Patent Application
20210399574
Not applicable
Not applicable
This invention relates to the field of electrical power control and monitoring. More specifically, the invention comprises a control module that can switch one or more electrical power lines according to remote inputs and possibly local inputs as well.
The present invention can be configured for use with many different types of electrical power distribution systems. It has been developed primarily for use in the final stage of electrical power distribution (generally understood to be the distribution of electrical power from a circuit breaker box to various loads). However, the invention can also be used for other purposes such as the switching of three-phase AC power and the switching of DC power. The embodiments provided in this disclosure should thus be viewed as exemplary. Many more applications will occur to those knowledgeable in the field, and it is impractical to attempt to illustrate each and every one of these applications.
The “smart home” concept has evolved rapidly in recent years. In this paradigm electrical receptacles and switches can be remotely controlled. As an example, a line of “smart” switches and receptacles are marketed by the Leviton Manufacturing Co., Inc., of 201 North Service Road, Melville, N.Y., U.S.A. These devices can be centrally controlled by a programmable processor. They can also provide certain power consumption monitoring functions. Similar products are offered by other manufacturers.
The “smart home” devices require the installation of “smart” switches and receptacles. These components are quite expensive in comparison to the conventional components they replace. In some cases additional control wiring must also be run. The installation burden for new construction is not overwhelming. However, the owner of an existing structure may not wish to endure the expense of removing every outlet and switch and replacing them with “smart” components.
The “smart home” systems have also traditionally employed a dedicated control system. If—for example—a user selects the previously-mentioned Leviton system, then the user must install a Leviton control system. In recent years, however, wireless control systems that are potentially independent of the hardware have emerged. A good example is the “ALEXA” virtual assistant marketed by Amazon, Inc., of Seattle, Wash., U.S.A. The ALEXA device interacts wirelessly with a wide range of external components. The ALEXA device is also user-configurable. Thus, a user can configure an ALEXA device to control other products around a home or office.
There presently exists a need to add “smart home” functionality to existing electrical distribution components. Suitable control systems already exist—such as the ALEXA device. The present invention presents a solution to this need, as well as a solution to many other needs.
The present invention comprises a remotely controlled switching module that provides switching and preferably dimming functions for one or more AC or DC power distribution lines. The inventive module is preferably sized to fit within existing outlet and switch boxes, while still leaving enough room for the conventional components that are also housed in such enclosures. Remote control is provided wirelessly—preferably using an existing wireless communication protocol. Local control is preferably also provided for the inventive switching module. Local control inputs preferably allow control via existing components—such as two-pole light switches.
The inventive switching module can be implemented in a wide variety of configurations. The following descriptions pertain to some specific embodiments. These descriptions should not be viewed as limiting, since the scope of the invention will be determined by the claims ultimately presented rather than the examples provided.
SW2 FEED leads into the second switch block—SW2. SW2 selectively connects SW2 FEED to SW2 OUT. As for SW1, SW2 can provide a simple binary state or a PWM output. The operation of the two switch blocks can be completely independent. They may also be ganged together if desired.
Power supply 14 receives external power via its AC input. It rectifies the AC input and generates regulated internal power for use within the control module. The power supply also preferably produces: (1) a 10V DC output line that can be switched as desired; (2) a +3 VDC output for use in control functions; and (3) a −3 VDC output for use in control functions.
Control of the inventive module is preferably carried out using a processor 12. In the example of
Processor 12 controls the functions of both switch blocks 16, 18. Processor 12 also receives information back from each of the switch blocks. The information preferably includes the present electrical current and voltage passing through each switch block. These values allow the processor to monitor the power being consumed by a load attached to SW1 OUT or SW2 OUT. The processor can store information regarding these values and periodically transmit this information to an external monitoring device.
Additional inputs and outputs are preferably provided for processor 12. Antenna 20 is provided to facilitate RF communication. Two control input lines (CTRL1 and CTRL2) are provided as well. These allow local control of the module, as will be explained subsequently.
