Abstract:
A dual sensor lighting controller has an AC input rectifier that includes an EMI filter, and an isolated AC-to-DC converter for 12 VDC and 5 VDC supplies, and a mechanical relay to control output AC Line voltage for the lighting device. The lighting controller also includes a motion PIR sensor, an internal photo sensor, an external photo sensor and an infrared receiver configured to receive signals from a remote control. The remote control is a handheld battery operated infrared remote control. Two wires provide 0-10 VDC dimming and a microcontroller preferably includes proprietary firmware controls. The microcontroller is connected to and reads PIR, internal or external photo sensors signals. The microcontroller has a clock that counts internal timing to control an output of the lighting device by a mechanical relay together with 0-10 VDC dimming control to save Electrical energy by activating or deactivating the output AC Line voltage.

Description:
FIELD OF THE INVENTION 
     The present invention is in the field of dual sensor lighting controllers. 
     DISCUSSION RELATED ART 
     There are a variety of different United States patents that describe lighting controllers, the disclosures of which are incorporated herein by reference. 
     For example, U.S. Pat. No. 8,901,496, titled Overhead Occupancy Sensor by General Electric Co., claims a motion sensor with a mechanical height adjustment setup for improved motion detection. This invention does not have infrared motion and photo sensors or an infrared remote control. 
     U.S. Pat. No. 8,844,361 titled Ultrasonic Sensor Control System for Occupany Sensing by Watt Stopper is another example. This patent claims an ultrasonic motion detector system with no infrared motion and photo sensors, and no infrared remote control. 
     Another example is presented in U.S. Pat. No. 8,373,125, titled Occupancy Detector Switch by Mtlc Electric, which claims an infrared motion sensor with mechanical relay to turn ON or OFF an AC power source for the connected lighting devices. This device does not have an infrared remote control. 
     Hubbell Inc. claims a Motion Sensor Switch for 3-Way Light Circuit and Method of Lighting Control Using the Same, U.S. Pat. No. 7,791,282. This invention is a 3-way light circuit that can be controlled at 2 locations, with an added motion sensor function. This device does not have an OR remote control capable of 1-button programming. 
     U.S. Pat. No. 7,411,489, titled Self-Adjusting Dual Technology Occupancy Sensor System and Method by Cooper Wiring Devices Inc., is another example. This invention claims a dual sensor system with Infrared and Ultrasonic technologies that is capable of self adjusting sensitivities. 
     Another example is claimed in U.S. Pat. No. 7,155,317, titled Occupant Counter Control Switch for Automatic Turning On and Off Electrical Appliances, by Nhan Tran. Watt Stopper Inc. claims a Light Management System Device and Method in U.S. Pat. No. 6,888,323. This invention comprises a wall switch unit fitted with a light sensor, motion sensor and night sensor. This device does not have an IR remote control. Watt Stopper Inc. also claims a Dual Technology Motion Sensor in U.S. Pat. No. 5,189,393. This invention comprises a dual sensors system with infrared and ultrasonic motion detection. This device does not have an IR remote control. 
     United States Patent Publication Number 2014/0125234, titled Dimmer with Motion and Light Sensing AC Phase Dim is another example. This patent claims a motion sensor and a Infrared sensor, with AC Phase cut and 0-10 VDC analog dimming control system. This invention also does not have an infrared remote control. 
     Another example is found in U.S. Pat. No. 8,587,415, titled Receiving and IR Control Signal Through a Fresnel Lens of Motion sensor, by Ixys. This invention comprises a wall mounted Infrared motion sensor, with AC Phase cut TRIAC dimmer and a handheld IR remote control. The handheld IR remote control can only control the TRIAC dimmer, not the sensor programming values. 
