Smart sense fixture connector with split sensor

Abstract

This document describes techniques for overcoming problems with shadowing from sensors in an architectural linear continuous run light fixture. A split sensor is described to detect occupancy, daylight, and infrared, the sensor is formed to a minimal profile to eliminate shadowing in a seamless run over the length of the lighting fixture.

Description

[0001] 2024PF80202

[0002] 1

[0003] Smart Sense Fixture Connector with Split Sensor

[0004] TECHNICAL FIELD

[0005] This patent relates to lighting in general, and specifically to sensors for lighting.

[0006] BACKGROUND

[0007] Linear and architectural lighting fixtures (for example, the SIGNIFY CONTINUA and DEFINE lighting product lines) can be joined and assembled to form a continuous run fixture based on the customer’s need. These fixtures can be suspended, recessed (ceiling mounted), wall or surface mounted. These lights require intelligent sensors and wireless radio capability to permit the coordination of lighting fixtures and the sensing of occupancy, daylight, and infrared detection to determine when to illuminate the area under the lighting fixture.

[0008] SUMMARY OF INVENTION

[0009] A solution is described herein that offers a “smart fixture connector” that can be used to join two lighting fixtures (e.g. two linear fixtures). The “smart fixture connector” is designed with a consistent diffusing lens used on the ground-facing side of the fixture with a small miniature opening for the sensor element to sense the ambient environment. The proposed inventions provide a smart sense fixture connector that connects two linear type fixtures and provides a seamless run over length without unpleasing breaks, by keeping the same diffuser material throughout the run.

[0010] This invention also proposes splitting the existing ambient sensors into two parts - a sensor board and a main board. The sensor board shall be redesigned to fit sensing components in a small thin form factor that shall be placed vertically on top of the diffuse lens of the “Smart Fixture Connector”.

[0011] In some aspects, the techniques described herein relate to an apparatus including: a u-shaped connector configured to mate on a first open side with an end of a first lighting element and on a second open side with an end of a second lighting element, and further configured to accept, on a third open side adjacent to both the first and second opens 2024PF80202

[0012] 2 sides, a consistent diffuse lens having an opening; a main board configured to attach to an inner surface of the u-shaped connecter, the main board including a light control interface configured to interface with LED drivers of the first and second lighting elements and further including a main processor; and a sensor board electrically connected to the main board and having at least one sensing component and a sensor processor configured to communicate sensor data from the at least one sensing component to the main processor, where the at least one sensing component is configured to attach to the opening of the consistent diffuse lens.

[0013] In some aspects, the techniques described herein relate to an apparatus wherein the u-shaped connecter has a cuboid shape.

[0014] In some aspects, the techniques described herein relate to an apparatus wherein the first and second open sides are parallel sides of the cuboid shape.

[0015] In some aspects, the techniques described herein relate to an apparatus where the sensor board is mechanically connected to the opening in the consistent diffuse lens with double-sided tape.

[0016] In some aspects, the techniques described herein relate to an apparatus where the at least one sensing component is an occupancy sensor.

[0017] In some aspects, the techniques described herein relate to an apparatus where the at least one sensing component is a daylight sensor.

[0018] In some aspects, the techniques described herein relate to an apparatus where the sensor board communicates with the main board using a universal asynchronous receiver / transmitter (UART).

[0019] In some aspects, the techniques described herein relate to an apparatus wherein the light control interface communicates with the LED drivers using a UART, digital addressable lighting interface (DALI), or 0-10 V signaling.

[0020] In some aspects, the techniques described herein relate to an apparatus further including a radio module.

[0021] In some aspects, the techniques described herein relate to an apparatus wherein the radio module is configured to wirelessly connect to one or more components of a lighting network.

[0022] In some aspects, the techniques described herein relate to a lighting network having a plurality of apparatuses described above, wherein the radio module of a first one of the plurality of apparatuses is configured to connect to radio modules of one or more others of the plurality of apparatuses. 2024PF80202

[0023] 3

[0024] In some aspects, the techniques described herein relate to an apparatus wherein the radio module of the first one of the plurality of apparatuses is configured to exchange sensor data with the radio modules of the one or more others of the plurality of apparatuses.

[0025] In some aspects, the techniques described herein relate to an apparatus wherein the radio module is configured to use a Bluetooth protocol or a Zigbee protocol.

