Patent Application
20130044444
This disclosure pertains to a photoelectric controller device and, in particular, to features enabling the device to resist UV degradation, dust and a high pressure water spray and, to the assembly of a PCB board and connectors.
Lighting fixtures can be automatically switched on at dusk and off at dawn using twist-lock photoelectric controllers. The lighting fixtures may be used to light roads, parking lots and other areas outdoors. The photoelectric controller senses the intensity of the ambient light and switches the lighting fixtures on and off as appropriate. The photoelectric controllers are typically oriented so that the photosensor faces North, away from direct sunlight in the Northern hemisphere (and in a southerly direction in the Southern hemisphere). It is also desired to be able to easily adjust the receptacle that receives the photoelectric controller to achieve the desired orientation.
Lighting fixtures for street lights typically include an electrical receptacle that receives the photoelectric controller that is mounted to a housing on the top of the lighting fixture. The electrical receptacle is wired to the power supply of the lighting fixture. The photoelectric controller has three main terminals that are inserted into the electrical receptacle and twisted to lock the photoelectric controller to the receptacle.
The orientation of the photoelectric controller in the Northern direction is accomplished by the use of a metal snap ring having fingers that engage the electrical receptacle and urge it toward the housing of the lighting fixture using a spring force. This is disclosed in U.S. Pat. No. 4,477,143. The electrical receptacle may be lifted up against the spring force and turned to orient the receptacle North. Circumferential holes located in an upper circular end plate of the electrical receptacle receive pins formed around an opening in the housing for securing the electrical receptacle to the housing. In another approach in which no snap ring is used, the electrical receptacle is oriented by loosening a screw in the top of the receptacle, rotating the receptacle until indicia on the receptacle points to the desired position and then re-tightening the screw.
The photoelectric controller is subjected to harsh environments at certain times and at certain locations. For example, the photoelectric controller may be used to control streetlights in arid climates where there are dust storms. It also may be subjected to snow and ice. The window may become coated with dust, snow and ice, interfering with proper operation of the photosensor. Maintenance vehicles will periodically spray the photoelectric controller with high pressure water to clean the window. High pressure water spray, high velocity dust, snow, ice and extended periods of direct sunlight is a problematic environment for a high voltage electronic device to be subjected to.
One embodiment of this disclosure pertains to a photoelectric controller device including a housing. An electrically insulating base plate is secured in the housing. At least two printed circuit boards are secured to the base plate in an interior of the housing (e.g., in electrical contact with each other). The printed circuit boards include a photosensor that enables power to a device (e.g., a lighting fixture) to be controlled in response to ambient light and communication circuitry for sending signals that communicate with the device. Electrically conductive, main terminals are secured in electrical contact with one of the printed circuit boards for providing power to the device as well as to the circuitry on the printed circuit boards. A communication terminal is also secured in electrical contact with the communication circuitry on one of the printed circuit boards. Reference to circuitry herein includes various electrical components used in the circuitry (e.g., capacitors, resistors, photosensor, diodes) as well as conductive paths included in the circuitry between the components.
Referring to specific features of this embodiment, the base plate is secured near an open end of the housing. The housing can comprise a window aligned with the photosensor. The housing can be cup shaped and can include a larger diameter body portion near an open end portion thereof. The larger diameter body portion can include a circumferentially extending shoulder and spaced apart ramp members extending outwardly of the shoulder (i.e., at a slope that decreases toward the open end). The base plate can be snap fit against the ramp members into contact with the shoulder. The base plate can include spaced apart cutouts or recesses on an outer surface thereof that engage the ramp members. Polymeric resin can optionally be used to secure the base plate to the housing.
In another aspect, the housing can include circumferentially spaced openings and the base plate can include circumferentially spaced, interiorly threaded portions at a periphery thereof aligned with the openings. Fasteners extend through the openings into the threaded portions.
The base plate can include an interior surface and fingers extending from the interior surface including ramp members at end portions thereof that enable an outer one of the printed circuit boards to be snap fit against said ramp members into contact with the fingers. The slope of the ramp members of the fingers decreases away from the open end.
The base plate can include first polymeric risers extending from an inner surface thereof through openings in an outer one of the printed circuit boards into contact and bonded with an inner one of the printed circuit boards. A second polymeric riser can extend from the inner surface of said base plate into contact and bonded with the outer circuit board. The main terminals are disposed inside the first risers and are secured in electrical contact with circuitry on the inner printed circuit board and the communication terminal is disposed inside the second riser into electrical contact with the communication circuitry on the outer printed circuit board.
The housing includes a window opening formed in a wall of the housing. The wall can include a channel surrounding the window opening and a window pane comprised of light transmitting material received in the channel.
