Patent Grant
7417384
The invention generally pertains to controlling electrical loads, and more specifically, to load control systems and methods.
Controls for adjusting the level of artificial lighting are commonplace, ranging from the simple household dimmer switch to extensive lighting circuits used in stage productions. These lighting controls play a significant role in the ambiance of a room.
Early lighting controls relied on variable resistors to dissipate power, thereby “dimming” the lights. Although functional, these early lighting controls wasted power and generated significant heat. Modern lighting controls use triacs. Triacs function by varying the point that a load is turned on during each alternating current (AC) cycle (in the United States, AC current has 60 cycles per second). That is, triacs vary the time at which the load is switched on after zero-cross during each AC cycle. This rapid “switching” serves to reduce the total current being delivered to the lights. But this rapid switching can also cause a “buzzing” sound in the light, as well as electromagnetic interference. Accordingly, most triacs include circuits with an inductor choke and an interference capacitor.
While simple lighting controls, such as the household dimmer switch, may be suitable for controlling a few lights, other lighting circuits may require different current-capacity triacs. By way of example, a banquet hall may require one or more higher current capacity triacs than the reception area of an office. In addition, a single room may have multiple light circuits requiring different current capacity triacs. For example, a higher-current capacity triac may be provided for the main lighting circuit in a room, and another, smaller capacity triac may be provided for a perimeter lighting circuit (e.g., to illuminate artwork hanging on the walls) in the same room.
Although triacs produce less heat than the early variable resistor dimmer switches, triacs still produce heat. Logically, triacs carrying higher current produce even more heat that needs to be dissipated. Accordingly, triacs carrying higher current are provided with larger heat sinks (e.g., having fins), or even fans to dissipate the heat that is generated by the triac. However, large heat sinks and fans are not aesthetically pleasing and fans can be noisy, typically requiring that these triacs be installed in utility closets or the like.
Manufacturing different current capacity triacs is also expensive. Not only is the related circuitry (e.g., inductor chokes and interference capacitors) more expensive for higher current capacity triacs, but the manufacturer must also maintain a large inventory of different size parts for manufacturing each of the different current capacity triacs. These direct costs are passed onto the installer, who incurs further overhead by having to maintain an inventory of different current capacity triacs. Eventually, these costs are passed onto the consumer.
An embodiment of load control system may comprise at least two triac devices connected in parallel to a load, the at least two triac devices operable to deliver current to the load. At least one driver circuit is linked to the at least two triac devices. A controller is linked to the at least one driver circuit, the controller signaling the at least one driver circuit to actuate the at least two triac devices at about the same time.
An embodiment of a method for controlling at least one load may comprise the steps of: reconfigurably connecting at least one triac device in parallel with at least one other triac device for providing current to the at least one load; and actuating each of the plurality of triac devices connected in parallel at about the same time to balance the total current delivered to the at least one load substantially the same portions through each of the plurality of triac devices connected in parallel.
Illustrative and presently preferred embodiments of the invention are shown in the drawings, in which:
a) and (b) are high-level schematic diagrams of a load control system according to one embodiment of the invention, illustrating the load control system configured to power (a) a single load, and (b) a plurality of loads;
a) and (b) are high-level schematic diagrams of a load control system according to another embodiment of the invention, illustrating the load control system configured to power (a) a single load, and (b) a plurality of loads.
Embodiments of load control system 100 are shown and described herein according to the teachings of the present invention as it may be used in a building automation environment. For purposes of illustration, load control system 100 may be used to control electrical power to one or more lighting circuits, although other uses are also contemplated as being within the scope of the invention. As an example, the load control system 100 may also be used to control electrical power to electric motors that operate window coverings and ceiling fans.
Load control system 100 is shown in
According to one embodiment, the circuit board 110 is mounted to a cover 120, as shown in
Load control system 100 may be linked in the building automation environment over bus 510 to a control device 520 (e.g., a keypad, a timer, etc.), as shown according to one embodiment in
More specifically, load control system 100 may comprise at least one controller 540 connected to a plurality of driver circuits 550-557 (hereinafter generally referred to as driver(s) 550). Each driver 550 is connected to one of a plurality of triac devices 500-507 (hereinafter generally referred to as triac(s) 500) on the circuit board 110, which control current to the load(s) 530.
