Lighting relay panel features for improved safety and reliability

• US 10,129,950 B1
• Filed: 03/01/2018
• Issued: 11/13/2018
• Est. Priority Date: 04/26/2017
• Status: Active Grant

• Current Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Original Assignee: ABL IP Holding LLC (Acuity Brands, Inc.)
• Inventors: Gross, Philip, Bierschbach, Justin, Pelliccio, Frank, Zulim, Dalibor
• Primary Examiner(s): Chen, Jianzi
• Application Number:
  US15/909,051
• Publication Number:
  US 20180317300A1
• Time in Patent Office: 257 Days
• CPC Class Codes: G01R 31/3278 of relays, solenoids or reed switches measuring contact resistance G01R27/205; high voltage magnetic switches G01R31/3271, G01R31/333; testing electric windings G01R31/72; monitoring of fail safe circuits H01H47/002
• CPC Class Codes: H01H 2047/009 with self learning features, e.g. measuring the attracting current for a relay and memorising it
• CPC Class Codes: H01H 47/002 Monitoring or fail-safe circuits
• CPC Class Codes: H01H 47/18 for introducing delay in the operation of the relay short-circuited conducting sleeves, bands or discs H01H50/46
• CPC Class Codes: H02H 3/22 of short duration, e.g. lightning
• CPC Class Codes: H02H 9/042 comprising means to limit the absorbed power or indicate damaged over-voltage protection device
• CPC Class Codes: H02J 9/061 for DC powered loads
• CPC Class Codes: H05B 41/36 Controlling
• CPC Class Codes: H05B 47/165 following a pre-assigned programmed sequence; Logic control [LC]
• CPC Class Codes: H05B 47/24 Circuit arrangements for protecting against overvoltage
• CPC Class Codes: H05B 47/25 Circuit arrangements for protecting against overcurrent

Abstract

A lighting relay panel may include lower-cost features or components related to improved safety and reliability. In some cases, the relay panel includes a power supply capable of protecting the panel from high-voltage and high-current transients. A microcontroller may determine a power interruption based on a zero-cross signal received from the power supply, and may also configure latching relays during the interruption. In some implementations, the relay panel includes a relay sense circuit that is capable of receiving actuation signals from multiple relays connected to different phases of a power signal, and the microcontroller may synchronize or repeat the actuations based on a signal from the relay sense circuit. The microcontroller may generate relay addresses based on the relay positions within the relay panel. In some cases, the relay panel may include isolation circuits that are capable of providing an isolated control signal having an improved voltage range.

Claims

1. A relay control interface for controlling a plurality of relays, comprising:

a first relay drive circuit connected to a first relay, wherein the first relay drive circuit includes a first relay close input, a first relay open input, and a first relay output based on a voltage across a first current sense resistor;

a second relay drive circuit connected to a second relay, wherein the second relay drive circuit includes a second relay close input, a second relay open input, and a second relay output based on a voltage across a second current sense resistor;

a relay sense circuit, wherein the first relay output is connected to a first input of the relay sense circuit and the second relay output is connected to a second input of the relay sense circuit, the first and second inputs of the relay sense circuit are connected to an input of an op amp, and an output of the op amp indicates current through an actuator of the first relay or current through an actuator of the second relay and is connected to an output of the relay sense circuit; and

a controller connected to the first relay close input and the first relay open input for controlling the first relay, connected to the second relay close input and the second relay open input for controlling the second relay, and connected to the output of the relay sense circuit,

wherein the controller determines a first relay actuation delay for the first relay based on a time difference between a first control signal on the first relay close input and a first output signal on the output of the relay sense circuit and determines a second relay actuation delay for the second relay based on a time difference between a second control signal on the second relay close input and a second output signal on the output of the relay sense circuit.

2. The relay control interface of claim 1, wherein a value of the first current sense resistor is based on a maximum rated current for the actuator of the first relay and a value of the second current sense resistor is based on a maximum rated current for the actuator of the second relay, and the maximum rated current for the actuator of the first relay is different than the maximum rated current for the actuator of the second relay.

3. The relay control interface of claim 1, wherein the controller is connected to a zero-cross detection circuit and the controller controls the first relay based on an input from the zero-cross detection circuit and the first relay actuation delay.

4. The relay control interface of claim 3, wherein the controller controls the second relay so that actuation of the first relay and actuation of the second relay are staggered.