[0026] In some aspects, the techniques described herein relate to an apparatus wherein the sensor board is mechanically mounted to the u-shaped connector.

[0027] In some aspects, the techniques described herein relate to an apparatus further comprising biscuit connectors configured to attach the u-shaped connector to the first lighting element.

[0028] BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0029] To easily identify the discussion of any particular element or act, the most significant digit or digits in a reference number refer to the figure number in which that element is first introduced.

[0030] Fig. 1 illustrates a cross-section of the lighting controller apparatus in accordance with one embodiment.

[0031] Fig. 2 illustrates a perspective view of the rectangular prism, the main board, and the sensor board in accordance with one embodiment.

[0032] Fig. 3 illustrates a perspective view of the lighting controller unit with a lighting fixture and a consistent diffuse lens in accordance with one embodiment.

[0033] Fig. 4 illustrates a perspective view of the lighting controller unit with two lighting fixtures and a consistent diffuse lens in accordance with one embodiment.

[0034] Fig. 5 illustrates a consistent diffuse lens with a miniature opening in accordance with one embodiment.

[0035] Fig. 6 illustrates the shadowing on a consistent diffuse lens around the miniature opening in accordance with one embodiment.

[0036] Fig. 7 illustrates a functional block diagram of the main board and the sensor board in accordance with one embodiment.

[0037] DESCRIPTION OF EMBODIMENTS

[0038] The proposed smart fixture controller apparatus includes a lighting connector 102 with a diffuse lens 106 and a sensor assembly 724 having a sensor board 112 and a main board 110. The lighting connector 102 is used to connect two lighting fixtures 302, 402. The 2024PF80202

[0039] 4 lighting connector 102 Explain that connector 104 can interconnect two lighting fixtures 302, 402, one in front and one in back. The lighting connector 102 is made up of the same or similar material to the respective lighting fixtures 302,402, and placed between the lighting fixtures 302,402. The bottom portion or open side 202 of the lighting connector 102 is open to enable the diffuse lens 106 to slide through its legs and includes one or more miniature openings 108 for connecting / positioning sensor elements 712,714,716.

[0040] The main board 110 of the sensor assembly 724 includes a board interface 718 to interface with the sensor board 112 portion of the sensor assembly 724. Board interface 718 can include, for example, a UART, a CAN interface, an RS485 interface, a MODBUS interface, a DALI interface, etc. The device interface 720 is coupled between and provides communication between the main MCU 702 and the LED drivers 114 to control light levels on the illumination LEDs 722. Device interface 720 may optionally communicate with other smart fixture controller apparatuses and / or other wireless components in a lighting network. The main MCU 702 serves as the controller of the main board 110. It controls the light illumination levels on the LEDs 722 using the light control interface 706 module and communicates with LED driver 114 using the device interface 720. The device interface 720 could include one of the following protocols: UART, DALI, 0-10V interface, or similar.

[0041] The sensor board 112 can be positioned in the open side 202 of the lighting connector 102 to sense desired environmental parameters. The sensor board 112 is designed in a vertical and thin form factor to enable it to be placed on top of the diffuse lens 106 vertically to reduce the shadow effect and the weight of the sensor. The main board 110 is positioned above the reflector 116 inside the smart fixture connector, ensuring no shadows from the main board 110.

[0042] Linear architectural lighting fixtures 302,402 can be joined and assembled to form a continuous run fixture based on customer need. The smart fixture connector may have the following main elements:

[0043] Fixture connector with diffuse lens: The smart fixture connector connects two different lighting fixtures 302, 402 using existing methods of fastening two fixtures. It uses a consistent diffuse lens 106 on the ground facing open side 202 of the lighting connector 102 with a small miniature opening 108 in the center to mount the sensor board 112. This gives the illusion of a continuous run fixture without any breaks.

[0044] Sensor assembly 724: The lighting connector 102 splits the functionality of the ambient sensors into two parts - a sensor board 112 and a main board 110. 2024PF80202

[0045] 5

[0046] The sensor board 112 may be designed to fit sensing components in a small thin form factor that shall be placed vertically on the top of the miniature opening 108 on the diffuse lens 106 of the smart fixture connector.