According to the teachings of the invention, load control system 100 may be configured by connecting one or more of the triacs 500 in parallel to one or more loads 530. By way of example, load control system 100 is shown configured in
Distributing current through a plurality of parallel connected triacs (e.g., as illustrated in the example of
In addition, it is readily apparent that substantial power savings can be realized by providing current to the load 530 through a plurality of triacs 500 connected in parallel. That is, power (P) is defined as the square of the current (i) flowing through the device times the resistance (R) of the device, or mathematically as P=i2R. As an example, if 4 amps of current are delivered to a load through a single triac, the power (P) consumption is 42R, or 16R Watts. If the same 4 amps is delivered through two triacs connected to the load in parallel (i.e., 2 amps through each triac), the power (P) consumption of each triac is 22R or 4R Watts, and the total power (P) consumption by both triacs is equal to 2×4R Watts or 8 Watts.
The power savings realized by load control system 100 directly translates to lower heat dissipation requirements. Operating load control system 100 at lower temperatures serves to extend the life of its electronic components, increasing the reliability of load control system 100. The lower heat dissipation requirements also allow the load control system 100 to be operated with smaller heat sinks, without the need for unsightly fins or noisy fans. Eliminating the need for elaborate heat sinks lowers manufacturing costs, and load control system 100 can be installed in more convenient locations (e.g., in walls of the building), reducing wiring and installation costs.
The costs of manufacturing load control system 100 are also reduced by using smaller-size electronic components (e.g., inductor chokes and interference capacitors). In addition to the direct cost savings, the manufacturer's inventory costs are also reduced by stocking same-size components as opposed to having to stock different-size components (e.g., for manufacturing different current capacity triac circuits). In addition to the cost savings, it has been found that the use of multiple, smaller-size inductor chokes and interference capacitors in load control system 100 function to better reduce RFI/EMI noise during operation.
As discussed briefly above and in more detail below, load control system 100 can be readily configured (and reconfigured) for use with a variety of different size loads 530 (see, e.g.,
In addition, it is not required that the triacs 500 be arranged in any particular manner to balance the current through the parallel connected triacs, as balancing is achieved by the controller 540 and/or driver circuit(s) 550. Other advantages of load control system 100 will also become readily apparent to one skilled in the art after having become familiar with the teachings of the invention.
Having briefly described load control system according to an embodiment of the invention, as well as some of its features and advantages, embodiments of the invention will now be described in detail.
Load control system 100 is shown according to one embodiment in
Triac 500 is shown thermally coupled to the heat sink 140 in
It is understood that the invention is not limited to use with heat sink 140. In other embodiments, the cover 120 need not comprise a heat sink 140. For example, one or more heat sinks may be provided for the control circuitry independently of cover 120. In other embodiments, a heat sink does not need to be provided at all.
The cover 120 may be mounted to housing 300 so that the circuit board 110 is at least partially enclosed, as shown in
Although in one embodiment, housing 300 is manufactured from sheet metal, it is understood that housing 300 may be manufactured from any of a wide variety of other materials (e.g., plastic). It is also understood that cover 120 can be attached to housing 300 in any suitable manner. For example, cover 120 may be attached to housing 300 by hinges, snaps, adhesives, and so forth.
Load control system 100 may be mounted to a building wall 400, as shown according to one embodiment in
Trim plate 410 may be positioned over the cover 120 for aesthetic purposes. In addition, the heat sink 140 of cover 120 may also be painted (e.g., to match the wall color) according to one embodiment. This is a significant advantage of the present invention, and can be achieved because of the low power consumption of the control circuitry and resulting low temperature rise of heat sink 140 during operation.
Although load control system 100 has been described having cover 120 and housing 300, it is understood that this is merely exemplary of one embodiment that may be used according to the teachings of the present invention. Load control system 100 is not limited to use with any particular type or style of cover or housing.
The control circuitry for load control system 100 will now be described in more detail according to one embodiment with reference to
Briefly, the CAN bus comprises a two-wire differential serial data bus. The CAN bus is capable of high-speed data transmission (about 1 Megabits per second (Mbits/s)) over a distance of about 40 meters (m), and can be extended to about 10,000 meters at transmission speeds of about 5 kilobits per second (kbits/s). It is also a robust bus and can be operated in noisy electrical environments while maintaining the integrity of the data.
