Electronic lock with power failure control circuit

• US 9,019,067 B2
• Filed: 12/30/2010
• Issued: 04/28/2015
• Est. Priority Date: 12/30/2010
• Status: Active Grant

• Current Assignee: Sargent Mfg Co (Assa Abloy AB)
• Original Assignee: Sargent Mfg Co (Assa Abloy AB)
• Inventors: Morse, Steve, Wren, Chris, Bryla, Mark D.
• Primary Examiner(s): PHAM, QUANG
• Application Number:
  US12/981,928
• Publication Number:
  US 20120169453A1
• Time in Patent Office: 1,580 Days
• Field of Search: 340/3.1, 702/80, 307/112, 320/166, 324/764.01, 455/127.1, 455/343.1, 455/343.5, 455/343.6, 455/572, 455/574
• US Class Current: 340/3.1
• CPC Class Codes: E05B 2047/0057 Feeding
• CPC Class Codes: E05B 2047/0059 by transfer between frame and wing
• CPC Class Codes: E05B 2047/0087 Electric spare devices, e.g. auxiliary batteries or capacitors for back up
• CPC Class Codes: E05B 47/00 Operating or controlling locks or other fastening devices by electric or magnetic means electric permutation locks E05B49/00
• CPC Class Codes: E05B 47/0001 with electric actuators; Constructional features thereof for vehicles E05B81/04
• CPC Class Codes: E05C 1/08 with latching action
• CPC Class Codes: G05B 19/042 using digital processors G05B19/05 takes precedence
• CPC Class Codes: Y10T 292/1014 Operating means
• CPC Class Codes: Y10T 70/7113 Projected and retracted electrically

Abstract

An electronic lock with power failure control circuit includes a lock mechanism having a latchbolt movable between extended and a retracted positions and an electrically powered lock actuator to lock and unlock the latchbolt. The power failure control circuit includes a microcontroller and the lock is connected to a primary power source and an auxiliary power source, preferably supercapacitors and charger that can be turned on by the microcontroller and off when the charger signals a full charge. A power monitor circuit detects low voltage on the primary power supply and sets a power failure interrupt causing the microcontroller to execute power failure instructions that control the actuator so that the lock is placed into a desired locked or unlocked final state during the power failure. upon detection of the return of good power, the system resets the lock.

Claims

1. An electronic lock comprising:

a lock including a latchbolt movable between an extended and a retracted position, the lock having a locked state and an unlocked state, the latchbolt being prevented from moving to the retracted position when the lock is in the locked state;

a lock control circuit including a microcontroller and a memory having a stored control program including microcontroller executable instructions for a power failure state and microcontroller executable instructions for a normal power state;

a primary power supply input connected to the lock control circuit and adapted for connection to a primary source of electrical power;

an electrically powered lock actuator connected to the microcontroller, the lock actuator being responsive to a signal from the microcontroller to move the lock between the locked state and the unlocked state;

a power monitor circuit having an input connected to the primary power supply input to detect a power failure condition, the power monitor circuit generates a control output to an electrically controllable switch circuit and a signal output connected to the microcontroller in response to the power failure condition, the power monitor circuit signaling the microcontroller via a power failure signal applied to the signal output when the power failure condition is detected at the primary power supply input;

wherein the power monitor circuit includes a lower voltage threshold and determines the power failure condition based on whether a voltage at the primary power supply input is below the lower voltage threshold and wherein the power monitor circuit includes an upper voltage threshold and signals the microcontroller to stop executing the microcontroller executable instructions for the power failure state and begin executing the microcontroller executable instructions for the normal power state when the voltage at the primary power supply input raises above the upper voltage threshold for a preset period of time after the power failure condition occurred,

an auxiliary power supply having an auxiliary power output;

the electrically controllable switch circuit having a primary power input connected to the primary power supply input, an auxiliary power input connected to the auxiliary power output of the auxiliary power supply, a power output connected to the microcontroller to provide power to the microcontroller and the lock actuator, and a control input connected to the control output of the power monitor circuit, the power monitor circuit controlling the electrically controllable switch circuit to selectively connect the power output between the primary source of electrical power and the auxiliary power supply; and