[0047] The main board 110 may include a radio module 704 configured to connect to and communicate with other smart fixture controller apparatuses and / or other wireless components in the lighting network.

[0048] DETAILED DESCRIPTION OF DRAWINGS

[0049] FIG. 1 shows a cross-section of the smart fixture controller apparatus, including the lighting connector 102, the diffuse lens 106, and a lighting fixture 302 in the background. The lighting connector 102 comprises a u-shaped connector frame 104 with an open side 202. The open side 202 can be closed in with the diffuse lens 106. The parallel front and rear sides are open, and this view shows through to the lighting fixture 302. In some embodiments, a reflector 116 is mounted across the open side 202 at an angle to reflect the light from the illumination LEDs 722 in the lighting fixture 302.

[0050] The lighting connector 102 contains the main board 110 that can be mounted to the side wall of the u-shaped connector frame 104, for example using an adhesive such as double-sided tape 306. The main board 110 may be connected to the sensor board 112 with a wire set (e.g., a 4-wire set) corresponding to board interface 718. The sensor board 112 can be mounted on the diffuse lens 106, and is held to a miniature opening 108 in the diffuse lens 106 using an adhesive such as double-sided tape 304.

[0051] The lighting fixture 302 has a reflector 116, illumination LEDs 722, and an LED driver 114 that are visible through the lighting connector 102. The LED driver 114 may be connected directly to the illumination LEDs 722. The LED driver 114 may be connected by a wire set to the main board 110 on the lighting connector 102.

[0052] FIG. 2 shows a perspective view of the lighting connector 102. The u-shaped connector frame 104 could be ABS plastic, Low-density polyethylene (LDPE) plastic, Polyethylene terephthalate (PET) plastic, High-density polyethylene (HDPE) plastic, Polypropylene (PP) plastic, Vinyl / polyvinyl chloride (PVC) plastic, Polystyrene (PS) plastic, Polycarbonate plastic, silicone, glass, aluminum, brass, bronze, copper, lead, gold, silver, platinum, steel, ceramic, and similar materials. The u-shaped connector frame 104 used could be formed through injection molding, 3D printing, subtractive methods (milling), vacuum forming, polymer casting, extrusion, blow molding, rotational molding, etc. The 2024PF80202

[0053] 6 lighting connector 102 may be made of the same material as the lighting fixtures 302, 402 and may have a protrusion / mating part that aligns with the respective fixture's housing.

[0054] The u-shaped connector frame 104 is a three-sided cuboid structure with three open sides. One side is an open side 202 on the bottom. The open side 202 has slots just inside of the opening, on the parallel walls of the u-shaped connector frame 104, configured to receive the diffuse lens 106 by allowing the diffuse lens 106 to slide through the slots. Alternately, the diffuse lens 106 could be flexed to snap into the slots.

[0055] There are two parallel sides of the u-shaped connector frame 104 that are open and configured to mate with the sides of the lighting fixtures 302, 402. Alternatively, a closed-end plate could be used to enclose one or both of the two parallel open sides.

[0056] The sensor assembly 724 could be mounted inside of the u-shaped connector frame 104. The main board 110 can be mounted to one of the parallel sides of the u-shaped connector frame 104, for example using an adhesive such as double-sided tape 306. In other embodiments, the main board 110 may be attached to the u-shaped connector frame 104 with an adhesive, by mechanical means such as screws, bolts, snap, clips, wires, or similar. In some embodiments, the main board 110 is injection molded at the same time as the molding of the u-shaped connector frame 104, perhaps through a two-part injection molding process (overmolding).

[0057] FIG. 3 shows a perspective view of the lighting connector 102 as it is about to connect to a lighting fixture 302. The diffuse lens 106 is seen with the miniature opening 108. The sensor board 112 can be held to the diffuse lens 106 using an adhesive, such as double-sided tape 304. In other embodiments, the sensor board 112 may be attached to the diffuse lens 106 with an adhesive, by mechanical means such as screws, bolts, snaps, clips, wires, or similar. In some embodiments, the sensor board 112 is injection molded at the same time as the molding of the diffuse lens 106, perhaps through a two-part injection molding process. In some embodiments, to mount the sensor board 112 onto the diffuse lens 106, an adhesive (e.g. double-sided tape 304) will be used along with drilling a miniature opening 108 in the diffuse lens 106 in the appropriate location.