     Unfortunately, many sensor lighting control systems have (dual in-line package) DIP switches, or Potentiometers (POTs) or other manual adjustment apparatus to adjust the default settings for specific applications. However, these systems with manual adjustment are very inconvenient when the system is installed high above on the ceilings, building side walls or lighting poles. If any adjustments are necessary after the installation the installer needs to use a lift device or ladder to reach the manual adjustments. The installer then needs to descend back to floor level to verify proper settings. This procedure may need to be repeated multiple times and is very inconvenient. A remote control unit is very desirable for this situation to eliminate the tedious and costly process of manual adjustments, but oftentimes becomes yet another cryptic enigma. Also, in some other sensor lighting control systems on the markets with sealed enclosure suitable for outdoor wet or damp application, the DIP Switch and POT are not accessible for manual adjustment. Wet area enclosures are required to have accessible compartments with weather proof sealed covers. 
     SUMMARY OF THE INVENTION 
     A dual sensor lighting control system has a built-in Passive Infrared (PIR) sensor and a built-in internal Photo sensor. A stand alone external Photo sensor assembly can be plugged in to redirect the photo sensing direction to any desired orientation. A 28 key handheld Infrared (IR) remote control transmitter is also included to communicate and program the lighting controller settings for specific applications with a single button push. The lighting controller output is AC LINE power switched by a mechanical relay, and includes industrial standard 2-wire 0-10 VDC dimming. Any industrial lighting fixtures, LED drivers or fluorescent lamp ballasts with compatible 0-10 VDC dimming can be programmed at 50% dimming level or lower to comply with current standards such as the California Title 24 2013 Building Energy Efficiency Standard. 
     The IR remote control has a unique feature of single button programming, which reduces the complex programming sequence with a new idea of single button activation. The system can be set for desired operation in most applications with just a single button activation. 
     A sensor lighting control system with remote control can resolve the above adjustment difficulties. Most common sensor lighting control system local remote controls are either radio Frequency (RF) or Infrared (IR). The RF remote control signal is wide angle signal and it could affect any nearby units which are not targeted for adjustments. The IR remote control has a narrow angle direct line-of-sight signal, so that only the unit intended to be adjusted will receive proper IR signal and be adjusted accordingly. The IR remote control output power is reduced to avoid bouncing outside of aimed angle, so that only the unit intended to be adjusted will receive proper IR signal and be adjusted accordingly. In the present invention, all of the most common commands are presented on the array of buttons on the IR remote control in a single button push action. 
     A dual sensor lighting controller has an AC input rectifier that includes an EMI filter, and an isolated AC-to-DC converter for 12 VDC and 5 VDC supplies, and a mechanical relay to control output AC Line voltage for the lighting device. The lighting controller also includes a motion PIR sensor, an internal photo sensor, an external photo sensor and an infrared receiver configured to receive signals from a remote control. The remote control is a handheld battery operated infrared remote control. 
     Two wires provide 0-10 VDC dimming and a microcontroller preferably includes proprietary firmware controls. The microcontroller is connected to and reads PIR, internal or external photo sensors signals. The microcontroller has a clock that counts internal timing to control an output of the lighting device by a mechanical relay together with 0-10 VDC dimming control to save Electrical energy by activating or deactivating the output AC Line voltage. 
     The microcontroller is connected to and reads the infrared signal received from the infrared receiver and interpret the received code into most common and popular programming needs which has greatly simplified the infrared handheld remote control method into a single button programming technique. The remote control has seven groups of commands, namely: power control, motion detector PIR sensitivity control, motion detector PIR standby time control, ambient light threshold control, dimming level control, dimming time control, quick test control. The remote control has 28 buttons in a 4×7 grid. The remote control operates with a narrow angle less than five degrees, and requires a direct line-of-sight infrared connection. The remote control has a first infrared remote control group 1 for power control, that has of ON, OFF, AUTO and RESET 4 keys for simple ON, OFF and AUTO for default automatic Photo sensor enabled, and RESET for Photo sensor disable functions. The remote control has a second infrared remote control group for motion detector PIR sensor sensitivity control with 20%, 50%, 75% and default 100% sensitivity 4 keys for motion detection range adjustments. The remote control has a third remote control group for motion detector PIR Standby time control having 10 SEC, 1 MIN, default 5 MIN, 15 MIN, 30 MIN and 60 MIN 6 keys for motion detection Standby time adjustments. 
