AU2013100509B4

AU2013100509B4 - Easy connect power control module

Info

Publication number: AU2013100509B4
Application number: AU2013100509A
Authority: AU
Inventors: Jason Gerard
Original assignee: Gerard Lighting Holdings Pty Ltd
Current assignee: Gerard Lighting Holdings Pty Ltd
Priority date: 2012-10-25
Filing date: 2013-04-14
Publication date: 2014-01-16
Anticipated expiration: 2021-04-14
Also published as: AU2013205199A1; AU2013100509A4

Abstract

A modular power control system that includes a connector unit for making contact with a mains cable and an interchangeable control unit for distributing or utilising power from it. The mains cable further includes control signals such as DALI for communicating with the control unit. Control units can be readily interchanged to offer an upgrade path from simple switching using a conventional switch to an intelligent lighting system.

Description

I Easy Connect Power Control Module FIELD OF THE INVENTION [0001] The present invention relates to mains power control, in particular a system providing readily interchangeable power control modules. BACKGROUND TO THE INVENTION [0002] Conventional power control systems utilise switch board mounted components such as relays and dimmers connected by star wiring to loads. These systems require that a new installation is planned from outset and is difficult to retro-fit or convert back to conventional wiring if required. [0003] For a lighting power control system conventional wiring standards have an active cable that is routed down the wall to a switch, the switch completes the circuit and the switched active is routed back up to the load, the other side of the load is then wired to neutral. In this case each circuit is completed as stand-alone. [0004] For conventional wiring the switch may be replaced at the wall with a dimmer switch or an intelligent dimmer that can offer lighting control functions. The stand-alone dimming functions offer limited dimming functionality. Other control inputs such as wireless control can offer control of multiple dimmers, providing some extended functionality such as scene control. These more advanced functions can be expensive and require electrical contractors to install the intelligent dimmers. [0005] The object of this invention is to provide a power control module that alleviates the above problems, or at least provides the public with a useful alternative. SUMMARY OF THE INVENTION [0006] In a first aspect the invention provides a modular power control system comprising a coupling unit including electrically conductive connections to a mains cable and first electrical contacts for accessing power from the mains cable; and a first control unit including second electrical contacts for utilizing or distributing power from via the first electrical contacts of the coupling unit, wherein the electrically conductive connections to the mains cable are made via insulation displacement connectors and the first control unit is readily mechanically interchangeable with a second control unit.

[0007] Preferably the first control unit includes switch contacts between the second electrical contact and a mains power socket. [0008] Preferably the mains cable includes conductors for signaling that are electrically coupled to the first control unit and the first control unit further comprises a DALI (Digital Addressable Lighting Interface) controller used to switch mains power from the second electrical contacts to a mains power socket. [0009] Preferably the coupling unit includes locking tabs for attaching the first control unit via locking holes. [0010] It should be noted that any one of the aspects mentioned above may include any of the features of any of the other aspects mentioned above and may include any of the features of any of the embodiments described below as appropriate. BRIEF DESCRIPTION OF THE DRAWINGS [0011] Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows. [0012] Figure 1 is an exploded view of an easy connect power control module of the invention seen from above. [0013] Figure 2 shows the control module of figure 1 seen from below. [0014] Figure 3 shows a cable fitted to a coupler base. [0015] Figure 4 shows a coupler top fitted to a coupler base. [0016] Figure 5 shows a cut away unit fitted to a coupler. [0017] Figure 6 shows an assembled basic control module. [0018] Figure 7 shows a schematic of a basic control module. [0019] Figure 8 shows a DALI control unit. [0020] Figure 9 shows a schematic of a DALI control unit 100211 Figure 10 shows an intelligent dimmer control unit. [00221] Figure 11 shows an intelligent LED driver control unit. [0023] Figure 12 shows an RGB+W LED driver control unit.

