Abstract:
A modular controller for a lamp allows for the easy addition of remote control to multiple lamp fixture designs. The controller housing protects circuitry from shorts and has a window included for receiving remote control signals. The window is detachable and can be re-oriented relative to the controller housing to accommodate different lamp fixture designs. The position of the sensors within the controller housing can also be reconfigured, and it is also possible to connect external sensors to the controller for situations where sensors must be placed in a tight space. In some embodiments, the lamp power supply is incorporated within the modular controller, saving space and cost, and allowing for dimming of individual lamps.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present invention claims priority under 35 USC 119 based on US Provisional patent application No. 61/516,269, filed on Apr. 1, 2011. The subject matter of this priority document is incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    Remote controlled lighting systems used to control lamp position and/or brightness have wide application including use in entertainment settings, surgical settings, and retail settings. Some remote-controlled light fixtures may include a lamp secured to a track via a light fixture housing. The fixture housing may contain a lamp power supply, motors for positioning the lamp, and control electronics. A hand-held remote makes it convenient to control the lamp without the need for ladders. 
         [0003]    However, the mechanisms and control required to enable remote control are not standard features of most light fixtures, and most manufacturers are not prepared to add remote control to their lamps. In some cases, barriers to manufacturers making such an addition include the need to invest in the re-design of light fixtures to include the control electronics and mechanisms required for remote control. 
       SUMMARY 
       [0004]    In some aspects, a control module is provided. The control module is for controlling a position of a lamp, the lamp being moved between positions by a motor. The control module includes a housing including sidewalls, at least one of the sidewalls including an opening. The control module includes a window in the opening, the window being selectively removable from the housing and connectable to the housing in a plurality of orientations. The control module also includes a sensor disposed within the housing so as to face the window, the sensor configured to receive a signal provided from outside the housing, and a controller disposed in the housing, the controller being configured to receive a signal output from the sensor, and to reposition the lamp by outputting a signal to the motor. 
         [0005]    The control module may include one or more of the following features: The window is selectively removable from the housing and connectable to the housing in a plurality of orientations in such a way that the opening is completely covered regardless of window orientation. When the window is in a first orientation relative to the housing, the window resides within the opening within a first one of the sidewalls, and when the window is in a second orientation relative to the housing, the window resides within the opening within a second one of the sidewalls. The window includes a flange, and when the window resides within the opening within the first one of the sidewalls, the flange resides within the opening in the second one of the sidewalls, and when the window resides within the opening within a second one of the sidewalls, the flange resides within the opening in the first one of the sidewalls. The window is dome shaped. The window is optically translucent. The window protrudes from an outer surface of the housing. The sensor is repositionable relative to the housing between a first position in which a detecting surface of the sensor is parallel to a first one of the sidewalls, and a second position in which the detecting surface of the sensor is parallel to a second one of the sidewalls. The control module further includes a power supply disposed in the housing, wherein the power supply is configured to receive alternating current power and to provide a direct current at voltage that is reduced relative to the received power, the controller and power supply are separated from the motor and lamp by the sidewalls, and the power supply provides power to the controller and to at least one of the lamp and the motor. 
         [0006]    In some aspects, a control module is provided. The control module is for controlling a position of a lamp, the lamp being moved between positions by a motor. The control module includes a housing including sidewalls, at least one of the sidewalls including an opening, and a sensor disposed within the opening, the sensor configured to receive a signal provided from outside the housing and being repositionable relative to the housing. The control module also includes a controller disposed in the housing, the controller configured to receive a signal output from the sensor, and to reposition the lamp by outputting a signal to the motor. 