     The remote control has a fourth remote control group for ambient light level threshold control with default Minimum MIN, 10 LUX, 30 LUX, 50 LUX and Learning 5 keys for Photo sensor adjustments. The remote control has a fifth infrared remote control group for Dimming level control, with 0, 10%, default 20% and 30% 4 keys for Dimming level adjustment. The remote control has a sixth remote control group for dimming time control with 24 H, 1 MIN, 30 MIN and default 60 MIN, which are four buttons for dimming time adjustment. The remote control has a seventh remote control group for quick test with a TEST key for quick test of motion PIR sensor functions. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a circuit diagram of the AC input section, with a low power AC-to-DC converter, and the lighting output control mechanical relay. 
         FIG. 2  is a circuit diagram that shows the sensors input signals, Microcontroller and output control signals. 
         FIG. 3  is a diagram showing a top surface of the battery operated IR remote control S618RC 
     
    
    
     The following call out list of elements can be a useful guide in referencing the element numbers of the drawings. 
     
         
           101  AC Line 
           102  AC Neutral 
           103  Fuse 
           104  Bridge Rectifier 
           105  Capacitor 
           106  Inductor 
           107  Capacitor 
           108  Controller Chip 
           109  Isolated Transformer 
           110  N-Channel MOSFET 
           111  Rectify Diode 
           112  Output Filtering Capacitor 
           113  AC-to-DC Converter Output +12 VDC 
           114  Linear 5V Regulator 
           115  +5 VDC 
           116  Filtering Capacitor Cap 
           117  Diode 
           118  Transistor NPN 
           119  Limiting Base Resistor R 
           120  Mechanical Relay 
           121  AC Line Output 
           122  Relay-ON 
           201  Microcontroller 
           202  Passive Infrared (PIR) Sensor 
           203  Operational Amplifier OpAmp 
           204  PIR-IN 
           205  Internal Photo Sensor 
           206  INT-PHOTO-IN 
           207  External Photo Sensor 
           209  Infrared (IR) Receiver 
           210  IR-IN 
           211  IR Remote Control Block Diagram 
           212  Battery 
           213  Push Button Matrix 4×7 for 28 Keys 
           214  Microcontroller 
           215  IR LED 
           216  LED-OUT 
           217  RED LED 
           218  Analog-Dim-OUT 
           219  Transistor NPN 
           220  Transistor PNP 
           221  Transistor NPN 
           222  Resistor R 
           223  Capacitor C 
           224  OpAmp 
           225  Transistor PNO 
           226  Dimming Positive Wire or +DIM 
           227  Diming Negative Wire or −DIM 
           230  power control buttons 
           231  on button 
           232  off button 
           233  auto button 
           234  reset button 
           240  sensitivity control buttons 
           241  sensitivity 20% button 
           242  sensitivity 50% button 
           243  sensitivity 75% button 
           244  sensitivity 100% button 
           245  sensitivity test button 
           250  time delay control buttons 
           251  time delay 10 second button 
           252  time delay one minute button 
           253  time delay five minute button 
           254  time delay 15 minute button 
           255  time delay 30 minute button 
           256  time delay 60 minute button 
           260  ambient light setting threshold control button group 
           261  sun button 
           262  single lumen button 
           263  three lumen button 
           264  five lumen button 
           265  eye button 
           270  dimming setting level button group 
           271  dimming setting zero button 
           272  dimming setting 10% button 
           273  dimming setting 20% button 
           274  dimming setting 30% button 
           280  set dimming time delay button control group 
           281  24 hour button 
           282  one minute button 
           283  30 minute button 
           284  60 minute button 
       
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     AC input, AC-to-DC converter and output relay: The AC Line ( 101 ) input wire goes through Fuse ( 103 ) for over current protection, then it is connected to Bridge Rectifier ( 104 ) on the AC input pin. The AC Neutral ( 102 ) is connected to Bridge Rectifier ( 104 ) on the other AC input pin. The rectified high voltage DC is filtered by a “Pi” Filter consists of a Capacitor ( 105 ), an Inductor ( 106 ) and another Capacitor ( 107 ), to reduce harmful Electro-Magnetic Interference (EMI). This is the simplified “Rectifier and EMI Filter” section in  FIG. 1 . 