[0058] To connect two lighting fixtures 302, 402 together with a smart fixture connector, biscuit aligners may be used. The smart fixture connector may be designed to have the same mating part as the lighting fixture 302, 402 housing design. This allows two lighting fixtures 302, 402 to be separated, and a lighting connector 102 inserted in between. 2024PF80202

[0059] 7

[0060] The main board 110 and the sensor board 112 may be connected together with a 4-wire set to support a UART interface corresponding to board interface 718) or may communicate through a radio interface.

[0061] FIG. 4 shows the lighting connector 102 from the top right side as it is to be connected between the lighting fixture 302 and the second lighting fixture 402. The diffuse lens 106 is seen with the miniature opening 108. The double-sided tape 304 is shown for connecting the sensor board 112 to the diffuse lens 106.

[0062] FIG. 5 shows the same components as FIG. 4, from the bottom perspective, as assembled. The diffuse lens 106 is located in the slots in the lighting connector 102, the lighting fixture 302, and the second lighting fixture 402. This is the view most will see of the overall lighting fixtures. The environmental sensors 502 are visible in the miniature opening 108 in the diffuse lens 106.

[0063] FIG. 6 is a simulation illuminance diagram showing the intensity of the light from two lighting fixtures 302, 402 with the lighting connector 102 installed between the fixtures. The miniature opening 108 can be seen in the middle of the diagram. This diagram shows the minimal shadowing of the lighting connector 102.

[0064] FIG. 7 shows a high-level block diagram for the sensor assembly 724, including the split sensor with the required interfaces. The sensor assembly 724 splits the ambient sensor functionality into 2 parts - a sensor board 112 and a main board 110. The sensor board 112 may include all of the required environment sensing components.

[0065] The environmental sensing components may include the passive infrared ("PIR") motion sensor to determine occupancy (occupancy sensor 712), which may be electrically connected to the sensor MCU 710 through general -purpose input and output pins on the sensor MCU 710. In some embodiments, an analog signal is returned from the occupancy sensor 712 to the sensor MCU 710. In other embodiments, an analog-to-digital converter may be used for the interface, returning a digital value. A PIR sensor can detect changes in the amount of infrared radiation impinging upon it, which varies depending on the temperature and surface characteristics of the objects in front of the sensor. When an object, such as a person, passes in front of the background, such as a wall, the temperature at that point in the sensor's field of view will rise from room temperature to body temperature, and then back again. The sensor converts the resulting change in the incoming infrared radiation into a change in the output voltage, and this triggers the detection. Objects of similar temperature but different surface characteristics may also have a different infrared emission 2024PF80202

[0066] 8 pattern, and thus moving them with respect to the background may trigger the detector as well.

[0067] The environmental sensing components may include a daylight sensor 714 connected to the sensor MCU 710 with an analog-to-digital converter. In some embodiments, an analog signal is returned from the daylight sensor 714 to the sensor MCU 710. In other embodiments, general -purpose input and output pins on the sensor MCU 710 may be used for the interface. The daylight sensor 714 may use a photocell to detect the level of light in an environment. In some embodiments, the amount of light is returned as an analog signal that the sensor MCU 710 may convert into a Boolean value based on a threshold. In other embodiments, the daylight sensor 714 has a built-in threshold level and returns an on-off signal to a general -purpose sensor MCU 710 pin.

[0068] The environmental sensing components may include an infrared sensor 716. that may be electrically connected to the sensor MCU 710 through general -purpose input and output ("GPIO") pins on the sensor MCU 710. In other embodiments, an analog-to-digital converter may be used for the interface. The infrared sensor 716 may be an active infrared sensor, utilizing an LED and a receiver to detect infrared light from the LED that reflects off of an object. When an object comes close to the sensor, the infrared light from the LED reflects off of the object and is detected by the receiver. Active IR sensors act as proximity sensors. In other embodiments, the infrared sensor 716 receives commands or signals from a remote-control device. This remote-control device could be used to identify, configure, calibrate, etc. the lighting connector 102.

[0069] The sensor MCU 710 could be a processor, an ASIC, a small microprocessor, or custom logic with several GPIO pins, perhaps a few analog pins to a built-in analog-to- digital converter, and may have a UART interface (board interface 718) for serial communications. The UART interface may provide a transmit pin, a receive pin, a 12-volt power pin, and a ground pin operating a serial protocol. Serial protocols could be proprietary, MODBUS, TCP / IP, etc.