The CAN specification is currently available as version 1.0 and 2.0 and is published by the International Standards Organization (ISO) as standards 11898 (high-speed) and 11519 (low-speed). The CAN specification defines communication services and protocols for the CAN bus, in particular, the physical layer and the data link layer for communication over the CAN bus. Bus arbitration and error management is also described. Of course the invention is not limited to any particular version and it is intended that other specifications for the CAN bus now known or later developed are also contemplated as being within the scope of the invention.
It is understood, however, that the present invention is not limited to use with a CAN bus and other types and/or configurations are also contemplated as being within the scope of the invention. For example, the load control system 100 may be used in an Ethernet or a wireless network (e.g., radio frequency (RF), BLUETOOTH™), or accessed via a remote link (e.g., dial-up or Internet connection), to name only a few. In addition, the load control system 100 may be used in a subnet and controlled from another network or subnet. In addition, the control device may be directly linked to the load control system 100 (e.g., as a stand-alone device).
It is also understood that the control device 520 may comprise any node (e.g., a keypad, knob, slider, touch-screen, sensor, clock, etc.) which is generally configured to respond to an event (e.g., receive input and generate a signal based on the received input). By way of example, control device 110 may be a keypad. When the user presses a key (or sequence of keys) on the keypad, one or more signals may be generated that are representative of the key(s) that were pressed.
In one embodiment, the signal may correspond to program code (e.g., scripts) for performing a predetermined function at the load control system 100 (e.g., adjust light intensity to 50%). Embodiments for controlling a device using program code or scripts is described in co-pending, co-owned U.S. patent application entitled “DISTRIBUTED CONTROL SYSTEMS AND METHODS FOR BUILDING AUTOMATION” of Hesse, et al., filed on Apr. 24, 2003; Ser. No. 10/422,525, which is hereby incorporated herein by reference for all that it discloses.
Of course control device 520 is not limited to a keypad or keyboard. Examples of control devices 520 also include, but are not limited to, graphical user interfaces (GUI), personal computers (PC), remote control devices, security sensors, temperature sensors, light sensors, and timers.
In any event, controller 540 of the load control system 100 is preferably responsive to receiving the signal. Controller 540 is linked to each of a plurality of triacs 500-507 (generally referred to as 500) through driver circuits 550-557 (generally referred to as 550). Accordingly, controller 540 receives the signal and actuates the triacs 500 via driver circuits 550, thereby delivering current to the load(s) 530.
In one embodiment, controller 540 is provided with computer-readable program code (e.g., firmware, scripts) stored on suitable computer-readable storage operatively associated with the controller 540. The computer-readable program code for actuating the triacs 500 via driver circuits preferably comprises program code for signaling each driver circuit 550 for the parallel connected triacs at about the same time.
In one embodiment, the computer-readable program code comprises program code for repeatedly signaling each driver circuit 550 for the parallel connected triacs. Preferably, the program code repeatedly signals each driver circuit 550 from one time up to about 255 times during each half AC cycle (i.e., between each zero cross). Accordingly, in the event that one or more of the parallel connected triacs 500 do not actuate, the controller 540 repeatedly attempts to actuate the triacs 500 during the same half AC cycle so that each of the triacs 500 actuates preferably at the same time, but at least at substantially the same time. Actuating each of the triacs 500 at substantially the same time makes it more likely that each of the parallel connected triac 500 will deliver about the same current.
Of course it is understood that the number of times the program code repeatedly signals each driver circuit 550 is not limited to 255 times during each half AC cycle. For example, the number of attempts may also vary based on where in the half AC cycle the triac should be actuated to provide the desired current to the load 530. In other embodiments, program code may be provided that repeatedly signals each driver circuit 550 more frequently, within the constraints imposed by the hardware.
As briefly described above, triacs 500 (or other suitable semiconductor switching devices) can be connected in parallel to control load 530 by connecting one or more gates 570-576 (generally referred to as 570) of the triacs 500 and then connecting the output of each triac to the same load. Accordingly, the load control system 100 can be configured for use with a variety of different loads 530.