     The filtered high voltage DC is fed to the “Isolated AC-to-DC Converter” section, with simplified components of a Controller Chip ( 108 ), a N-Channel MOSFET ( 110 ), an Isolated Transformer ( 109 ), a secondary side Rectify Diode ( 111 ) and an output filtering capacitor ( 112 ). The AC-to-DC Converter output +12 VDC ( 113 ) is fed to a linear 5V Regulator ( 114 ), and generated +5 VDC ( 115 ) with a filtering capacitor Cap ( 116 ). 
     After the AC Line ( 101 ) power source is passed through Fuse ( 103 ), it is connected to the power input terminal of a mechanical Relay ( 120 ). This Relay&#39;s activation coil is driven by the +12 VDC ( 113 ) power source and a Transistor NPN ( 118 ), controlled by an output port P0.0 on pin-19 signal named Relay-ON ( 122 ) from the main control Microcontroller ( 201 ) via a current limiting base resistor R ( 119 ). The Relay&#39;s coil is connected in parallel with a Diode ( 117 ) to shunt the high spike voltage to protect the circuitry when the coil&#39;s current is turned off. 
     The dual sensor lighting control system outputs the AC Line Output ( 121 ) to supply the lighting devices (Incandescent lamps, LED lighting fixtures or Fluorescent lamps) AC Line input power source.  FIG. 2  shows a variety of sensor input signals, microcontroller and output control signals. The microcontroller ( 201 ) with proprietary firmware is the core of the sensor lighting control system. The microcontroller ( 201 ) runs on +5 VDC power source and processes the four input signals from the Passive Infrared (PIR) sensor ( 202 ), internal Photo Sensor ( 205 ), external Photo sensor ( 207 ) and Infrared (IR) Receiver ( 209 ), then outputs three signals, namely the Relay-ON ( 122 ), LED-OUT ( 216 ) and Analog-Dim-OUT ( 218 ) according to the preprogrammed firmware. 
     The PIR sensor ( 202 ) also uses a +5 VDC power source. The output is amplified by the Operational Amplifier OpAmp ( 203 ), (simplified circuitry shown) then the output signal named PIR-IN ( 204 ) is fed to an input port P0.2 on pin-3 of the Microcontroller ( 201 ). The internal Photo sensor ( 205 ) uses the +5 VDC power source. The output signal named INT-PHOTO-IN ( 206 ) connects to an input port P0.3 on pin-4 of the Microcontroller ( 201 ). 
     The external Photo sensor ( 207 ) has a case and cable assembly, with a 3-pin female connector. A mating 3-pin male connector is mounted on the S618-P-DR plastic housing, with +5 VDC, ground and the output signal named EXT-PHOTO-IN which is fed to an input port P0.4 on pin-5 of the Microcontroller ( 201 ). 
     The IR Receiver ( 209 ) runs on the +5 VDC power source. The output signal named IR-IN ( 210 ) is fed to an input port P0.5 on pin-6 of the Microcontroller ( 201 ). The remote control S618RC is a handheld battery operated IR remote control transmitter. This IR remote control block diagram ( 211 ) shows internal components of Battery ( 212 ), push button matrix 4×7 for 28 keys ( 213 ), Microcontroller ( 214 ) and IR LED ( 215 ). The Relay ( 120 ) control signal Relay-ON ( 122 ) comes from an output port P0.0 on pin-19 of the Microcontroller ( 201 ). The RED LED ( 217 ) control signal LED-OUT ( 122 ) comes from an output port P4.4 on pin-18 of the Microcontroller ( 201 ). 
