filed Feb. 7, 2013 and titled “Configurable Multi-Pole Relay,” the contents of which are hereby incorporated by reference.
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