Processor 12 can be programmed to operate in a number of different modes of operation. Various means can be used to access the various modes. As a first example, the current mode could be set via wireless communication from an external device (such as a tablet or smartphone). In the example of
The main switching function is provided by TRIAC 28. “TRIAC” stands for “triode for alternating current.” A discussion of the function of these devices is beyond the scope of this disclosure, but those skilled in the art will know that they are well suited to the switching of alternating current. They can be cycled rapidly using a low-power control signal on gate line 32. Opto-coupler 30 is provided to isolate control line 34 from gate line 32 (a common practice). A low-power control signal provided by the processor on control line 34 is passed through opto-isolator 30 to gate line 32. The control signal then controls the amount of current passed through TRIAC 28.
TRIACs are of course known for switching AC power signals (since they can pass current in both directions). However, a TRIAC can also switch a DC power signal. The use of a TRIAC provides the flexibility of switching an AC signal in some applications and a DC signal in other applications. The TRIAC used is preferably rated at 800V and 25 A. This allows for current up to 20 A and voltage in the range of 10 VDC to 480 VAC.
In addition to simple on/off switching, a TRIAC in the configuration shown can cycle rapidly. This allows a pulse-width-modulated (“PWM”) output. The PWM output can be used to provide dimmer functions for a lighting load. It can also provide other load-control functions, such as controlling the speed of a motor. The switching and PWM functions can be provided for AC input signals and DC input signals, as will be explained.
Exemplary conventional circuit components are shown in the schematic, such as resistors R1, R2, and R3. These components are used to provide the proper operation of the opto-isolator and the TRIAC. The switch block preferably also includes output current and voltage measuring circuitry. The processor controls the operation of the switch block. It also receives information from the switch block. The information received preferably includes the switch block's output voltage and output current. This allows the processor to determine the amount of electrical power passing through the switch block and therefore the amount of power being consumed by a load connected to SW1 OUT.
Differential amplifier 36 measures the voltage drop across the resistor R4. According to Ohm's Law, this voltage drop is proportional to the current flowing through R4, which is the current flowing on SW1 OUT. The resistor R4 is of course selected to have a low resistance and a suitable current carrying capacity. The signal on current line 38 is a voltage signal that is proportional to the amount of current on SW1 OUT. Current line 38 is connected to an input on the processor. The processor reads this voltage and uses a first predetermined constant to calculate the current carried on SW1 OUT.
Resistor R5 connects the SW1 OUT line to amplifier 40. Resistor R6 connects a node between R5 and amplifier 40 to ground. Those skilled in the art will realize that a voltage present on voltage line 42 is proportional to the output voltage on SW1 OUT. Voltage line 42 is connected to an input of the processor. The processor reads this voltage and uses a second predetermined constant to calculate the output voltage on SW1 OUT. The processor preferably also calculates the power output for SW1 OUT (P=V*I).
Those skilled in the art will realize that the switching circuitry shown in
The power supply is also preferably able to accept an external DC input if no AC power is available. In that case an external DC supply voltage can be provided on the 10 VDC output line. This will eliminate the need for the rectifier and directly feed analog supply 46 and digital supply 48.
The inventive control module can be physically packaged in a wide variety of ways. One embodiment is a stand-alone package that is intended to be housed within existing switch boxes and receptacle enclosures such as are commonly used in residential and commercial electrical systems. For this application the physical packaging is preferably compact.
In order to fit within the available space, module 10 shown in
In this example, the various input and output wires are captured between the housing and the lid. Suitable flexible grommets are provided to locate the wires and provide strain relief. A suitable length is provided for all the wires. A common method of connecting such wires is the use of wire nuts (Marrette connectors). These allow all connections to be made while the components are pulled out the front of an enclosure. The wire is then coiled and carefully urged back into the enclosure. A suitable length for the wires in this environment is 75 mm to 150 mm. A pre-stripped portion can also be provided on the end of each wire.