         [0007]    The control module may include one or more of the following features: The sensor is repositionable relative to the housing between a first position in which a detecting surface of the sensor is parallel to a first one of the sidewalls, and a second position in which the detecting surface of the sensor is parallel to a second one of the sidewalls. The sensor is further movable relative to the housing to a third position in which the detecting face of the sensor faces away from an outer surface of one of the sidewalls and leads connecting the sensor to the controller reside within the opening. The control module further comprises a window, and when the sensor is in the first position, the window resides within the opening and is parallel to a first one of the sidewalls, and when the sensor is in the second position, the window resides within the opening and is parallel to a second one of the sidewalls. The sensor comprises an optical sensor. The control module further comprises a first printed circuit board, and the controller is mounted to the first printed circuit board, and wherein the sensor comprises an optical sensor mounted to a second printed circuit board, and the second printed circuit board is detachably electrically connected to the first printed circuit board via a connector. The control module further comprises a power supply disposed in the housing, wherein the power supply is configured to receive alternating current power and to provide a direct current at voltage that is reduced relative to the received power, the controller and power supply are separated from the motor and lamp by the sidewalls, and the power supply provides power to the controller and to at least one of the lamp and the motor. 
         [0008]    In some aspects, a control module is provided. The control module is for controlling a position of a lamp, the lamp being moved between positions by a motor. The control module includes a controller configured to output a signal to the motor, and a power supply for providing power to the controller and to the lamp and the motor, the power supply configured to receive alternating current power and to provide a direct current at voltage that is reduced relative to the received alternating current power. The control module further comprises a housing within which the controller and power supply are disposed and configured to separate the controller and power supply from the motor and lamp. 
         [0009]    The control module may include one or more of the following features: The housing includes an opening; and a sensor is disposed within the opening, the sensor configured to receive a signal provided from outside the housing, and to be repositionable relative to the housing. The control module further comprises a window in the housing, the window being selectively removable from the housing and connectable to the housing in a plurality of orientations. 
         [0010]    In some aspects, a lighting and control system is provided that includes a light fixture including a fixture housing and a lamp supported on the fixture housing, and a motor disposed in the fixture housing and connected to the lamp, the motor configured to move the lamp between different positions. The system further includes a control module for controlling a position of the lamp. The control module includes a housing, a window in the housing, the window being selectively removable from the module housing and connectable to the module housing in a plurality of orientations. The control module further includes a sensor disposed within the housing so as to face the window, the sensor configured to receive a signal provided from outside the housing, and a controller disposed in the housing, the controller being configured to receive a signal output from the sensor, and to reposition the lamp by outputting a signal to the motor. 
         [0011]    Among other advantages, the control module provides the control electronics required for achieving a remote control lamp in a modular form that is flexible to use and convenient for installation by manufacturers. The control module includes all the features that are required to add remote control features to a light fixture housing. 
         [0012]    Furthermore, the control module can be physically reconfigured so that it can work in many different lamp designs having various geometries. By providing a single, reconfigurable control module that permits remote control, a manufacturer can stock a single part that will work in many different light fixtures, permitting the manufacturer to minimize stock of parts and reduce costs. 
         [0013]    Further advantageously, the control module is enclosed within a module housing. The module housing is an important feature of the control module since it protects the control board, including its components and circuitry from forming an electrical short circuit with other parts of the light fixture such as the light fixture housing or motors. In addition, by providing the control functions within a module housing, the module as a unit can be fully evaluated and safety approved by government agencies, streamlining implementation of the control module into a lighting fixture design. 
         [0014]    Still further advantageously, the control module includes a housing for control electronics and power supply that has a reconfigurable window for receiving laser and control signals from a transmitter. The window can be detached from an opening in the housing, and replaced within the opening in a different orientation relative to the housing. The window is sized and shaped to completely fill the opening regardless of orientation. An optical sensor and an indicator lamp are disposed in the window, and thus may be repositioned relative to the housing to correspond to the orientation of the window. The reconfigurability of the window and sensor relative to the housing is convenient because it allow a manufacture to arrange one module to fit in many different light fixtures. For example, sometimes housings are large and square to accommodate a large power supply such as metal halide, and sometimes they are very small because the lamp will run on mains power, so there is no lamp power supply. In some configurations, for example when the window is on the end of the control module rather than the side, the result is a slimmer design. 
         [0015]    In addition, the window not only passes optical signals (such as laser light), it is also functions to pass radio frequency control signals into the housing. This is critical for use in light fixture housings that are formed of materials that block radio signals. In these cases, to enable reception, the control module is positioned within the light fixture with the module window within an opening in the light fixture. The window is relatively small, and is preferred to an unsightly external antenna. In some embodiment, the window is optically translucent. For example it may have a frosted surface that will scatter laser light that hits the window at an angle, aiding detection by the optical sensor. The frosted surface also scatters light emitted from an “on” indicator lamp disposed within the housing that indicates that the lamp is ready for control. The scattering makes the light more uniformly visible from a variety of angles. 