-Y [00241 Figure 13 shows a wireless access control unit. [0025] Figure 14 shows a DC power supply control unit. LIST OF COMPONENTS [0026] The drawings contain the following components [0027] 10 control module (exploded view) 12 control module (assembled) 14 coupler unit 15 mains cable 16 light switch 17 switch cable 20 coupler base 21 cable channel 28 locking holes 29 locking tabs 30 coupler top 31 insulation displacement connectors 32 interconnecting pads 38 locking holes 40 basic control unit 41 PCB 42 interconnecting pads 43 switch terminal block 44 access holes 45 mains socket 46 side walls 49 locking tabs 80 DALI control unit 81 DALI interface circuit 82 commissioning switch 83 indicator LEDs 85 mains switch 100 intelligent dimmer control unit 101 DALI control circuit 102 dimmer switch 103 indicator LEDs 110 intelligent LED driver control unit 111 DALI control circuit 112 control switch 113 indicator LEDs 114 transformer 115 current driver circuit 116 terminal block 120 RGB+W LED driver control unit 121 DALI control circuit 122 commissioning switch 123 indicator LEDs 124 transformer 125 driver circuits 126 terminal block 130 wireless access control unit 131 DALI interface circuit 132 commissioning switch 133 indicator LEDs 135 wireless transceiver 136 antenna 140 DC power supply control unit 141 indicator LED 142 transformer 143 power supply circuit 144 terminal block DETAILED DESCRIPTION OF THE INVENTION [0028] The following detailed description of a preferred embodiment of the invention refers to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings and the following description to refer to the same and like parts. Dimensions of certain parts shown in the drawings may have been modified and/or exaggerated for the purposes of clarity or illustration. In particular circuit elements that are well known are shown as simple blocks and interconnecting wires have been omitted for clarity of illustration [0029] The invention provides an adaptable system for installing mains power wiring. It is suitable for any type of mains power application, and is particularly suited to lighting systems. The present disclosure focuses on lighting applications, but it is to be understood that the features of the invention are suitable for other power control applications [0030] For a basic lighting system the invention provides wiring and functionality equivalent to conventional wiring in which mains power is routed to various light fittings and switch wires are routed to switches. A basic control module provides the interconnectivity between the mains power, switch wire and light fitting. Multiple control modules can be fitted to a single cable. The basic system can be provided and installed at a cost comparable to conventional and can then be upgraded when desired to an intelligent lighting system by merely replacing the basic control modules with intelligent control modules without the need to replace the mains wiring. The intelligent control can be implemented by a DALI (Digital Addressable Lighting Interface) system or the like. This offers considerable cost advantages and flexibility. Of course intelligent controllers or a mix of intelligent and basic controllers could be installed in the first instance. [0031] An exploded view of a control module 10 and a mains cable 15 to which it connects is shown from above in figure 1 and from below in figure 2. Figures 3 to 6 show the various components of the invention coming together to form an assembled control module 12. [0032] A control module 10 comprises 3 main components, a coupling unit for making connections to the mains cable 15 formed by coupler base 20 and coupler top 30, and control unit 40 which provides control functionality, connections to switches and light fittings. A basic control unit 40 is shown in figures 1, 2, 5 and 6 which provides simple switching functionality. Different control units offering increased functionality are shown in subsequent figures. In figure 6 the control unit is shown with side walls 46. The remaining figures show controllers with side walls cut-away to allow the internal components to be viewed.

V [00331 The coupler base 20 would typically be attached to a ceiling joist by means of screws (not shown) and supports a mains cable 15 in cable channel 20. The base includes locking tabs 29 for attaching a coupler top 30 and locking holes 28 for attaching a control unit 40. [0034] The mains cable 15 provides 5 cores for Active, Neutral and Earth mains power signals as well as two control bus signals which in the preferred embodiment are DALI signals. [0035] The coupler top 30 locks together with the base 20 and in doing so makes contact with the cores of the cable 15 by means of insulation displacement connectors 31 on the underside of the top. The mains cable signals are brought to interconnecting pads 32 on the top of the coupler top. The interconnecting pads 32 are arbitrarily separated into 2 groups, one for the mains power signals and the second for the DALI control signals. The coupler top 30 is secured and aligned to the coupler base 20 by means of locking holes 38 in the top and locking tabs 29 in the base. The cable channel 20 of the base is sized to match the width of the cable 15 to ensure that the insulation displacement connectors align with the cable cores. [0036] As shown in figure 4 the coupler base 20 and coupler top 30 together form a coupler unit 14 which can then be fitted with a control unit. The coupler unit provides interconnecting pads 32 that support a variety of different control units. Figure 5 shows a basic control unit 40 fitted to the coupler unit 14 via means of locking tabs 49 of the control unit engaging locking holes 28 of the coupler base 20. Various other control units shown in subsequent figures attach to the coupler unit in the same manner. [0037] The basic control unit 40 is best seen in figures 1 and 2 and comprises PCB 41, mains socket 45 and switch terminal block 43. The underside of the PCB has interconnecting pads 42 to connect to Active, Neutral and Earth power signals from the corresponding interconnecting pads 32 of the coupler top 30. Interconnecting pads for DALI signals are also shown, but not used in the basic controller. The Neutral and Earth signals are connected directly to the mains socket 45 whilst the Active signal is routed to a first pin of the switch terminal block 43. A second pin of the switch terminal block provides a Switched Active signal that is connected to the mains socket 45. Access holes 44 provide access to the screws of the terminal block 43. [0038] A basic control unit 40 is shown in schematic form in figure 6. A conventional light switch 16 is connected via switch cable 17. The mains socket will allow any light requiring mains power to be plugged in. [0039] Figures 8 and 9 show in physical and schematic form a DALI control unit 80 that may be used in place of a basic control unit 40 as part of an intelligent lighting system. The DALI control unit 80 comprises a DALI interface circuit 81 which is used to control a mains switch 85. The DALI control unit utilises the DALI signals from the coupler unit 14. The switch 85 is typically implemented with FETs, but any functional equivalent including a relay could be used. The control unit includes commissioning switch 82 to help with DALI commissioning or for manual operation, and indicator LEDs that may be used during commissioning or display communication activity, faults or switch status. [0040] Figure 10 shows an intelligent dimmer control unit 100 which includes control unit 101 that provides dimmer functionality under DALI control. A dimmer switch 102 is provided for manual dimming operation as well as DAL configuration. Indicator LEDs 103 assist with commissioning and provides status information during normal operation. [0041] Figure 11 illustrates an intelligent LED driver control unit 110 that can be used to drive LED lighting directly under DALI control. This abrogates the need for a separate LED driver and power transformer as may be used in conjunction with the previously discussed control units that provide a mains power output. The LED driver control unit 110 comprises a DALI control circuit 111, transformerl14, current driver circuit 115 and terminal block 116. The control unit includes control switch 112 to help with DALI commissioning or for manual operation, and indicator LEDs that may be used during commissioning or display communication activity, faults or LED output status. [0042] Figure 12 illustrates an intelligent RGB+W LED driver control unit 120 that can be used to drive RGB+W LED lighting directly under DALI control. Similar to the intelligent LED driver control unit 110 this abrogates the need for a separate RGB+W LED driver and power transformer. The RGB+W LED driver control unit 120 comprises a DALI control circuit 121, transformer124, driver circuits 125 and terminal block 126. The control unit includes commissioning switch 122 to help with DALI commissioning or for manual operation, and indicator LEDs that may be used during commissioning or display communication activity, faults or LED output status.