     The 0-10 VDC dimming control signal Analog-Dim-OUT ( 218 ) comes from an output port P4.3 on pin-17 of the Microcontroller ( 201 ). The Analog-Dim-OUT ( 218 ) is a Pulse Width Modulation (PWM) signal buffered by Transistor NPN ( 219 ), and then driven by push-pull configuration Transistor PNP ( 220 ) and Transistor NPN ( 221 ). This PWM signal is integrated by resistor R ( 222 ) and capacitor C ( 223 ) into a DC voltage. This DC voltage is buffered by OpAmp ( 224 ) in “unit gain” configuration. The output of OpAmp ( 224 ) is further buffered by Transistor PNP ( 225 ) in “emitter follower” configuration. The Transistor PNP ( 225 ) output on Emitter Electrode is the 0-10 VDC dimming positive wire, or +DIM ( 226 ). The 0-10 VDC dimming negative wire, or −DIM ( 227 ) is simply the system ground. 
     The sensor lighting control has numerous lighting control operations. Without using the 1-button IR remote control S618RC, the sensors lighting control system S618-P-DR can work on the factory default settings, or the previously setting programmed by the 1-button IR remote control S618RC. 
     The following description begins with the factory default settings assuming no previous programming using the 1-button IR remote control S618RC. Later, the description discusses the operation of the 1-button IR remote control S618RC for changing the settings. 
     At initial power up, the Relay-ON ( 122 ) signal is set high at logic 1, or 5V. The Relay ( 120 ) coil is activated and the AC Line power is fed to the AC Line Output ( 121 ) to power up the lighting devices connected to the system. The Analog-Dim-OUT ( 218 ) signal is at 100% PWM, or continuous at +5 VDC. The 0-10 VDC dimming signal between +DIM ( 226 ) and −DIM ( 227 ) is at a maximum 10 VDC. If the connected lighting device has 0-10 VDC dimming input wires and are connected to +DIM ( 226 ) and −DIM ( 227 ), the lighting device will be at the maximum luminance. 
     Without intervention of the IR remote control S618RC, the lighting device starts in the default “AUTO” mode, which will set other default settings—“Sensitivity” as 100%, “Standby time” as 5 minutes, “LUX” as minimum, “Dimming level” as 20% and “Dimming time” as 60 minutes. 
     The default “AUTO” operation will turn ON the lighting device output with maximum intensity with 10 VDC output on the 0-10 VDC dimming wires. The PIR sensitivity is set at maximum range with maximum sensitivity at 100%. The “Stand-by time” is set at five minutes. If PIR senses or detects any motions, the “Stand-by time” will be reset to 5 minutes again to avoid lighting interruption such as if the lighting devices were dimmed or turned OFF. When the PIR sensor detects no motion for continuous 5 minutes, the lighting devices are set to the default dimming level of 20% (equivalent 2 VDC on the dimming wires). Then, the lighting devices have a default dimming time of 60 minutes. When the PIR sensor does not detect motion detected within continuous 60 minutes, then the lighting device will be turned full OFF. However, if the PIR sensor detects motion during the dimming time period of 60 minutes, then the lighting device is turned full ON, and the stand-by time is reset to 5 minutes. Then the same process will restart again. However, the IR remote control S618RC can be used to change the current status, or the programmable settings other than the default as described in the next portion of this description. 
     The infrared remote control has a variety of one button control functions that are activated by a single button press. This is different than a variety of multiple sensor lighting control systems currently on the market that have complicated programming procedures to setup and alter the default settings to fit customers&#39; specific applications. The complicated procedures are almost impossible for common users to memorize, unless they are used frequently on the daily or weekly. The complex procedures are very intimidating to most customers and not practical for users to change the setting only once a while. They are programmed into wrong settings very often, and the users have to read the programming guides and relearn them almost every time. 
     The present invention eliminates the complex programming procedure. Only the most common programming procedures are necessary. The applicant has modified the S618 system (S618-P-DR and IR remote control S618RC) to incorporate a “1-button” programming technique, which is the core of the disclosed invention here. 
