Universal power control device

• US 9,419,435 B2
• Filed: 11/09/2015
• Issued: 08/16/2016
• Est. Priority Date: 04/19/2012
• Status: Active Grant

• Current Assignee: Pass & Seymour Incorporated (Legrand SA)
• Original Assignee: Pass & Seymour Incorporated (Legrand SA)
• Inventors: Testani, Anthony
• Primary Examiner(s): Barnie, Rexford
• Assistant Examiner(s): WILLOUGHBY, TERRENCE RONIQUE
• Application Number:
  US14/936,086
• Publication Number:
  US 20160064929A1
• Time in Patent Office: 281 Days
• Field of Search: 307/31
• 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;

a sensor element coupled to the plurality of terminals and configured to provide a sensor signal based on at least one load power parameter of 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 between the AC power source and at least one electrical load, the at least one series pass element being configured to provide output power to the at least one electrical load in accordance with the user load setting, the output power being less than or equal to the AC power; and

a regulation circuit coupled to the sensor element and the at least one series pass element, the regulation circuit being configured to enter a calibration mode when AC power is applied to at least a portion of the plurality of terminals, in the calibration mode the regulation circuit being configured to provide the at least one series pass element with an initial output power setting while monitoring the at least one load power parameter, the regulation circuit being further configured to increment the initial output power setting to at least one incremental output power setting while monitoring the at least one load power parameter, the regulation circuit being configured to identify a load type of the at least one electrical load based on the at least one incremental output power setting and the at least one load power parameter that results in the at least one electrical load being energized, the regulation circuit selecting calibration values based on the load type, the selected calibration values corresponding to the minimum setting and the maximum setting.

2. The device of claim 1, wherein the plurality of terminals includes a neutral terminal or a ground terminal.

3. The device of claim 1, wherein the identified load type determines if the at least one electrical load operates in a forward phase control mode or a reverse phase control mode.

4. The device of claim 1, wherein the regulation circuit includes a microcontroller coupled to a memory, the memory being configured to store a plurality of characteristic load curves stored therein, the plurality of characteristic load curves including a plurality of incremental power settings and a plurality of load power parameters, each characteristic load curve of the plurality of characteristic load curves correlating each load type with a predetermined incremental output power setting versus a predetermined load power parameter.

5. The device of claim 4, wherein the predetermined load power parameter includes an inrush current parameter.

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

7. The device of claim 6, wherein the power supply is a half wave power supply that is selectively coupled to the AC power source via one of three diodes, and wherein the plurality of terminals includes a phase terminal, a first traveler terminal and a second traveler terminal, the power supply being individually coupled to phase terminal, a first traveler terminal and a second traveler terminal by corresponding diodes of the three diodes.

8. The device of claim 1, wherein the regulation circuit includes a zero cross circuit coupled to the AC power source via one of three electrical paths, each of the three electrical paths including a diode.

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

10. The device of claim 1, wherein the regulation circuit is configured to enter the calibration mode when at least a portion of the at least one variable control mechanism is actuated.

11. The device of claim 10, wherein the portion includes an ON/OFF control.

12. The device of claim 1, wherein the sensor element is a current sensor configured to sense current propagating through the at least one electrical load.

13. The device of claim 1, wherein the at least one electrical load is selected from a group of electrical loads including a variable speed motor, an incandescent lighting load, a magnetic low voltage (MLV) load, a fluorescent lighting load, an electronic ballast (EFL) type lighting load, a halogen light load, an electronic low voltage (ELV) load, and a compact florescent light (CFL) load.

14. The device of claim 1, wherein the series pass element is selected from a group of series pass elements including a thyristor device, a triac device, and at least one transistor device.

15. The device of claim 14, wherein the at least one transistor device includes a first MOSFET transistor coupled to a second MOSFET transistor, the first MOSFET transistor being configured to provide the output power in a first half cycle of the AC power source and the second MOSFET transistor being configured to provide the output power in a second half cycle of the AC power source.

16. 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;

a sensor element coupled to the plurality of terminals and configured to provide a sensor signal based on at least one load power parameter of 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 between the AC power source and at least one electrical load, the at least one series pass element being configured to provide output power to the at least one electrical load in accordance with the user load setting, the output power being less than or equal to the AC power; and

a regulation circuit coupled to the sensor element and the at least one series pass element, the regulation circuit being configured to enter a calibration mode when AC power is applied to at least a portion of the plurality of terminals, in the calibration mode the regulation circuit being configured to provide the at least one series pass element with an initial output power setting while monitoring the at least one load power parameter, the regulation circuit being further configured to increment the initial output power setting to at least one incremental output power setting while monitoring the at least one load power parameter, the regulation circuit being configured to select a forward phase control mode or a reverse phase control mode based on the at least one incremental output power setting or the at least one load power parameter that results in the at least one electrical load being energized.

17. The device of claim 16, wherein the regulation circuit selects calibration values based on which of the forward phase control mode or the reverse phase control mode is selected, the selected calibration values corresponding to the minimum setting and the maximum setting.

18. The device of claim 16, wherein the regulation circuit is configured to identify a load type of the at least one electrical load based on the at least one incremental output power setting and the at least one load power parameter that results in the at least one electrical load being energized, the regulation circuit selecting calibration values based on the load type, the selected calibration values corresponding to the minimum setting and the maximum setting.