a visual indicator operable by the microcontroller to indicate the power failure condition;

the microcontroller executing the microcontroller executable instructions for the power failure state after receiving the power failure signal from the power monitor circuit,

wherein the microcontroller executable instructions including;

a normal power loop, corresponding to the normal power state, of the microcontroller executable instructions organized as a cooperative multitasking loop of tasks and executed by the microcontroller to operate the electronic lock in normal power conditions of the normal power state, the normal power loop including;

an instruction for checking to determine if the power monitor circuit has signaled detection of the power failure condition based on the power failure signal applied to the signal output;

an instruction for checking to determine if an at least one supercapacitor of the auxiliary power supply is fully charged;

an instruction for turning on they a supercapacitor charging circuit to charge the at least one supercapacitor when the at least one supercapacitor is not fully charged; and

an instruction for turning off the supercapacitor charging circuit when the at least one supercapacitor is fully charged;

a power failure loop, corresponding to the power failure state, of the microcontroller executable instructions;

the microcontroller executing the power failure loop after the power monitor circuit has signaled the detection of the power failure condition based on the power failure signal applied to the signal output, the power failure loop including;

an instruction for checking to determine if the power monitor circuit has signaled the power failure condition,

an instruction for resetting the microcontroller after the power monitor circuit determines the primary power supply input returned if the voltage of the primary power supply input raises above the upper voltage threshold for the preset period of time;

at least one instruction for turning on the visual indicator to signal the power failure condition after the power monitor circuit has signaled the detection of the power failure condition;

at least one instruction for sending a signal to the lock actuator to switch the lock actuator to a desired locked or unlocked state in response to the power failure condition after the power monitor circuit has signaled the detection of the power failure condition; and

wherein the lower voltage threshold and the upper voltage threshold relate by hysteresis to prevent oscillation at or near transition points between the power failure state and the normal power state whereby upon detecting the power failure condition the electrically controllable switch circuit receives power from the auxiliary power supply to reduce power load on and enable recovery of the primary power supply input, and once the primary power supply input has recovered the electrically controllable switch circuit switching power back to the primary power supply input.

2. The electronic lock of claim 1 wherein the electrically controllable switch circuit includes a diode circuit having first and second power inputs and the power output, the first power input receiving power from the primary power supply input, the second power input receiving power from the auxiliary power supply power output and the power output being connected to provide power to the microcontroller and the lock actuator from the auxiliary power supply during a power failure condition.

3. The electronic lock of claim 2 wherein the diode circuit uses Schottky diodes.

4. The electronic lock of claim 1 further including a voltage regulator circuit connected between the power output of the electrically controllable switch and the microcontroller.

5. The electronic lock of claim 1 wherein the supercapacitor charging circuit connected to the microcontroller, the supercapacitor charging circuit having an input for turning on and off the supercapacitor charging circuit and an output for signaling the microcontroller when the at least one supercapacitor is fully charged, the microcontroller turning on the supercapacitor charging circuit to charge the at least one supercapacitor and turning off the supercapacitor charging circuit when the at least one supercapacitor is fully charged.

6. The electronic lock of claim 5 wherein the microcontroller prevents execution of the microcontroller executable instructions for the power failure state until after the supercapacitor charging circuit has signaled the at least one supercapacitor is fully charged.

7. The electronic lock of claim 6 wherein the microcontroller enables setting of a power failure interrupt after the supercapacitor charging circuit has signaled the at least one supercapacitor is fully charged and the microcontroller sets the power failure interrupt after the power failure interrupt has been enabled and after receiving the power failure signal from the power monitor circuit.

8. The electronic lock of claim 7 wherein the microcontroller handles the power failure interrupt by discontinuing execution of instructions for the normal power state and setting a power failure flag, the microcontroller then returning to the execution of instructions for the normal power state, one such normal power state instruction including checking the power failure flag, the microcontroller leaving the normal power state and entering the power failure state and executing the microcontroller executable instructions for the power failure state only after checking the power failure flag during execution of the normal power state instructions and detecting that the power failure flag has been set.

