Digital output lock

A lock assembly comprising a lock body, a shackle, and a locking member configured to selectively lock the shackle relative to the lock body. At least one combination dial is rotatable between various combination positions. The at least one combination dial is associated with the locking member and is configured such that entry of a given series of combination positions causes the locking member to unlock the shackle relative to the lock body. A sensor is configured to sense the rotational position of the al least one combination dial. A display screen is associated with the sensor and is configured to display a position indicia which corresponds to the rotational position of the at least one combination dial.

BACKGROUND OF THE INVENTION

The present invention relates in general to locks, and more particularly to combination locks, and most particularly to combination locks having a digital readout.

Heretofore, many types of combination lock mechanisms have been devised, wherein rotation of a dial or dial knob assembly through a selected combination of turns to different predetermined angular positions conditions a locking mechanism within the lock casing or body to release a locking shoulder or the like from the shackle member or other lock member. This permits the shackle member or other lock member to be shifted to a release position relative to the lock casing or body.

SUMMARY OF THE INVENTION

The present invention provides a lock assembly comprising a lock body, a shackle, and a locking member configured to selectively lock the shackle relative to the lock body. At least one combination dial is rotatable between various combination positions. The at least one combination dial is associated with the locking member and is configured such that entry of a given series of combination positions causes the locking member to unlock the shackle relative to the lock body. A sensor is configured to sense the rotational position of the at least one combination dial. A display screen is associated with the sensor and is configured to display a position indicia which corresponds to the rotational position of the at least one combination dial.

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIGS. 1-5, a lock assembly10in accordance with an exemplary embodiment of the invention is shown. In the present embodiment, the lock assembly10is in the form of a padlock, with a u-shaped shackle14lockably moveable relative to a lock body or casing12. A combination dial18extends from the casing12and is rotatable relative thereto. In the present embodiment, the dial18is generally supported internally within the casing12, with only a contact portion19extending radially outward through a slot16in the casing12. A notch17is provided in the front face22of the casing12to allow a user to see the combination indicia20on the face of the dial18. A corresponding indicator21is provided on the front face22adjacent to the notch17. Alignment of the dial indicia20with the indicator21provides a first indication of the position of the dial18relative to the casing12.

In the present embodiment, the front face22of the casing12has a recess24configured to receive a digital display assembly50. The digital display assembly50includes a housing52configured to be retained within the recess24. In a desired embodiment, the housing52is releaseably retained in the recess24, for example, via a snap fit, such that the digital display assembly50may be removed to change a battery or the like. Other mechanisms for releaseably retaining the digital display assembly50may also be utilized, for example, a thread between the housing50and the recess24or a mechanical fastener extending through the housing50and engaged with the casing12. Alternatively, the digital display assembly50may be permanently secured in the recess24. In such an embodiment, the battery access may be provided through the face of the digital display assembly50or via some other means.

The digital display assembly50includes a digital display screen54configured to display a digital indicia55which represents a second indication of the position of the dial18relative to the casing12. The digital display screen54can have various forms, for example, but not limited to, a light-emitting diode (LED); a vacuum fluorescent display (VFD) or a liquid crystal display (LCD). A light switch56or the like may be provided on the digital display assembly50to allow a user to provide additional illumination to the digital display screen54.

The digital indicia55will correspond to the dial indicia20that is aligned with the casing indicator21. As such, the user will be able to monitor the position of the dial18via either the dial indicia20or the digital indicia55. To correlate the dial indicia20with the digital indicia55, an engagement member28extends from the front face of the dial18through an opening26in the casing12. The opening26is preferably within the recess24such that the engagement member28may engage the digital display assembly50and remain concealed when the digital display assembly50is positioned within the recess24.

Referring toFIG. 4, the digital display assembly50includes a microcontroller60, for example, in the form of a printed circuit board or the like. A bi-directional location sensor64is associated with the microcontroller60and is configured for engagement with the engagement member28extending from the dial18. In the illustrated embodiment, the engagement member28includes a plurality of teeth29configured to engage corresponding teeth (not shown) on the sensor64such that rotation of the dial18in either direction causes corresponding rotation of a portion of the sensor64which in turn provides an electrical signal to the microcontroller corresponding to such rotation. Alternatively, the sensor64may not require mechanical engagement with the engagement member28, but may instead electronically monitor the position of the engagement member28. For example, the engagement member28and sensor64may include corresponding magnets and a hall-effect sensor to monitor the rotational position of the dial18. Other engagement configurations between the engagement member28and the sensor64may also be utilized.

The digital display assembly50preferably includes a mechanism51to synchronize the microcontroller60with the position of the dial18. For example, the digital display assembly50may include a reset button (not shown) which is pressed when the dial18is at a predetermined indicia20(for example, at the zero position), thereby synchronizing the microcontroller60to the dial18position. Alternatively, the sensor64may include a contact switch61which is actuated when the digital display assembly50is positioned in the recess24. Upon actuation of the switch, the microcontroller60is reset to a given indicia. A user would be instructed to set the dial18to the given indicia prior to installation of the digital display assembly50, thereby synchronizing the microcontroller60to the dial18position. Other means for synchronizing the microcontroller60with the dial18may also be utilized.