The main terminals can each be arcuate and L-shaped external to the base plate. The main terminals are (e.g., circumferentially) spaced around the communication or signaling terminal (e.g., a dimming terminal). The communication terminal can be circular or ring shaped, for example, it can comprise a centrally located pin and a surrounding ring member around which the main terminals are disposed (i.e., an RCA contact), a pin only or a ring member only. Also, more than two communication members may be used each having a circular or ring shape, for example, a central pin surrounded by two ring members.
The printed circuit boards can include two printed circuit boards extending in contact with and along a plane of the base plate (e.g., oriented parallel with each other and to the base plate plane) and a third printed circuit board oriented transverse (e.g., substantially perpendicular) to the two printed circuit boards. The third printed circuit board can include circuitry for enabling wireless (e.g., RF) communication between the photoelectric controller device and another device at a remote location. However, it is possible to embed wireless communication circuitry in the second printed circuit board as micro chips gets smaller and more efficient. The third printed circuit board can be flexible. The housing can include a protective coating and the window can include a protective coating comprised of light transmissive material. For example, this coating on at least the window and possibly on the entire photoelectric controller can be a thin film of the transparent compound, indium tin oxide.
Referring to a more specific aspect of the first embodiment, the photoelectric controller device includes a housing including a window opening formed in a wall of the housing. The wall includes a channel surrounding the window opening. A window pane comprised of light transmitting material is received in the channel. An electrically insulating base plate is secured at an open end of the housing. The housing and the base plate include structure enabling the base plate to be snap fit against the housing. At least two printed circuit boards are secured in an interior of the housing and are fastened to the base plate. The printed circuit boards include a photosensor that enables power to a lighting fixture to be controlled in response to ambient light, and dimming circuitry enabling the lighting fixture to be dimmed. Electrically conductive, main terminals are secured in electrical contact with one of the printed circuit boards and extend through the base plate to provide power to the lighting fixture and circuitry on the printed circuit boards. A circular or ring shaped electrically conductive, dimming terminal is secured in electrical contact with the dimming circuitry on one of the printed circuit boards and extends through the base plate.
Referring to more specific features of this aspect of the disclosure, the printed circuit boards include a third printed circuit board oriented transverse to the two printed circuit boards. The third printed circuit board can include circuitry for enabling wireless communication between the photoelectric controller device and another device at a remote location. The third printed circuit board can be flexible. The base plate can include first polymeric risers extending from an inner surface thereof through openings in an outer one of the printed circuit boards into contact and bonded with an inner one of the printed circuit boards. A second polymeric riser extends from the inner surface of the base plate into contact and bonded with the outer circuit board. The main terminals are disposed inside the first risers and are secured in electrical contact with circuitry on the inner printed circuit board and the dimming terminal is disposed inside the second riser into electrical contact with the dimming circuitry on the outer printed circuit board. Any other of the specific features described above with regard to the first embodiment, may be used in any combination with this embodiment.
A second embodiment features a photoelectric controller device including a housing including a window opening formed in a wall of the housing. The wall includes a channel surrounding the window opening. A window pane comprised of light transmitting material is received in the channel. At least one printed circuit board is secured in an interior of the housing. Electrically conductive, main terminals are secured in electrical contact with the printed circuit board.
Referring to features of this second embodiment of this disclosure, the window pane can include a chamfered ridge that is snap fit against the wall. A circular or ring shaped, communication terminal can be secured in electrical contact with one of the printed circuit boards.
A third embodiment features a photoelectric controller device including a cup shaped housing that includes a larger diameter body portion near an open end portion thereof. The larger diameter body portion includes a circumferentially extending shoulder and spaced apart ramp members extending outwardly of the shoulder along a longitudinal axis of the photoelectric controller device (i.e., toward the open end of the housing). A base plate is snap fit against the ramp members into contact with the shoulder. At least one printed circuit board is secured in an interior of the housing to the base plate. Electrically conductive, main terminals are secured in electrical contact with the printed circuit board and extend through the base plate.
Referring to specific features of the third embodiment, the base plate includes spaced cutouts or recesses on an outer surface thereof that engage the ramp members. Polymeric resin can secure the base plate to the housing.
A fourth embodiment features a controller device including a conducting or insulating housing and an electrically insulating base secured in the housing. At least one printed circuit board is secured to the base in an interior of the housing. The printed circuit board includes a sensor selected from the group consisting of a photosensor, infrared sensor, visible detector, and combinations thereof, that enables power to a device (e.g., a lighting fixture) to be controlled in response to ambient light or detection of an object. The printed circuit board also includes communication circuitry that sends signals that communicate with the device. Main electrically conductive terminals are secured in electrical contact with the printed circuit board for providing power to the device. A communication terminal is secured in electrical contact with the communication circuitry on the printed circuit board. The communication terminal can be circular or ring shaped, for example, it can comprise a centrally located pin and a surrounding ring member around which the main terminals are disposed (i.e., an RCA contact), a pin only or a ring member only. Also, more than two communication members may be used each having a circular or ring shape, for example, a central pin surrounded by two ring members.