     The IR remote control functions are grouped into 7 categories. The power control buttons  230  provide power control on the top row of four buttons “ON”, “OFF”, “AUTO” and “RESET”. The “ON” button  231  overrides other controls to turn on the light. Afterwards, the sensor returns to the previous state after 20 minutes if continuously uninterrupted by motion. The “OFF” button  232  overrides and turns off the light and keeps the light off. The sensor returns to the previous setting after 20 m if continuously uninterrupted by motion. The “AUTO” button  233  enables auto mode and provides for a default set of parameters where Sensitivity=100%, Standby Time Delay=5 m, Dimming Time Delay=24 h (none), Dimming Level=20%, and Ambient Light Threshold=5 lumens. The “RESET” button  234  resets the sensor to factory settings where Sensitivity=100%, Standby Time Delay=5 m, Dimming Time Delay=60 m, Dimming Level=20%, Ambient Light Threshold=disabled. 
     The sensitivity level setting control button set  240  is shown on the top second row and includes exactly four buttons, namely “20%”, “50%”, “75%” and “100%”. The sensitivity level setting has four buttons and can set the PIR element detector sensitivity. The sensitivity 20% button  241  sets the sensitivity to 20%. The sensitivity 50% button  242  sets the sensitivity to 50%. The sensitivity 75% button  243  sets the sensitivity to 75%. The sensitivity 100% button  244  sets the sensitivity to 100%. The sensitivity test button  245  provides a test function. The test button  245  is on the third row right most button and labeled “TEST”. The test button turns off a light if the light is already on, and then turns on the light on for a short time such as a second if motion is detected. Then the light is turned off and the process is repeated for 2 ms. 
     The remote control also includes a set of standby set time delay buttons  250  shown on the top third and fourth row left three buttons “10 s”, “1 m”, “5 m”, “15 m”, “30 m” and “60 m”. The standby time delay buttons set the duration of time before an activated sensor dims a light once motion is no longer detected. The time delay 10 second button  251  sets the time delay for 10 seconds. The time delay one minute button  252  sets the time delay to one minute. The time delay five minute button  253  sets the time delay to five minutes. The time delay 15 minute button  254  sets the time delay to 15 minutes. The time delay 30 minute button  255  sets the time delay to 30 minutes. The time delay 60 minute button  256  sets the time delay to 60 minutes. 
     The ambient light setting threshold button control group  260  is shown on the top fifth row of four buttons including the “SUN”, “1”, “3”, “5” and fourth row rightmost button “LEARN”. The “SUN” button  261  is a symbol of the Sun. The “LEARN” button  265  is a symbol of an eye. The ambient light setting threshold is disabled when pressing the sun button and can be changed to 1, 3, or 5 lumens. The sun button  261  disables the ambient light setting threshold. The one lumen button  262  sets the ambient light setting threshold to one lumen. The 3 lumens button  263  sets the ambient light setting threshold to 3 lumens. The 5 lumens button  264  sets the ambient light setting threshold to 5 lumens. The eye button  265  learns an ambient light setting threshold which sets the ambient light setting threshold to the current ambient light setting such that the firmware is configured to keep the light levels at the current ambient light. If the ambient light is less than the learned ambient light setting threshold, the lights will turn on or increase in intensity. If the ambient light is greater than the learned ambient light setting threshold, the lights will turn off or dim. The detection cut off can be changed by a single button press. 
     The dimming setting level button group  270  provides a sixth row of four buttons “0”, “10%”, “20%” and “30%”. The dimming setting zero button sets the dimming level to zero. The dimming setting 10% button  272  sets the dimming setting to 10%. The dimming setting 20% button  273  sets the dimming setting to 20%. The dimming setting 30% button  274  sets the dimming setting to 30%. The light dimming level can after time delay has passed (sensor dims light to save energy). 
     The set dimming time delay button control group  280  is configured on the seventh row of four buttons including “24 h”, “1 m”, “30 m” and “60 m”. The 24 hour button  281  sets the dimming time delay to 24 hours so that the light is dimmed down for a total of 24 hours before turning off completely. The one minute button  282  sets the dimming time delay to one minute so that the light is dimmed down for a total of 24 hours before turning off completely. The 30 minute button  283  sets the dimming time delay to 30 minutes so that the light is dimmed down for a total of 30 minutes before turning off completely. The 60 minute button  284  sets the dimming time delay to an hour so that the light is dimmed down for a total of one hour before turning off completely.