Universal power control device

• US 9,184,590 B2
• Filed: 03/11/2013
• Issued: 11/10/2015
• Est. Priority Date: 04/19/2012
• Status: Active Grant

• Current Assignee: Pass And Seymour Incorporated (Legrand SA)
• Original Assignee: Pass And Seymour Incorporated (Legrand SA)
• Inventors: Testani, Anthony
• Primary Examiner(s): BARNIE, REXFORD N
• Assistant Examiner(s): Willoughby, Terrence
• Application Number:
  US13/792,566
• Publication Number:
  US 20130278058A1
• Time in Patent Office: 974 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: G05F 3/04 wherein the variable is ac
• CPC Class Codes: H02J 3/00 Circuit arrangements for ac mains or ac distribution networks
• CPC Class Codes: H05B 39/04 Controlling
• CPC Class Codes: H05B 47/165 following a pre-assigned programmed sequence; Logic control [LC]
• CPC Class Codes: H05B 47/17 Operational modes, e.g. switching from manual to automatic mode or prohibiting specific operations
• CPC Class Codes: Y02B 20/40 Control techniques providing energy savings, e.g. smart controller or presence detection

Abstract

The present invention is directed to an intelligent dimmer that is capable of “learning” the type of load it is controlling, and adjusts its operating parameters accordingly. The present invention can adaptively drive electrical loads over a wide range of wattages. The intelligent dimmer of the present invention is configured to automatically calibrate itself based on the load current demands of a particular electrical load. The intelligent dimmer of the present invention also adaptively limits in-rush currents to extend the life expectancy of the solid state switching components used therein.

Claims

1. An electrical wiring device comprising:

a housing assembly including a plurality of terminals at least partially disposed therein, the plurality of terminals being configured to be coupled to an AC power source and at least one electrical load, the plurality of terminals being configured to provide the electrical wiring device with AC power in a device energized state and not provide the device with AC power in a device deenergized state;

a load current sensor coupled to the plurality of terminals and configured to provide a current sensor signal based on a current propagating through the at least one electrical load;

at least one variable control mechanism coupled to the housing assembly, the at least one variable control mechanism being configured to adjustably select a user adjustable load setting, the user adjustable load setting being adjustable between a minimum setting and a maximum setting;

at least one series pass element coupled to the at least one variable control mechanism, the at least one series pass element being configured to provide load power to the at least one electrical load in accordance with the user load setting;

a regulation circuit coupled to the load current sensor and the at least one series pass element, the regulation circuit being configured to enter a calibration mode when the device transitions from the device deenergized state to the device energized state such that the regulation circuit directs the at least one series pass element to incrementally increase the load voltage value until a load-determined current threshold is reached defining a calibration load voltage value, the regulation circuit being configured to adjust the minimum setting to substantially correspond to the calibration load voltage value.

2. The device of claim 1, wherein the plurality of terminals includes a neutral terminal or a ground terminal to which the power supply is coupled.

3. The device of claim 1, further comprising a power supply being configured to provide at least one source of voltage derived from the AC power source.

4. The device of claim 3, wherein the power supply is a half wave power supply that is coupled to the AC power source via one of three diodes.

5. The device of claim 3, wherein the plurality of terminals includes a first traveler terminal and a second traveler terminal, the power supply being individually coupled to each traveler by way of a diode.

6. The device of claim 5, wherein the plurality of terminals includes a phase terminal configured to be coupled to either the AC power source or the at least one load, the power supply being coupled to the phase terminal by way of a diode.

7. The device of claim 6, wherein the regulation circuit includes a zero cross circuit coupled to receive power from the AC power source via one of three electrical paths, each of the three electrical paths including a diode.

8. The device of claim 7, wherein each of the three electrical paths are coupled to one of the first traveler terminal, the second traveler terminal and a phase terminal.

9. The device of claim 6, wherein the regulation circuit is configured to enter the calibration mode if the phase terminal is coupled to either the AC power source or to one of the electrical loads.

10. The device of claim 1, wherein the plurality of terminals includes a phase terminal, and wherein the regulation circuit is configured to enter the calibration mode if the phase terminal is coupled to either the AC power source or to one of the electrical loads.

11. The device of claim 10, wherein the load current sensor is disposed in series with the phase terminal.

12. The device of claim 10, wherein the at least one series pass element is disposed in series with the phase terminal.

13. The device of claim 12, further including a latching relay configured to selectively couple the phase terminal to selected ones of the plurality of terminals.

14. The device of claim 1, wherein the regulation circuit includes a latching relay configured to selectively couple one of the plurality of terminals to at least one other terminal of the plurality of terminals.

15. The device of claim 14, wherein the regulation circuit is configured to actuate the latching relay in calibration mode until it detects the current sensor signal.

16. The device of claim 1, wherein the regulation circuit is configured to set the load determined current threshold to a predetermined current threshold if the current sensor signal is not detected within a predetermined period of time.

17. The device of claim 1, wherein the regulation circuit is configured to incrementally increase the load voltage from the minimum load voltage value to the calibration load voltage value in predetermined step increases.

18. The device of claim 17, wherein the regulation circuit is configured to determine that the current sensor signal corresponds to the load determined current threshold when a predetermined number of current sensor signal samples obtained during a step increase is greater than or equal to the load determined current threshold.

19. The device of claim 17, wherein the minimum load voltage value provided during calibration mode corresponds to a predetermined minimum current sensor signal level.

20. The device of claim 1, wherein the minimum load voltage value provided during calibration mode corresponds to a predetermined minimum current sensor signal level.

21. The device of claim 1, wherein the minimum load voltage value is incrementally increased by an amount corresponding to a pre-defined safety factor.

22. The device of claim 1, wherein the at least one series pass element is switchable between a forward phase control mode and a reverse phase control mode.

23. The device of claim 22, wherein the regulation circuit is configured select either the forward phase control mode or the reverse phase control mode based on a measurement of at least one parameter of the current sensor signal.

24. The device of claim 23, wherein the at least one measurement parameter includes measurement of an inrush current.

25. The device of claim 1, further including a manual adjustment member configured to provide an adjustable low end setting configured to manually adjust the minimum setting to a low preset load voltage value.

26. The device of claim 1, further including a manual adjustment member configured to provide an adjustable high end setting configured to manually adjust the maximum setting to a high preset load voltage value.