[0070] The sensor board 112 may be interfaced with main board 110 via a 4-wire cable with full duplex UART communication lines (Rx & TX) and 2 wires for power supply (VCC and GND). The main board 110 may provide the required interfaces for wireless control (Zigbee or Bluetooth) and LED driver interfaces (Serial, DALI, or 0-10V).

[0071] Previous ambient sensors are assembled in horizontal form factor with all components placed on a single board, which poses two problems: the use of the bulky sensor and placing it horizontally on the diffuse lens 106 creates a shadow on the diffuse lens 106 2024PF80202

[0072] 9 when a fixture is lit-up, and the sensor is too heavy to place on the diffuse lens 106, creating a bulge on the diffuse lens 106 and with time might damage the material in the diffuse lens 106.

[0073] To avoid these two problems, the sensor assembly 724 is split into two parts. The sensor board 112 could be designed in a vertical and thin form factor such that it can be conveniently placed on top of the diffuse lens 106 vertically to reduce the shadow effect and the weight of the sensor. The main board 110 could be placed above the reflectors 116 inside the smart fixture connector, ensuring no shadows from the sensor.

[0074] The main board 110 has a main MCU 702. The main MCU 702 could be a processor, an ASIC, a small microprocessor, a Bluetooth chipset, a Zigbee chip, or custom logic with several GPIO pins, perhaps a few analog pins to a built-in analog-to-digital converter, and may have a UART interface (board interface 718) for serial communications. The UART interface may provide a transmit pin, a receive pin, a 12-volt power pin, and a ground pin, and may be used to interface with the sensor board 112. The main MCU 702 may have a radio module 704 for wireless communication with other main MCUs 702 in other lighting connectors 102. In some embodiments, the radio module 704 could wirelessly communicate with other wireless components in a lighting network. This communication may include the exchange of sensor readings with the other lighting connectors 102 so that the energizing of the lighting fixtures 302, 402 can be coordinated. In some embodiments, the sensor board 112 also has a radio module, and the sensor data is exchanged between the sensor board 112 and the main board 110 wirelessly, perhaps using Bluetooth, Zigbee, NFC, or another simple protocol. In some embodiments, the sensor board radio module could wirelessly communicate with other wireless components in a lighting network.

[0075] The main board 110 may also include a light control interface 706 connected to the main MCU 702. The light control interface 706 provides instructions to the LED driver 114 to power the illumination LEDs 722 and at what intensity. Color instructions may also be sent to the LED driver 114.

[0076] The device interface 720 between the light control interface 706 and the LED driver 114 may be a UART interface with a transmit pin, a receive pin, a 12-volt power pin, and a ground pin operating a serial protocol.

[0077] In other embodiments, the device interface 720 between the main board 110 and the LED driver 114 may include a digital addressable lighting interface (DALI), as specified by a series of technical standards in IEC 62386. A DALI network consists of at least one application controller and bus power supply (which may be built into any of the 2024PF80202

[0078] 10 products) as well as input devices (e.g. sensors and push-buttons), control gear (e.g., electrical ballasts, LED drivers and dimmers) with DALI interfaces. Application controllers can control, configure, or query each device by means of a bi-directional data exchange. Unlike DMX, multiple controllers can co-exist on the bus. The DALI protocol permits addressing devices individually, in groups, or via broadcast. Scenes can be stored in the devices, for recall on an individual, group, or broadcast basis. Groups and scenes are used to ensure simultaneous execution of level changes, since each packet requires about 25 ms - or 1.5 seconds if all 64 addresses were to change level.

[0079] In still another embodiment, the device interface 720 could be a 0-10V interface. 0-10 V is one of the first and simplest electronic lighting control signaling systems, used as an early fluorescent dimming system. Simply put, the control signal is a DC voltage that varies between zero and ten volts. Two standards are recognized: current sourcing and current sinking. Both provide full lighting at 10 volts and no lighting at 0 volts.