For purposes of illustration, load control system 100 is shown configured in
In one exemplary embodiment, load control system 100 comprises eight triacs 500 that can be connected to power 560 (e.g., a 20 amp supply breaker). In this example, each triac is rated for 8 amps, although in use, each triac only delivers about 2 amps (±10%) of current at 120 Volts AC. Accordingly, load control system 100 operates more efficiently. It is also more robust. For example, if one or more of the triacs are improperly wired (e.g., to deliver more than 2 amps to a load), or if one or more of the other triacs fails, load control system 100 can continue to operate.
Each triac can be connected individually to switch a load of 240 Watts, or two or more of the triacs can be connected in parallel to switch larger loads. According to this embodiment, up to eight triacs can be connected in parallel to switch a total load of about 1920 Watts (e.g., the UL limit for 20 amp service). Of course the invention is not limited to this embodiment, and it is provided merely as illustrative of one embodiment according to the teachings of the present invention.
In any event, the load control system 100 of the present invention may preferably be configured and reconfigured for use with a variety of loads and combinations of loads. Preferably, the triacs 500 can be logically connected to automatically enable an operating arrangement (e.g., two operating arrangements are illustrated in
It is understood that controller 540 may be provided with the operating arrangement of load control system 100 in any suitable manner. For example, the operating arrangement may be defined in program code (e.g., scripts). In another example, controller 540 may be operated in a current-sensing mode to determine which of the triacs 500 are connected in parallel to the same load, and which of the triacs 500 are connected to individual loads.
In one embodiment, controller 540 may be operatively associated with a sensor circuit 580 to make this determination. An exemplary sensor circuit 580 is shown in
Double pole switch 585 may be operated (e.g., closed) so that one leg connects the triacs 500 in parallel (e.g., during installation) and another leg connects, by way of example, a signal source 581 (e.g., low voltage signal) to the controller 540. When the triacs 500 are connected in parallel, the state of the switch identifies the parallel connected triacs 500 to the controller 540. For example, when the switch is closed the voltage level detected by controller 540 from the other leg of the switch may change, thereby indicating that the triacs 500 are connected in parallel. Alternatively, other types of signal(s) (e.g., optical) may indicate to the controller 540 which of the triacs 500 are connected in parallel.
Of course a combination sensor circuit and program code definition may also be used to provide controller 540 with the operating arrangement of load control system 100. For example, the operating arrangement determined by the sensor circuit may be compared to the operating arrangement defined in the program code. If the operating arrangements do not match, controller 540 may generate an alert that either the program code should be updated to correspond to the actual operating arrangement, or the hard-wired connections should be changed to correspond to the operating arrangement defined by the program code.
In addition to logically connecting the triacs 500, the gates 570 can also be connected to one another to connect the triacs 500 in parallel. In exemplary embodiments, the gates 570 may be connected with connectors such as jumpers, mechanical switches, electronic switches (e.g., relays), optical switches, hard-wiring, etc. In any event, controller 540 preferably signals the driver circuit(s) 550 for the triacs 500 to actuate the various load(s) 530 connected to load control system 100.
Driver circuits 550 may comprise individual opto-couplers. Opto-couplers are well known in the electronics arts and in one embodiment comprise a light-emitting diode (LED) that can be actuated by a low-voltage signal (e.g., about 20 volts or less) from the controller 540. Light emitted by the LED actuates a phototransistor, and outputs a low-voltage signal from the opto-coupler. Opto-couplers are understood by those skilled in the art, and therefore further description herein is not necessary for a full understanding of the invention.
In the load control system 100, output from the opto-coupler actuates the triac 500. The actuated triac 500 delivers AC current from the power 560 to the load 530. Program code (e.g., scripts) can be provided to adjust the intensity, slew rate, etc. to electronically control the load 530. For example, the slew rate may be adjusted by changing over a period of time the point after zero cross at which the triac turns on.
According to preferred embodiments, at least one of the opto-couplers 550 actuates all of the parallel connected triacs 500 at substantially the same time. Preferably, only one of the opto-couplers 550 actuates all of the parallel connected triacs 500 at substantially the same time. Actuating all of the parallel connected triacs 500 at substantially the same time enables each triac 500 to deliver about the same amount as each of the other parallel connected triacs 500 to the load 530.