         [0016]    In some embodiments, the control module receives alternating current from mains power, possibly through a track, which powers a power supply that drives the repositioning motor(s). In other embodiments, the control module could be powered by 12 VAC, which is often the voltage in pre-installed track systems. In these embodiments, the lamp is powered independently of the control module. In other embodiments, the modular controller includes a power supply that will drive the lamp in addition to positioning motors. This configuration saves money and space, and is particularly practical with switching power supplies used for LED lamps, which are small and create less heat. With this power configuration, it is also an option to add individual controlled dimming to the modular controller. 
         [0017]    Advantageously, a small external sensor assembly can be included in the control module. The external sensor assembly includes only the sensor and indicator lamp, and is connected to the control board of the control module via leads passing through the housing. This is helpful when the location for the window within the light fixture is in a very tight and at a location that is remote relative to the control module. In some cases, the optical sensor and indicator lamp that are directly connected to the control board of the control module are snipped off, and the external sensor assembly would be connected to the control board of the control module via a connector provided for that purpose. Most likely, a custom window would be created by the manufacturer. 
         [0018]    Modes for carrying out the present invention are explained below by reference to an embodiment of the present invention shown in the attached drawings. The abovementioned object, other objects, characteristics and advantages of the present invention will become apparent from the detailed description of the embodiment of the invention presented below in conjunction with the attached drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0019]      FIG. 1  illustrates use of a remote to select a light fixture and to a remotely control the brightness, position, and/or orientation of a lamp.  FIG. 2  is a rear isometric view of the control module. 
           [0020]      FIG. 3  is an exploded front perspective view of the control module of  FIG. 2 . 
           [0021]      FIG. 4  is a sectional view of a motorized lamp fixture including the control module of  FIG. 2  within the lamp fixture. 
           [0022]      FIG. 5A  is a front perspective view of the control module with the window in a first position relative to the module housing. 
           [0023]      FIG. 5B  is a front perspective view of the control module with the window in a second position relative to the module housing. 
           [0024]      FIG. 5C  is a front perspective view of the control module with the window removed and including a remote sensor assembly. 
           [0025]      FIG. 6A  is a sectional view of another motorized lamp fixture including the control module of  FIG. 2  within the lamp fixture. 
           [0026]      FIG. 6B  is a detail view of a portion of the control module of  FIG. 2  configured as shown in  FIG. 6A . 
           [0027]      FIG. 7  is a rear perspective view of another embodiment of the control module. 
           [0028]      FIG. 8A  is a block functional diagram for the control module of  FIG. 2 . 
           [0029]      FIG. 8B  is a block functional diagram for another embodiment of the control module. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]    Referring to  FIG. 1 , a system for remotely controlling the brightness, position, and/or orientation of a single light fixture, or group of light fixtures, includes a hand-held remote control transmitter  100  and remote-controlled light fixtures  102 . The light fixtures  102  used for the purposes of this description are mounted in a track  31 , but fixture mounted, wall mounted, or table top devices could be used equally well in the system. The light fixtures  102  can be controlled either individually or as a group. A control module  40  is provided in each lamp fixture  102 . The control module  40  is configured to receive signals from the remote control transmitter  100 , and to control the position of a lamp  35  supported on the light fixture  102 , as discussed further below. For individual control, the remote control transmitter  100  is pointed at the selected light fixture  102   b,  and a select button is pressed, sending out a directional signal such as a laser. An indicator lamp on the selected light fixture  102   b  lights to show that the module is ready to accept omni-directional remote control commands. In this condition, it is no longer necessary to point the remote control at the lamp fixture to control it. This allows the user to concentrate on the light field emitted by the lamp  35  during positioning, rather than aiming the remote control transmitter  100 . 