Not all physical packaging examples will include all the possible input and output wires. In this example, two feed lines 54 (SW1 FEED and SW2 FEED) and two output lines 56 (SW1 OUT and SW2 OUT) are included. A ground line 58 is also included to connect the device to the distribution system's ground line. AC input lines 60 provide power to the internal power supply. DC output lines 62 provide the 10 VDC/3 A output. Control lines 64 provide inputs for local control, as will be explained in the exemplary installations to follow. Antenna line 66 facilitates radio frequency communication with the processor within the control module. Additional DC output lines can be provided as well (+3 VDC and −3 VDC). These are not shown in the example of
Field disassembly of the components of the inventive control module is unlikely. Thus, it can be advantageous to pot all the components into solid potting compound. In some versions the “housing” can just be a solidified block of potting compound. In other versions a thin housing can be used to contain the potting compound as it is introduced around the components and allowed to solidify.
Returning now to
Processor 12 also monitors the electrical power on each output line, such as by monitoring line current and voltage. Processor 12 can use the communication link to transmit this obtained information to the external computing device. The transmission is preferably made wirelessly. Processor 12 preferably runs a controlling software program that can direct a variety of possible actions. For example, the processor can:
1. Periodically report a cumulative power consumption for loads attached to the output lines;
2. Report only when an “exceedance” is detected, such as a current spike;
3. Report regularly at defined intervals; and
4. Perform a “data dump” a few times each day in which the data is summarized and transmitted at a set time.
The two control input lines (CTRL1 and CTRL2) are provided so that a local control can furnish an input to the operation of control module 10. For example, the control module can be installed in an electrical enclosure housing a pair of residential light switches. In such an installation the inventive module provides wireless remote control of the lights. However, it is often also desirable to retain the local control provided by the light switches themselves. The two control input lines can be used to monitor the status of the light switches, as will be explained.
The inventive control module has many different applications. It is of course impossible to illustrate them all.
The duplex receptacle is contained within a conventional enclosure 68 (shown larger than its actual size). The enclosure is fed by a pair of two-conductor cables 74. Under the conventions established by the National Electrical Code of the United States, the term “two-conductor cable” means an insulated jacket in which three separate conductors are contained. The three separate conductors are known as the line conductor, the neutral conductor, and the ground conductor. The line and neutral conductors both have a separate insulting jacket. By convention, the line conductor is black and the neutral conductor is white.
In this example, the two-conductor cable 74 in the upper left travels to a breaker box. The two-conductor cable 74 in the upper right travels to additional receptacles fed by the same circuit. Connections are made using wire nuts 80. Neutral conductor 78 is connected to the neutral side of duplex receptacle 70 as is ordinarily done. The same wire nut also connects the neutral conductor to the rest of the parallel circuit—as is also conventional. However, line conductor 76 is not directly connected to the line side of duplex receptacle 70. Instead, the line conductor is connected to SW2 FEED on control module 10 (The selection of SW2 FEED instead of SW1 FEED is arbitrary in this example). The AC power connections to the control module are not shown for reasons of visual simplicity. However, it is a simple matter to add these connections to the wirenut-based connections already shown. Antenna line 66 is customarily passed out one of the bottom openings in enclosure 68. The antenna is allowed to dangle below the outlet block—typically behind the drywall.
The configuration shown in
Further, control module 10 can be used to monitor all electrical power passing through duplex receptacle 70. Even if no remote switching is desired, the monitoring and reporting functions can be significant.
The configuration of
SW2 FEED is connected to the input line conductor 76. SW2 OUT us connected to load 94. The load's return path is through a neutral conductor 78 as usual. Control module 10 is configured to toggle load 94 on and off. If switch 88 is in the off position and an “on” command is given wirelessly to the control module, then the control module toggles on load 94 (and monitors power consumption as usual). If switch 88 is then flipped, control module 10 senses a change in the state of the input to CTRL2 and toggles load 94 off. Switch 88 is therefore no longer an on/off switch but acts like a switch in a “three-way” light circuit. That is, the switch no longer has a defined “on” position. Flipping the switch simply changes the state of the load irrespective of the starting position. The control module is configured to sense a change in the voltage state on CTRL 2, and when such a change is detected the control module toggles the state of the load.