9. The electronic lock of claim 1 wherein the microcontroller repeatedly checks that power has returned while waiting the preset period of time before resetting the microcontroller.

10. The electronic lock of claim 1 wherein the visual indictor comprises an LED indicator connected to the microcontroller, the microcontroller blinking the LED indicator to indicate the power failure state.

11. The electronic lock of claim 1 wherein the microcontroller disables a WiFi radio after entering the power failure state and before signaling the electrically powered lock actuator to move between the locked state and the unlocked state.

12. A system for shutting down and restarting an electronic lock under power failure conditions comprising:

a microcontroller including a stored control program having a plurality of microcontroller executable instructions;

a lock actuator output adapted for connection to a lock actuator, the lock actuator output being connected to the microcontroller and the microcontroller sending a signal to the lock actuator output to switch the lock actuator between a locked and an unlocked state;

a primary power supply input adapted for connection to a primary source of electrical power;

an auxiliary power supply having at least one supercapacitor for providing auxiliary power and a supercapacitor monitoring and charging circuit connected to the microcontroller;

an electrically controllable switch circuit connected to the primary power supply input and the auxiliary power supply to supply auxiliary power during a power failure condition;

a power monitor circuit having a comparator, the power monitor circuit being connected to the primary power supply input to detect the power failure condition, the power monitor circuit also being connected to the microcontroller to signal a normal power condition and a power failure condition, the power monitor circuit also being connected to the electrically controllable switch circuit and the power monitor circuit switching the electrically controllable switch circuit to selectively connect a power output of the electrically controllable switch circuit between the primary source of electrical power and the auxiliary power supply to provide power to the microcontroller and the lock actuator upon detection of the power failure condition;

wherein the power monitor circuit includes a lower voltage threshold and determines the power failure condition by comparing a voltage at the primary power supply input to the lower voltage threshold, wherein the power monitor circuit includes an upper voltage threshold and signals the microcontroller to stop executing the microcontroller executable instructions for a power failure state and begin executing the microcontroller executable instructions for a normal power state when the voltage at the primary power supply input raises above the upper voltage threshold for a preset period of time after the power failure condition occurred, and wherein the lower voltage threshold and the upper voltage threshold relate by hysteresis to prevent oscillation at or near transition points between the power failure state and the normal power state whereby upon detecting the power failure condition the electrically controllable switch circuit receives power from the auxiliary power supply to reduce power load on and enable recovery of the primary power supply input, and once the primary power supply input has recovered the electrically controllable switch circuit switching power back to the primary power supply input; and

a visual indicator operable by the microcontroller to indicate the power failure condition;

wherein the microcontroller executable instructions including;

a normal power loop, corresponding to the normal power state, of the microcontroller executable instructions organized as a cooperative multitasking loop of tasks and executed by the microcontroller to operate the electronic lock in normal power conditions, the normal power loop including;

an instruction for checking to determine if the power monitor circuit has signaled the detection of the power failure condition;

an instruction for checking to determine if the at least one supercapacitor of the auxiliary power supply is fully charged;

an instruction for turning on the supercapacitor monitoring and charging circuit to charge the at least one supercapacitor when the at least one supercapacitor is not fully charged; and

an instruction for turning off the supercapacitor monitoring and charging circuit when the at least one supercapacitor is fully charged;

a power failure loop, corresponding to the power failure state, of the microcontroller executable instructions;

the microcontroller executing the power failure loop after the power monitor circuit has signaled the detection of the power failure condition, the power failure loop including;

an instruction for checking to determine if the power monitor circuit has signaled the power failure condition,

an instruction for resetting the microcontroller after the power monitor circuit determines the primary power supply input returned if the voltage of the primary power supply input raises above the upper voltage threshold for the preset period of time;

at least one instruction for turning on the visual indicator to signal the power failure condition after the power monitor circuit has signaled the detection of the power failure condition;

at least one instruction for sending a signal to the lock actuator output to switch the lock actuator to a desired locked or unlocked state in response to the power failure condition after the power monitor circuit has signaled the detection of the power failure condition.