         [0031]    Referring to  FIGS. 2 and 3 , the control module includes a module housing  1 . The module housing  1  is a rectangular, clam-shell housing including a top half  12  and a bottom half  13  held together by screws  11 . In some embodiments, the screws are covered by a label  10 . The top and bottom halves  12 ,  13  provide sidewalls  60  that surround a control board  14  that is supported within the module housing  1 . In the illustrated embodiment, the sidewalls  60  include a top  60   a,  a bottom  60   b  opposed to the top  60   a,  opposed lateral sides  60   c,    60   d  that join the top  60   a  to the bottom  60   b  along the side edges thereof, a front end  60   e  and a rear end  60   f  opposed to the front end  60   e.  The front and rear ends  60   e,    60   f  join the top  60   a  to the bottom  60   b  along the end edges thereof. Here, references to direction, including “top”, “bottom”, “lateral”, “front end” and “rear end”, are made with respect to the orientation shown in  FIG. 3  for purposes of description of the embodiment, and are not intended to be limiting. 
         [0032]    An opening  52  is formed in the module housing  1 . The opening  52  extends within the top  60   a  inward from an edge of the top  60   a  adjoining the front end  60   e.  In addition, the opening  52  also extends within the front end  60   e  inward from an edge of the front end  60   e  adjoining the top  60   a.  The opening  52  forms a generally U-shaped cut-out in each of the top  60   a  and front end  60   e.    
         [0033]    The housing  1  also includes a window  2  that snap-fits within in the opening  52 . In the illustrated embodiment, the window  2  is round and dome shaped such that it protrudes outward relative to outer surface of the sidewall  60 . In addition, the window  2  is translucent. Translucence can be achieved, for example, by forming the window  2  of a material containing a light-scattering matrix of particles, or by providing the outer and/or inner surface of the window with a texture or frost. By using a translucent window  2 , the reception of laser is improved due to light scattering. In particular, the scattering will send a misdirected beam in many directions, increasing the chance for beam to be received by the photodiode  17 . Frosting of the window  2  has the added benefit of hiding the electronics from view. 
         [0034]    In the illustrated embodiment, the window  2  includes a flange portion  5  that extends from a periphery of the window  2  in a direction perpendicular to a plane defined by the window  2 . The flange portion  5  has a peripheral shape that is similar to that of the window, that is, it has a U-shape. As a result, the window  2  is L-shaped in cross-section. The window  2  can be detached from the module housing  1  and reconnected to the module housing  1  in a plurality of orientations. By providing the window  2  with the flange portion  5  that has the same peripheral shape, when the window  2  is removed, flipped to another orientation, and reconnected to the housing  1 , the window  2  still covers the entire opening  52 . 
         [0035]    The control board  14  includes a microcontroller  42 , a motor driver  43  that is controlled by the microcontroller  42 , and a power supply  15  that provides power to the microcontroller  42  and motor driver  43 . The control board  14  includes a radio receiver  16 , a photodiode  17 , and an indicator lamp  18  for indicating that the control module  40  is active. In some embodiments, the indicator lamp  18  is an LED. The control board  14  also includes a connector  19  configured to receive a corresponding connector of an external sensor assembly  46 , and provide an electrical connection between the external sensor assembly  46  and the microcontroller  42 . In  FIG. 3 , the photodiode  17  and LED  18  are arranged in a vertical orientation. 
         [0036]    Referring to  FIG. 8A , the control module  40  is powered using alternating current power from the power grid (e.g., mains power). Mains power enters the control module housing  1  via two wires  3  and supplies the power supply  15 , which in turn, provides direct current at voltage that is reduced relative to the mains power. In some embodiments, the power supply  15  provides 5 V DC. In addition, the control module  4  has two output connectors  4  for connection to lines that permit selective powering and driving of lamp-positioning motors  32 ,  34  (the motors are shown in  FIG. 4 ). The lamp  35  is powered separately from the modular controller  40  via a lamp power supply  37 . 
         [0037]    In use, an ID Laser detect circuit (not shown) provided in the microcontroller  42  would be activated from a directional laser signal transmitted from the hand-held remote control transmitter  100 , enabling the microcontroller  42  to start following commands from the radio or infrared receiver. Based on those commands, the microcontroller  42  controls a motor driver circuit  43  to direct the lamp-positioning motors  32 ,  34 . 