Of course, the programming for the control module can be more sophisticated than a simple toggle function. The R/F command sent can change the input from the SPST switch 88 to be a conventional on/off switch or a toggle-function switch.
Each SPDT switch 100 has a common terminal 102 and two traveler terminals 104. Flipping the switch alternatively connects each traveler terminal to the common terminal. Line conductor 76 is connected to the common terminal 102 of the left SPDT switch 100. The left traveler terminal of the left SPDT switch 100 is connected to the left traveler terminal of the right SPDT switch 100. Likewise, the right traveler terminal of the left SPDT switch 100 is connected to the right traveler terminal of the right SPDT switch 100. Those skilled in the art will know that three-way light circuits can be wired in other ways—such as via the use of a three-conductor or four-conductor cable.
In the configuration of
This describes the operation of a conventional three-way circuit. But, in addition, control module 10 can also be switched by the receipt of an external wireless signal. The receipt of such a signal will also cause control module 10 to toggle the state of load 94. Thus, in the configuration of
Line conductor 76 is likewise connected to input pole 92 on the right SPST switch 88. Output pole 90 on the right SPST switch is connected to the CTRL 2 input on control module 10. Flipping the left switch 88 to “on” places AC voltage on CTRL 1. Flipping the right switch 88 to “on” places AC voltage on CTRL 2. Control module 10 is programmed to interpret a change of state on either CTRL 1 or CTRL 2 as a command to toggle the state of load 94. In addition, control module 10 is programmed to interpret an external wireless input as a command to toggle the state of load 94. The power monitoring functions of control module 10 are present as well.
Another scenario involves the substitution of a dimmer switch for the SPST switch 88 shown in
Some embodiments of the inventive control module can be configured to sense line AC voltages on CTRL 1 and CTRL2, while other embodiments can be configured to sense lower voltages. It is possible to create sensing circuitry that is suitable for either, but such circuitry adds expense and complexity. For example, the processor itself will often have I/O ports that can directly sense the presence of a +3 VDC signal on one of the control lines. One would not of course directly connect 110 VAC to the same I/O port. Instead, a high-impedance sensing circuit would likely be provided.
Looking again at
The invention can be operated in many additional configurations. As an example, the inventive control module can function as a remotely controllable 3-phase switch. In this application the switch blocks are used to switch two of the three phases.
In the preferred embodiments the operating mode will be set when the inventive control module is installed. An example of this is shown in
Numerous other features can be provided alone or in combination. These features include, without limitation.
1. Wireless communication protocols other than BLUETOOTH, such as ZIGBEE or THREAD;
2. Additional local control inputs beyond the two provided;
3. Additional switched lines beyond the two provided;
4. An internal battery to preserve logic functions in the event of a power interruption;
5. The ability to set a desired operating mode via RF communication with the processor;
6. The provision of software running on an external device that communicates with the inventive control module in order to monitor the power consumption of devices being fed by SW1 OUT and SW2 OUT;
7. The provision of software running on an external device that provides a user interface for operating and monitoring the inventive control module(s);
8. The provision of software running on an external device that provides a user interface for aggregating information from multiple inventive control modules; and
9. The use of existing external devices (such as ALEXA) to control the inventive control module and receive information from the inventive control module.
Although the preceding descriptions contain significant detail, they should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. Those skilled in the art will know that many other variations are possible without departing from the scope of the invention. Accordingly, the scope of the invention should properly be determined with respect to the claims that follow rather than the examples given.
This non-provisional patent application claims the benefit of U.S. Pat. App. Ser. No. 63/040,701. The parent application was filed on Jun. 18, 2020. It listed the same inventors.
| Number | Date | Country | |
|---|---|---|---|
| 63040710 | Jun 2020 | US |