[0080] The main board 110 may also have status LEDs 708 driven from the main MCU 702, perhaps directly from pins on the main MCU 702 using general-purpose input and output pins. These pins may provide indications of the status of the environmental sensors 502, the LED driver 114, the illumination LEDs 722, and the radio module 704. industrial applicability

[0081] The smart lighting controller is used in architectural and commercial lighting to control the light and intensity of a lighting fixture 302 without introducing shadowing as seen through the diffuse lens 106.

[0082] 2024PF80202

[0083] 11

[0084] LISTING OF DRAWING ELEMENTS:

[0085] 102 lighting connector

[0086] 104 u-shaped connector frame

[0087] 106 diffuse lens

[0088] 108 miniature opening

[0089] 110 main board

[0090] 112 sensor board

[0091] 114 LED driver

[0092] 116 reflector

[0093] 202 open side

[0094] 302 lighting fixture

[0095] 304 double-sided tape

[0096] 306 double-sided tape

[0097] 402 second lighting fixture

[0098] 502 environmental sensors

[0099] 602 Receiver

[0100] 702 main MCU

[0101] 704 radio module

[0102] 706 light control interface

[0103] 708 status LEDs

[0104] 710 sensor MCU

[0105] 712 occupancy sensor

[0106] 714 daylight sensor

[0107] 716 infrared sensor

[0108] 718 board interface

[0109] 720 device interface

[0110] 722 illumination LEDs

[0111] 724 sensor assembly

Claims

2024PF8020212CLAIMS:

1. An apparatus comprising: a u-shaped connector configured to mate on a first open side with an end of a first lighting element and on a second open side with an end of a second lighting element, and further configured to accept, on a third open side adjacent to both the first and second opens sides, a consistent diffuse lens having an opening; a main board configured to attach to an inner surface of the u-shaped connector, the main board including a light control interface configured to interface with LED drivers of the first and second lighting elements and further including a main processor; and a sensor board electrically connected to the main board and having at least one sensing component and a sensor processor configured to communicate sensor data from the at least one sensing component to the main processor, wherein the at least one sensing component is configured to attach to the opening of the consistent diffuse lens.

2. The apparatus of claim 1 wherein the u-shaped connector has a cuboid shape.

3. The apparatus of claim 2 wherein the first and second open sides are parallel sides of the cuboid shape.

4. The apparatus of claim 1 wherein the sensor board is mechanically connected to the opening in the consistent diffuse lens with double-sided tape.

5. The apparatus of claim 1 wherein the at least one sensing component is an occupancy sensor or a daylight sensor.

6. The apparatus of claim 1 wherein the sensor board communicates with the main board using a universal asynchronous receiver / transmitter (UART).2024PF80202137. The apparatus of claim 1 wherein the light control interface communicates with the LED drivers using a UART, digital addressable lighting interface (DALI), or 0-10 V signaling.

8. The apparatus of claim 1 wherein the main board further includes a radio module.

9. The apparatus of claim 8 wherein the radio module is configured to wirelessly connect to one or more components of a lighting network.

10. A lighting network having a plurality of apparatuses as in claim 8, wherein the radio module of a first one of the plurality of apparatuses is configured to connect to radio modules of one or more others of the plurality of apparatuses.

11. The lighting network of claim 10 wherein the radio module of the first one of the plurality of apparatuses is configured to exchange sensor data with the radio modules of the one or more others of the plurality of apparatuses.

12. The apparatus of claim 8 wherein the radio module is configured to use a Bluetooth protocol or a Zigbee protocol.

13. The apparatus of claim 1 wherein the sensor board is mechanically mounted to the u-shaped connector.

14. The apparatus of claim 1 further comprising biscuit connectors configured to attach the u-shaped connector to the first lighting element.

15. A lighting system comprising: a first lighting element; a second lighting element; a u-shaped connector configured to mate on a first open side with an end of the first lighting element and on a second open side with an end of the second lighting element, and further configured to accept, on a third open side adjacent to both the first and second opens sides, a consistent diffuse lens having an opening;2024PF8020214 a main board configured to attach to an inner surface of the u-shaped connector, the main board including a light control interface configured to interface with LED drivers of the first and second lighting elements and further including a main processor; and a sensor board electrically connected to the main board and having at least one sensing component and a sensor processor configured to communicate sensor data from the at least one sensing component to the main processor, wherein the at least one sensing component is configured to attach to the opening of the consistent diffuse lens.

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