19. The device of claim 16, wherein the plurality of terminals includes a neutral terminal or a ground terminal.

20. The device of claim 16, wherein the regulation circuit includes a microcontroller coupled to a memory, the memory being configured to store a plurality of characteristic load curves stored therein, the plurality of characteristic load curves including a plurality of incremental power settings and a plurality of load power parameters, each characteristic load curve of the plurality of characteristic load curves correlating each load type with a predetermined incremental output power setting versus a predetermined load power parameter.

21. The device of claim 16, further comprising a power supply coupled to the AC power source, the power supply being configured to provide at least one supply voltage.

22. The device of claim 21, wherein the power supply is a half wave power supply that is selectively coupled to the AC power source via one of three diodes, and wherein the plurality of terminals includes a phase terminal, a first traveler terminal and a second traveler terminal, the power supply being individually coupled to phase terminal, a first traveler terminal and a second traveler terminal by corresponding diodes of the three diodes.

23. The device of claim 16, wherein the regulation circuit includes a zero cross circuit coupled to the AC power source via one of three electrical paths, each of the three electrical paths are selectively coupled to one of a first traveler terminal, a second traveler terminal or a phase terminal via a diode.

24. The device of claim 16, wherein the regulation circuit is configured to enter the calibration mode when at least a portion of the at least one variable control mechanism is actuated, the portion including an ON/OFF control.

25. The device of claim 16, wherein the sensor element is a current sensor configured to sense current propagating through the at least one electrical load.

26. The device of claim 16, wherein the at least one electrical load is selected from a group of electrical loads including a variable speed motor, an incandescent lighting load, a magnetic low voltage (MLV) load, a fluorescent lighting load, an electronic ballast (EFL) type lighting load, a halogen light load, an electronic low voltage (ELV) load, and a compact florescent light (CFL) load.

27. The device of claim 16, wherein at least one load power parameter is based on a current propagating through the at least one electrical load.

28. The device of claim 16, wherein the series pass element is selected from a group of series pass elements including a thyristor device, a triac device, and at least one transistor device.

29. The device of claim 28, wherein the at least one transistor device includes a first MOSFET transistor coupled to a second MOSFET transistor, the first MOSFET transistor being configured to provide the output power in a first half cycle of the AC power source and the second MOSFET transistor being configured to provide the output power in a second half cycle of the AC power source.

30. A method for controlling an electrical wiring device, the method comprising:

providing a housing assembly having 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 housing also including 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, the housing further including at least one series pass element coupled between the AC power source and at least one electrical load, the at least one series pass element being configured to provide output power to the at least one electrical load in accordance with the user load setting, the output power being less than or equal to the AC power;

entering a calibration mode when AC power is applied to at least a portion of the plurality of terminals;

providing the at least one series pass element with an initial output power setting while monitoring at least one load power parameter;

incrementing the initial output power setting to at least one incremental output power setting while monitoring the at least one load power parameter; and

selecting a forward phase control mode or a reverse phase control mode based on the at least one incremental output power setting or the at least one load power parameter that results in the at least one electrical load being energized.

31. The method of claim 30, further comprising the step of selecting the calibration values based on which of the forward phase control mode or the reverse phase control mode is selected, the selected calibration values corresponding to the minimum setting and the maximum setting.

32. The method of claim 30, further comprising the step of identifying a load type of the at least one electrical load based on the at least one incremental output power setting and the at least one load power parameter that results in the at least one electrical load being energized.

33. The method of claim 30, further comprising the step of selecting calibration values based on the load type, the selected calibration values corresponding to the minimum setting and the maximum setting.

34. The method of claim 30, wherein the plurality of terminals includes a neutral terminal or a ground terminal.

35. The method of claim 30, wherein the step of providing includes providing a microcontroller coupled to a memory, the memory being configured to store a plurality of characteristic load curves stored therein, the plurality of characteristic load curves including a plurality of incremental power settings and a plurality of load power parameters, each characteristic load curve of the plurality of characteristic load curves correlating each load type with a predetermined incremental output power setting versus a predetermined load power parameter.

36. The method of claim 30, wherein the step of providing includes providing a power supply coupled to the AC power source, the power supply being configured to provide at least one supply voltage.

37. The method of claim 36, wherein the power supply is a half wave power supply that is selectively coupled to the AC power source via one of three diodes, and wherein the plurality of terminals includes a phase terminal, a first traveler terminal and a second traveler terminal, the power supply being individually coupled to phase terminal, a first traveler terminal and a second traveler terminal by corresponding diodes of the three diodes.

38. The method of claim 30, wherein the step of providing includes providing a zero cross circuit coupled to the AC power source via one of three electrical paths, each of the three electrical paths are selectively coupled to one of a first traveler terminal, a second traveler terminal or a phase terminal via a diode.

39. The method of claim 30, further comprising the step of entering a calibration mode when at least a portion of the at least one variable control mechanism is actuated, the portion including an ON/OFF control.

40. The method of claim 30, wherein the series pass element is selected from a group of series pass elements including a thyristor device, a triac device, and at least one transistor device.

41. The method of claim 40, wherein the at least one transistor device includes a first MOSFET transistor coupled to a second MOSFET transistor, the first MOSFET transistor being configured to provide the output power in a first half cycle of the AC power source and the second MOSFET transistor being configured to provide the output power in a second half cycle of the AC power source.