Referring to specific features that can apply to this fourth embodiment, the controller device can include a second printed circuit board which, for example, is generally parallel or orthogonal to the (first) printed circuit board. The second circuit board can include circuitry for enabling wireless communication between the controller device and another device at a remote location. The circuit board can be generally circular. Any of the other specific features described above regarding the other embodiments can apply to the fourth embodiment.
Many additional features, advantages and a fuller understanding of the invention will be had from the accompanying drawings and the Detailed Description of the Invention that follows. It should be understood that the above Brief Description of the Invention describes the invention in broad terms while the following Detailed Description of the Invention describes the invention more narrowly and presents embodiments that should not be construed as necessary limitations of the broad invention as defined in the claims.
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On one of the PCBs 32, 34 is disposed a photosensor 54 that is aligned with the window 28 so that ambient light is used to control the operation of the lamp 52. In addition, dimming circuitry (a dimming control) 56 is disposed on at least one of the PCBs, enabling the lamp 52 to be dimmed at desired times, ambient lighting conditions or as instructed wirelessly from a remote location. In this regard, a wireless communication device 58 can be disposed on a third PCB 60 that extends perpendicular to the inner PCB 34, which will be discussed in more detail below.
Referring to
The base plate 30 includes three main risers 92 extending from the inner surface 80 of the base plate. Each of the main risers 92 includes a passage 94 that receives the elongated portion 44 of the main terminals 38 in an interference fit. The main risers 92 pass through openings 96 in the outer PCB 32 and engage outer surface 98 of the inner PCB 34 at shoulders 100 of the main risers where they can be secured with polymer resin. The main risers are secured with polymeric resin to the outer and inner PCBs 32 and 34. An inner end portion 102 of each of the main terminals 38 is exposed from an inner end 104 of the main riser 92 and extends through an opening 106 of the inner PCB 34 where it is soldered in electrical contact with circuitry on the inner PCB. The main riser 92 extends around the main terminal through the opening in the inner PCB 34. (see
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For outdoor applications it is desired that the housing of the photocontroller is UV and IR stable for prolonged periods of time. Typically, polymeric materials are used for this application. However, a metal housing made of aluminum or aluminum alloy enforced with oxides can be used for the housing. For ease of manufacturing, UV stabilized polymeric materials are used. Polymer degradation is a change in the properties—tensile strength, color, shape, etc.—of a polymer or polymer-based product under the influence of one or more environmental factors such as heat, light or chemicals such as acids, alkalis and some salts. The changes in properties are often termed “aging”. The polymeric material that is being used should retain its structural properties for a prolonged period of time. There are several ways of avoiding UV degradation in plastics—by using stabilizers, absorbers or blockers. For many outdoor applications, the simple addition of carbon black at around a 2% level will provide the protection for the structure by the blocking process. Other pigments such as titanium dioxide can also be effective. Certain strength criteria and materials optical properties should be retained over the lifetime of the device. There are several commercial materials available for the photovoltaic industry by Dupont and SABIC. For example Rynite® (RT Dupont®) Polyester SUV resins were developed specifically for outdoor applications in the photovotaic industry. Zytel® ST801AW BK195 is also an exterior weatherable material—a super-tough 66 nylon used for years in SUV roof racks. SABIC® Xenoy® and Valox® reinforced polycarbonate material also can be used for this purpose. The materials can be further coated with oxide or metal/metal alloys to further improve their weatherability.
Despite the harsh environment to which the photocontroller device is subjected, its design described herein withstands the high pressure water sprayed on it as determined by high pressure water spray tests. The photocontroller passed water tests in which water was projected by a nozzle (6.3 mm) against the device from any direction had no harmful effects. The test duration was three minutes. Water was sprayed at a flow rate of 12.5 liters per minute at a pressure of 30 kN/m2 at distance of 3 meters. In addition, the photocontroller passed dust exposure criteria in which ingress of dust need not be entirely prevented, but it must not enter in sufficient quantity to interfere with the satisfactory operation of the equipment. There was complete protection against contact. In addition the photocontroller passed the criteria of being dust tight in which there was no ingress of dust and complete protection against contact. The design of the photoelectric controller enabling it to pass high pressure water spray tests includes the base plate and housing connection and the design of the window.