With the microcontroller60synchronized with the dial18position, the microcontroller60is configured to receive signals from the sensor64which correspond to a given change in dial position in either direction. The microcontroller60continuously relates the position change with the previously stored position of the dial18and continuously determines the current position of the dial18. The microcontroller60converts the current position to the appropriate digital indicia55which is displayed on the display screen54. The microcontroller60is preferably powered by a replaceable battery62or the like.

The digital display assembly50may be further configured to include a speaker or the like (not shown) to provide audible indicia. The microcontroller60sends a signal to the speaker corresponding to the current position of the dial18and the speaker converts the signal received from the microcontroller60and outputs an audible indicia corresponding to the current position of the dial18.

Referring toFIG. 5, the lock assembly10of the present embodiment is a padlock with a locking member that includes a drive cam30, a hasp32and a series of notched wheels34mounted on a spindle36connected to the dial18. While the present embodiment shows four wheels34, any number of wheels34may be utilized. When the dial18is turned, the spindle36turns the drive cam30. Attached to the drive cam30is a drive pin31. As the cam30turns, the drive pin31eventually makes contact with a small tab on the adjacent wheel34called the wheel fly37.

Each wheel34has a wheel fly37on each of its sides. The drive pin31spins the first wheel fly37until it makes contact with the wheel fly37of the wheel34adjacent to it. This continues until all the wheels34are spinning. Each wheel34on the spindle36has a notch35cut into it. When the right combination is dialed, as indicated by either the dial indicia20or the digital indicia55, all the wheels34and their notches35line up perfectly. The hasp32is a small metal bar attached to a lever33. The hasp32engages the shackle14and prevents the lock assembly10from being opened without the combination being dialed. In the present invention, a user of the lock assembly10may monitor the combination being dialed using either the dial indicia20or the digital indicia55.

Referring toFIGS. 6-12, a lock assembly10′ in accordance with another exemplary embodiment of the invention is shown. The lock assembly10′ is substantially the same as in the previous embodiment with only the differences described herein. In the present embodiment, the front face22′ of the casing12′ includes a display opening40configured to align with the digital display assembly50. As shown inFIG. 7, a cover41or the like is configured to fit in the opening40to protect the digital display screen54.

Referring toFIGS. 7 and 8, the digital display assembly50is configured to be supported on a digital display platform42which is supported within the casing12′. The digital display platform42may further include a battery contact43configured to electronically engage the battery62, however, the battery62and associated contacts43may be otherwise positioned within the casing12′. The platform42also supports the microcontroller engagement teeth44which are configured to engage the teeth29′ of the engagement member28′ extending from the dial18. As shown, the teeth29′ and44may configured to have a single engagement orientation such that the sensor64is synchronized with the dial18upon interconnection.

Referring toFIGS. 9 and 10, the digital display platform42may further support a contact assembly80to sense the position of the dial18. In this embodiment, the contact assembly80forms a part of the sensor64. The contact assembly80includes an inner set of radial contacts82and an outer set of radial contacts84supported on a first portion42A of the platform42. Each contact84of the outer set preferably corresponds to a position of the combination dial18. While one or more inner contacts82may be used, multiple inner contacts82are preferred to assist with synchronization of the components. A contact bar81having a pair of spaced contacts83and85is configured to be mounted on a second portion42B of the platform42such that the contact bar81rotates with the combination dial18. As shown inFIG. 10, one of the contacts83is aligned with the inner contacts82and the other contact85is aligned with the outer contacts84.

As the dial18is rotated, the contacts83and85will move between inner and outer contacts82,84, respectively. Each combination of inner contact82and outer contact84that the contact bar81is in contact with will have a distinct resistance or capacitance value. As such, by determining the resistance value or capacitance value occurring at any given time, the sensor64may determine the current position of the dial18and provide such to the digital display assembly50. In other regards, the lock assembly10′ operates substantially the same as the lock assembly10described above.

Referring toFIGS. 11 and 12, replacement of the battery62will be described. The battery62is supported on a battery tray46configured to be positioned in a battery compartment45defined within the casing12′. The battery tray46is configured to align with and engage the battery62with the battery contact43within the casing12′. The battery tray46includes a locking prong48biased toward a locking position. When the battery tray46is fully inserted into the battery compartment45, the locking prong48engages a shoulder (not shown) within the battery compartment45which prevents withdrawal of the battery tray46. A through hole47extends through the front face22′ of the casing12′ and is aligned with a portion of the locking prong48when such is in the locked position. To remove the battery62, a pin or the like (not shown) is inserted through the through hole47such that the locking prong48is pushed from engagement with the shoulder. With the locking prong48disengaged, the battery tray46may be removed from the battery compartment45. The other embodiments described herein may include a similar battery compartment and battery tray or may include different battery configurations.