[00431 Figure 13 shows a wireless access control unit 130 which communicates with a remote system controller via antenna 135 and wireless transceiver 136. A DALI interface circuit 1310 conveys signals between the remote system controller and the DALI control signals on the mains cable 15 thus providing communication to other control units connected to the same mains cable. The control unit includes commissioning switch 132 to help with DALI commissioning and indicator LEDs that may be used during commissioning or display communication activity or faults. [0044] Figure 14 shows a DC power supply control unit 140 which operates as a simple DC power source. The control unit comprises a transformer 142, power supply circuit 143, terminal block 144 and indicator LED 141. [0045] Whilst a range of different control units have been discussed many other control units are readily envisaged. In its simplest form the control unit may simply provide screw terminals for the mains cable signals. A more complex example could be an interface to a heating and cooling system [0046] Many further variations of the invention are possible, for example: the mains cable may have a different number of conductors; a different control technology could be employed (e.g. LON instead of DALI); the cable connections could be made by screw terminals; the interconnections between the coupler unit and the control unit could be by any means of connectors; or, the various components could be clipped together in a different fashion or even screwed together. [0047] The reader will now appreciate the present invention which provides: simple installation for easy connection, conventional wiring and upgradable to intelligent control by means of incremental product upgrades; connection of the coupling unit in a safe manner that allows an unlicensed electrician to install this unit for rapid second fit-out; multiple coupling units can be coupled to a single mains cable which is readily associated with a single circuit breaker; simple placement of the coupling unit anywhere along the 5 core circuits position, minimising the cable run from the light fixture; and, simple coupling of wireless control onto the DALI bus to provide wireless control of the intelligent couplers. [0048] Further advantages and improvements may very well be made to the present invention without deviating from its scope. Although the invention has been shown and described in what is conceived to be the most practical and preferred embodiment, it is recognized that departures may be made therefrom within the scope and spirit of the invention, which is not to be limited to the details disclosed herein but is to be accorded the full scope of the claims so as to embrace any and all equivalent devices and apparatus. Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of the common general knowledge in this field. [0049] In the present specification and claims (if any), the word "comprising" and its derivatives including "comprises" and "comprise" include each of the stated integers but does not exclude the inclusion of one or more further integers.

Claims

1. A modular power control system comprising: a coupling unit including electrically conductive connections to a mains cable and first electrical contacts for accessing power from the mains cable; and a first control unit including second electrical contacts for utilizing power via the first electrical contacts of the coupling unit, wherein: the electrically conductive connections to the mains cable are made via insulation displacement connectors; and the first control unit is readily mechanically interchangeable with a second control unit.

2. A system as in claim 1 wherein the first control unit includes switch contacts between the second electrical contacts and a mains power socket.

3. A system as in claim 1 wherein the mains cable includes conductors for signaling that are electrically coupled to the first control unit via the coupling unit.

4. A system as in claim 3 wherein the first control unit further comprises a DALI (Digital Addressable Lighting Interface) controller used to switch mains power from the second electrical contacts to a mains power socket.

5. A system as in any of the preceding claims wherein the coupling unit includes locking tabs for attaching the first control unit via locking holes.