13. A method for shutting down and restarting an electronic lock under power failure conditions comprising:

monitoring a primary power supply input of the electronic lock with a power monitor and comparator circuit to detect a power failure condition and a normal power condition by comparing a voltage of the primary power supply input to a lower voltage threshold and an upper voltage threshold;

wherein the electronic lock comprising;

a lock including a latchbolt movable between an extended and a retracted position, the lock having a locked state and an unlocked state, the latchbolt being prevented from moving to the retracted position when the lock is in the locked state;

a lock control circuit including a microcontroller and a memory having a stored control program including microcontroller executable instructions for a power failure state corresponding to the power failure condition and microcontroller executable instructions for a normal power state corresponding to the normal power condition;

the primary power supply input connected to the lock control circuit and adapted for connection to a primary source of electrical power;

an electrically powered lock actuator connected to the microcontroller, the lock actuator being responsive to a signal from the microcontroller to move the lock between the locked state and the unlocked state;

the power monitor and comparator circuit having an input connected to the primary power supply input to detect the power failure condition, the power monitor and comparator circuit generates a control output to the electrically controllable switch circuit and a signal output connected to the microcontroller in response to the power failure condition, the power monitor and comparator circuit signaling the microcontroller via a power failure signal applied to the signal output when the power failure condition is detected at the primary power supply input;

wherein the power monitor and comparator circuit includes the lower voltage threshold and determines the power failure condition by comparing a voltage at the primary power supply input to the lower voltage threshold, wherein the power monitor and comparator circuit includes the upper voltage threshold and signals the microcontroller to stop executing the microcontroller executable instructions for the power failure state and begin executing the microcontroller executable instructions for the normal power state when the voltage at the primary power supply input raises above the upper voltage threshold after the power failure condition occurred, and wherein the lower voltage threshold and the upper voltage threshold related by hysteresis to prevent oscillation at or near transition points between the power failure state and the normal power state whereby upon detecting the power failure condition the electrically controllable switch circuit receives power from the auxiliary power supply to reduce power load on and enable recovery of the primary power supply input, and once the primary power supply input has recovered the electrically controllable switch circuit switching power back to the primary power supply input;

an auxiliary power supply having an auxiliary power output;

the electrically controllable switch circuit having a primary power input connected to the primary power supply input, an auxiliary power input connected to the auxiliary power output of the auxiliary power supply, a power output connected to the microcontroller to provide power to the microcontroller and the lock actuator, and a control input connected to the control output of the power monitor and comparator circuit, the power monitor circuit controlling the electrically controllable switch circuit to selectively connect the power output between the primary source of electrical power and the auxiliary power supply; and

a visual indicator operable by the microcontroller to indicate the power failure condition;

executing tasks, by the microcontroller of the electronic lock, in a loop during the normal power condition;

switching to the auxiliary power supply having at least one supercapacitor in the power failure condition to supply power to the electronic lock from the at least one supercapacitor during the power failure condition;

setting the electronic lock to a desired locked or unlocked state after detecting the power failure condition;

repeatedly monitoring a charge level of the at least one supercapacitor during the normal power condition;

turning on a supercapacitor charger during the normal power condition when the charge level of the at least one supercapacitor is below a desired level;

turning off the supercapacitor charger during the normal power condition when the charge level of the at least one supercapacitor has reached a desired level;

turning on the visual indicator during the power failure condition; and

resetting the electronic lock after the power failure condition has been detected if the normal power condition is subsequently detected for a predetermined period of time.

14. The method of claim 13 wherein the step of executing tasks in a loop during the normal power condition further includes the steps of:

checking to detect the power failure condition after a first indication that the charge level of the at least one supercapacitor has reached a desired level;

setting a power failure flag upon detection of the power failure condition and returning to tasks in the loop executed during the normal power condition; and

checking if the power failure flag has been set, and thereafter executing the steps of setting the electronic lock to a desired locked or unlocked state for the power failure condition, turning on the visual indicator and resetting the electronic lock after the power failure condition has been detected if the normal power condition is subsequently detected.

15. The method of claim 14 further including the step of turning off power consuming functions prior to the step of setting the electronic lock to a desired locked or unlocked state in the power failure condition.