Referring toFIGS. 13 and 14, a lock assembly10″ that is another exemplary embodiment of the invention will be described. In the present embodiment, the lock assembly10″ is again in the form of a padlock, with a u-shaped shackle14lockably moveable relative to a lock body or casing12″. A combination dial18′ extends from the casing12″ and is rotatable relative thereto. In the present embodiment, the dial18″ is generally supported internally within the casing12″, with only a contact portion19″ extending radially outward through an opening16″ in the casing12″. In the illustrated embodiment, the dial18″ is positioned along the side of the casing for easy thumb rotation, but other configurations may also be utilized. The dial18″ of the present embodiment does not include any indicia thereon. Instead, the indicia55and57are provided via a digital display assembly50″ attached to a front face22of the casing12″. In the present embodiment, clamps59are secured to the casing12″ and retain the digital display assembly50″ in position. As in the previous embodiment, the digital display assembly50″ includes a display screen54configured to display the indicia55and57.

In the present embodiment, locking and unlocking of the lock assembly10″ is electronically controlled via the microcontroller60″. A locking solenoid70is associated with the microcontroller60″ and includes a normally extended retractable locking bolt72. The locking bolt72is configured to engage a notch or the like in the shackle14. The locking solenoid70has a non-energized condition in which the locking bolt72is extended into the locked position such that the lock assembly10″ will remain locked even if the microcontroller60″ loses power.

The microcontroller60″ is configured to actuate the locking solenoid70and retract the locking bolt72upon entry of a target combination through the dial18″. The target combination is preferably stored in non-volatile memory such that the target combination is retained for the life of the lock assembly10″, even if the microcontroller60″ loses power. The target combination is preferably a series of numbers, letters, icons or the like in conjunction with corresponding directional rotation of the dial18″. For example, the target combination could be two turns to the right to the number35, one turn to the left to number12, and one turn to the right to number27. Various combinations of numbers, letters, icons, and directions may be utilized.

Entry of combination elements is through the combination dial18″ which engages a bi-directional position sensor64″. The bi-directional position sensor64″ is substantially the same as in the previous embodiment and may be a mechanical sensor, an electrical sensor or a combination thereof. The position and direction of rotation of the dial18″ are sensed by the sensor64″ and conveyed to the microcontroller60″. Synchronization is not required in the present embodiment. Upon power up, the microcontroller60″ may select and display any start position value, for example, a zero position value. The user would then have to enter the target combination by rotating the dial18″ as necessary from the start position value.

The microcontroller60″ is configured to receive signals from the sensor64″ which correspond to a given change in dial position in either direction. The microcontroller60″ continuously relates the position change with the previously stored position of the dial18″ and continuously determines the current position of the dial18″. The microcontroller60″ converts the current position to the appropriate digital indicia55which is displayed on the display screen54. The microcontroller60″ may further be configured to display a directional indicia57on the display screen54. Such directional indicia57would help the user viewing the display screen54to know that the dial18″ is being rotated in the correct direction. Once the target combination is entered through the dial18″, the microcontroller60″ actuates the locking solenoid70and the locking bolt72is retracted such that the shackle14is released and the lock assembly10″ is opened.

FIGS. 15 and 16illustrate additional alternative lock assemblies10″′ and10″″ in accordance with the present invention. The lock assembly10″′ illustrated inFIG. 15is in the form of a U-lock and includes a shackle14″′ engaged with a lock body or crossbar12″′. The crossbar12″′ includes a combination dial18″′ configured to manipulate a locking member within the crossbar12″′, either mechanically, electrically or a combination thereof. The crossbar12″′ further includes a digital display assembly50with a display screen54configured to display a digital indicia55corresponding to the position of the dial18″′ relative to the crossbar12″′. In other aspects, the lock assembly10″′ is substantially as described above.

The lock assembly10″″ illustrated inFIG. 16is in the form of a cable lock and includes a cable13extending from a lock body or casing12″″. An opposite end of the cable13includes a locking head14″″ configured to be inserted into the casing12″″ and engaged by a locking member therein such that the cable13and locking head14″″ define the shackle for the present embodiment. The casing12″″ includes a combination dial18″″ configured to manipulate the locking member within the crossbar12″″, either mechanically, electrically or a combination thereof. The casing12″″ further includes a digital display assembly50with a display screen54configured to display a digital indicia55corresponding to the position of the dial18″″ relative to the crossbar12″″. In other aspects, the lock assembly10″″ is substantially as described above.

While the exemplary embodiments are described herein with a notched wheel and cam driver locking member or a locking solenoid locking member, the invention is not limited to such. Various other locking members, for example, tumbler locking members, latch and bolt locking members and the like may be utilized. Additionally, while only a single combination dial is illustrated in each exemplary embodiment, more than one combination dial may be utilized. In embodiments utilizing more than one combination dial, a separate display screen may be provided for each dial or single display screen may be configured to display multiple indicia, with each indicia corresponding to a respective dial. Additionally, while the exemplary embodiments described herein are portable lock assemblies, the invention is not limited to such. The present invention may be embodied in a stationary combination lock, for example, a built in combination lock on a locker. In such an embodiment, the locking member may extend between to portions of the stationary structure. The digital display assembly may be provided on the lock structure or the stationary structure.