It is understood that the control circuitry shown and described herein may also comprise other components not specifically shown or referred to herein. For example, the triacs 500 preferably comprise inductor chokes and interference capacitors. A suitable interface is also preferably provided between the bus 510 and controller 540. Yet other control circuitry may also be provided according to the teachings of the present invention. Such ancillary control circuitry is well-understood and therefore are not shown or described herein as further description is not needed for a full understanding of, or to practice the invention.
Load control system 100 may be provided with an optional status system. In one embodiment, status system may comprise an LED display 595 (see e.g.,
Of course it is understood that status system is not limited to an LED display, and other status indicators are also contemplated as being within the scope of the invention. Other exemplary embodiments may comprise generating an audible alert, issuing a signal for remote delivery (e.g., via email or pager to the user), or generating a data entry in an error log, to name only a few.
Output from status system may also generate or otherwise result in an automatic response to a potential or pending problem (e.g., from controller 540). For example, the controller 540 may shut all or a portion of the circuitry of load control system 100 if the temperature or current of one or more of the triacs 500 exceeds a predetermined threshold. Alternatively, if a triac 500 fails or is failing, controller 540 may logically “rewire” load control system 100 so that another triac 500 is used instead of the failed or failing triac 500. In one embodiment, a back-up triac 500 may be connected to the load but not logically wired to the load. That is, the controller 540 does not signal the driver 550 for the backup triac 500 until at least one of the other triacs 500 is taken offline by the controller 540 and signals the driver 550 of the backup triac 500.
Status system may comprise at least one temperature sensor 596 for the load control system 100. A single temperature sensor 596 is shown in
Status system may also comprise a current sensor 597 for the load control system 100. Current sensor 597 is shown in
One embodiment of a current sensor 597 is shown in
In any event, current sensor 597 detecting a current imbalance through the parallel connected triacs may indicate a malfunction, pending failure, or that the load control system 100 is not properly configured. For example, one of the parallel connected triacs drawing most of the current being delivered to a load may indicate that one of the other triacs has failed or that the triacs were not properly connected in parallel. Current measurements may also be used to determine when a load is failing or has failed (e.g., a light bulb has burned out), and may be used to alert the user (e.g., pinpointing the failed load).
Another embodiment of load control system 1100 is shown in
The triacs 1500 can be connected in parallel to load 1530 by connecting the output of each triac 1500 to the same load. It is noted, however, that the gates of the parallel connected triacs 1500 are preferably not connected in this embodiment. Again, the load control system 1100 can be configured for use with a variety of different loads 1530.
For purposes of illustration, load control system 1100 is shown configured in
Driver circuits 1550 may comprise pulse transformers. Pulse transformers are well known and use electromagnetic induction to generate a low-voltage (e.g., about 20 volts or less) output signal. Pulse transformers are understood by those skilled in the art, and therefore further description is not necessary for a full understanding of the invention.
In the load control system 1100, output from the pulse transformer actuates the triac 1500. On actuating, the triac 1500 delivers AC current from the power 1560 to the load 1530.
According to preferred embodiments, each of the pulse transformers 1550 actuates all of the parallel connected triacs 1500 at substantially the same time. Actuating all of the parallel connected triacs 1500 at substantially the same time enables each triac 1500 to deliver about the same amount as each of the other parallel connected triacs 1500 to the load 1530.
Preferably, the triacs 1500 are logically connected to automatically enable an operating arrangement (e.g., two operating arrangements are illustrated in
It is readily apparent that embodiments of the present invention represent an important development in the field of electrical control circuitry in general, and more specifally to electrical control circuitry for building automation. However, it is also understood that load control system 100 of the present invention is not limited to use in building automation environments. Load control system may also be used in other environments, including but not limited to industrial or manufacturing enviroments.
Having herein set forth perferred embodiments of the present invention, it is anticipated that suitable modifications can be made thereto which will nonetheless remain within the scope of the present invention.
This application is a continuation patent application and claims priority to co-owned U.S. patent application Ser. No. 10/424,345 for “Load Control System and Method” of Hugh P. Adamson, et al., filed Apr. 28, 2003 now U.S. Pat. No. 6,927,546, hereby incorporated herein for all that it discloses.
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