Features of the lighting fixture and the photoelectric controller device 10 are described in U.S. patent application Ser. No. 12/899,731, entitled “Outdoor Lighting System,” which is incorporated herein by reference in its entirety, portions of which are described below.
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The photoelectric controller device 10 can include transient voltage surge suppression (TVSS) 184 for protecting the photoelectric controller device 10 from voltage surges on an input power line. An example TVSS device 184 for use in the module is a metal oxide varistor (MOV) surge suppressor. The input power line supplies power to a power supply 186 (e.g., at 120-480 volts), which can include a transformer, rectifier and a voltage regulator circuitry. The power supply 186 supplies power, for example DC power, to various components within the photoelectric controller device 10, such as the primary microcontroller 164 and dimming control 56.
The photoelectric controller device 10 can include a wireless communications printed circuit board 60 (which can be positioned perpendicular to the inner and outer PCBs)(
The photoelectric controller device 10 in certain embodiments also includes the photo sensor 54 which senses ambient light proximate the lighting fixture 40 and provides a sensed light signal or value to the dimming component 56. Instead of or in addition to the photosensor 54, an infrared sensor or visible detector (e.g., a camera) may be used. The dimming component 56 selectively provides the dimming control value or values (e.g., 0-10V signal, messages, etc.) to the ballast or driver 154 in certain embodiments based at least in part on the sensed light signal or value. For example, the dimming component 56 may be programmed or otherwise configured to provide dimmed light via the dimming control value selection at dawn and/or dusk for reduced power consumption and for aesthetic lighting, rather than the conventional full on/full off operation. In certain embodiments, moreover, the dimming component 56 may be operative to selectively dim the light output during certain times for energy conservation, for instance, to dim unused roadways to a safe but efficient level in the middle of the night, with possible dimming control modification/override according to signals or values received from an occupancy/motion sensor 194 operatively coupled with the primary microcontroller 164. In certain embodiments, moreover, the dimming control component 56 may be implemented as one or more software components executed by the primary microcontroller 164. The dimming control component 56 can include dimming control switches that are settable by a user to program various dimming parameters, such as dimming level for example. Alternatively, such dimming parameters can be set by downloading parameter settings to the photoelectric controller device 10, either locally or remotely.
In certain embodiments, the dimming component 56 is operative to selectively provide the dimming control value based at least in part on a received RF signal or value from an external RF device 190. For instance, an RF command signal can be sent to the photoelectric controller device 10 wirelessly (and such signal can be sent to multiple photoelectric controller devices 10) for initiating dimmed, full on, full off, flashing operation, or combinations thereof by a control device 190 having an RF transmitter, thus allowing security personnel to control outdoor lighting operation. The dimming component 56 may thus provide the dimming control value(s) to control the light output according to one or more criteria, some of which may be externally actuated (e.g., via the photoelectric sensor 54, motion sensor 194, and/or RF device 190 or combinations thereof) and some of which may be preprogrammed in the photoelectric controller device 10.
In addition to the wireless communications printed circuit board 60, the photoelectric controller device 10 can include one or more printed circuit boards 32, 34 (e.g., outer and inner PCBs) containing components and circuitry not provided on the wireless communications PCB. For example, components such as the TVSS 184, power supply 186, load rated relay 162 and photo sensor 54 can be provided on the inner circuit board 34, while the dimming control component 56 and primary microcontroller 164 can be provided on the other outer circuit board 32. Additional circuitry and/or components, or different variations of the circuitry and/or components, can be provided on either circuit board 32, 34. If only one printed circuit board is used, it can include all of the circuitry enclosed by the box 32 or 34 shown in
The system may also include one or more occupancy/motion sensors 194 operatively coupled with one of the RF-enabled outdoor lighting fixtures 40 or otherwise coupled with the network. For instance, the photoelectric controller device 10 may be operatively coupled with a motion sensor 194 to receive a wired or wireless signal (e.g., via transceiver and antenna 188, 188a) therefrom indicating detected or sensed motion or person/vehicle occupancy near and/or lit by the lighting fixture 40, and the dimming component 56 is operative to selectively provide the dimming control value based at least in part on a sensed motion light signal or value from the motion sensor 194. For example, the dimming component 56 may increase a dimmed power level (or go to full-on operation from a previously dimmed setting) when motion is sensed and continue this modified operation for a predetermined time or until a separate reset command is received at the photoelectric controller device 10. In other embodiments, the dimming control signal can be varied for output light flashing operation based at least in part on a received motion detection signal from the sensor 194.
Many modifications and variations of the invention will be apparent to those of ordinary skill in the art in light of the foregoing disclosure. Therefore, it is to be understood that, within the scope of the appended claims, the invention can be practiced otherwise than has been specifically shown and described.