5. The relay control interface of claim 1, wherein the first relay is connected to a first phase of a power source, the second relay is connected to a second phase of the power source, and the controller is connected to a zero-cross detection circuit, and wherein the controller controls the first relay and the second relay based on an input from the zero-cross detection circuit.

6. The relay control interface of claim 1, wherein the controller generates a third control signal on the first relay close input and receives a third output signal from the output of the relay sense circuit indicating that the first relay remains open beyond the first relay actuation delay, and in response, the controller generates a fourth control signal on the first relay close input.

7. The relay control interface of claim 1, wherein the controller generates an open relay control signal on the first relay open input and receives a third output signal from the output of the relay sense circuit indicating that the first relay remains closed beyond the first relay actuation delay, and in response, the controller generates a second open relay control signal on the first relay open input.

8. A method comprising:

controlling a first relay by generating a first control signal on a first relay close input, wherein the first control signal is based on an input received from a zero-cross detection circuit and a first relay actuation delay for the first relay;

controlling a second relay by generating a second control signal on a second relay close input, wherein timing of the second control signal is based on timing of the first control signal and a second relay actuation delay for the second relay and the second control signal controls the second relay to actuate at a different time than the first relay,

wherein the first relay is connected to a first relay drive circuit and the first relay drive circuit includes the first relay close input, a first relay open input, and a first relay output based on a voltage across a first current sense resistor,

wherein the second relay is connected to a second relay drive circuit and the second relay drive circuit includes the second relay close input, a second relay open input, and a second relay output based on a voltage across a second current sense resistor, and

wherein the first relay output is connected to a first input of a relay sense circuit and the second relay output is connected to a second input of the relay sense circuit, the first and second inputs of the relay sense circuit are connected to an input of an amplifier, and an output of the amplifier indicates current through an actuator of the first relay or current through an actuator of the second relay and is connected to an output of the relay sense circuit.

9. The method of claim 8, further comprising:

determining the first relay actuation delay by;

generating a control signal on the first relay close input to close the first relay;

receiving a signal from the output of the relay sense circuit which indicates a current through an actuator of the first relay; and

determining the first relay actuation delay based on a time difference between the control signal on the first relay close input and the signal from the output of the relay sense circuit.

10. The method of claim 9, further comprising maintaining information on each of the plurality of relays, including the first relay actuation delay and a first phase of a connected power source for the first relay and the second relay actuation delay and a second phase of the connected power source for the second relay.

11. The method of claim 10, wherein the second control signal is also based on the second phase and a relationship between the input from the zero-cross detection circuit and the second phase.

12. A lighting control panel comprising:

a latching relay capable of receiving power from a power supply, wherein the latching relay is configurable to have a first operational state and a second operational state, the first operational state and the second operational state each selected from a group of available states; and

a microcontroller capable of receiving an input from a user interface device, the microcontroller programmed to perform operations comprising;

determining the first operational state and the second operational state based upon the input received from the user interface device, and

configuring the latching relay to have the first operational state while the latching relay is receiving power from the power supply,

wherein, upon an interruption in the received power, the latching relay is capable of maintaining the first operational state.

13. The lighting control panel of claim 12, wherein the microcontroller is programmed to perform further operations comprising:

configuring the latching relay, during the interruption in the received power, to have the second operational state,

wherein, upon receiving a power-on event, the latching relay is capable of exiting the first operational state and entering the second operational state.

14. The lighting control panel of claim 12, further comprising a zero-cross detection component and a power supply voltage monitor;

wherein the microcontroller is programmed to perform further operations comprising;

determining the interruption in the received power based on a signal received from one of either the zero-cross detection component or the power supply voltage monitor.

15. The lighting control panel of claim 12, further comprising a backup power supply;

wherein the microcontroller is capable of receiving, during the interruption in the received power, backup power from the backup power supply;

wherein the microcontroller is programmed to perform further operations comprising;

during the interruption in the received power, reconfiguring the latching relay to have an additional operational state;

wherein, during interruption in the received power, the latching relay is capable of maintaining the additional operational state.

16. The lighting control panel of claim 15, wherein the backup power supply is a capacitor or a battery.

17. The lighting control panel of claim 12, wherein the group of available states includes closed, open, and momentary closure.