         [0038]    Referring to  FIG. 4 , the modular controller  40  is a self-contained, modular unit that can simply be placed inside a light fixture  102 . In  FIG. 4 , wiring and other ancillary structures have been excluded for clarity. The light fixture  102  is mounted to a track  30  via a track mounting  31 , and includes a fixture housing  39 . A lamp  35  is supported on the fixture housing  39 , and is connected to, and rotated by, a tilt motor  34  disposed within the fixture housing  39 . Mains power is supplied to the light fixture  102  through the input axis  36  of a pan motor  32 , which is also disposed within the fixture housing  39 . The input axis  36  is hollow for the purpose of receiving wires, and mains power lines pass through pan motor  32  to the control module  40 . A separate lamp power supply  37  is included in the light fixture housing  39  that powers the lamp  35  via wires passing through the tilt motor rotational axis  38 . The modular controller  40  is positioned within the light fixture  102  such that the window  2  protrudes through a hole formed in the fixture housing  39  for that purpose and allowing for the reception of signals. The modular controller  40  drives both the pan motor  32  and tilt motor  34 . 
         [0039]    Referring to  FIG. 5A , the control module  40  can be physically reconfigured so that it can work in many different lamp designs. As a result, a manufacturer can stock a single part that will work in many different light fixtures, permitting the manufacturer to minimize stock of parts and reduce costs. In particular, a first physical configuration is illustrated in  FIG. 5A , in which the window  2  is oriented within the opening  52  such that the flange portion  5  is received within the module housing front end  60   e,  and the window  2  is received within the module housing top  60   a.  In this configuration, the photodiode  17  and LED  18  are arranged within the housing  1  so as to face the window  2 . In particular, the photodiode  17  and LED  18  are disposed within the opening  52  within the top  60   a,  and are oriented so that a detection surface of the sensor  17  is parallel to the top  60   a  and faces outward relative to the module housing  1 . 
         [0040]    Referring to  FIG. 5B , in a second physical configuration of the control module  40 , the window  2  is oriented within the opening  52  such that the flange portion  5  is received within the module housing top  60   a,  and the window  2  is received within the module housing front end  60   e.  In this configuration, the photodiode  17  and LED  18  are arranged within the housing  1  so as to face the window  2 . In particular, the photodiode  17  and LED  18  are disposed within the opening  52  within the front end  60   e,  and are oriented so that a detection surface of the sensor  17  is parallel to the front end  60   e  and faces outward relative to the module housing  1 . In some embodiments, repositioning of the photodiode  17  and LED  18  within the module housing  1  is achieved by bending the leads used to connect the photodiode  17  and LED  18  to the control board  14 . 
         [0041]    Regardless of whether the control module  40  is used in the first or second configuration, the window  2  is shaped such that the opening  52 , including portions on the top  60   a  and on the front end  60   e,  is covered. 
         [0042]    Referring to  FIG. 5C , in a third physical configuration of the control module  40 , the window removed from the opening  52 . In this configuration, the photodiode  17  and LED  18  can be arranged within the housing  1  as described above for either of the first and second configuration. Alternatively, an external sensor assembly  46  that includes a photodiode  17  and LED  18  can be connected to the connector  19  of the control module  40  using leads  47  that pass through the opening  52 . The third configuration including the external sensor assembly  46  is advantageous since it permits manufacturers to place their own window in a remote location. It also permits sensors to be place within a small space at a location remote from the control board  14 , which is particularly useful for use in light fixtures of unusual geometries. 
         [0043]    Referring to  FIGS. 6A and 6B , the light fixture housing  39 ′ can be made much smaller than the embodiment shown in  FIG. 4  by providing the control module  40  in the second configuration among other modifications. When in the second configuration, the modular controller  40  is oriented with window  2  on the housing front end  60   e,  resulting in a module having a lower profile ( FIG. 6A , in which wires are excluded for clarity). The photodiode  17  and LED  18  are bent from an orientation perpendicular to the control board  14  to and orientation generally parallel to the control board  14  to accommodate the window configuration ( FIG. 6B ). 
         [0044]    Referring to  FIG. 7  and  FIG. 8B , a second modification to the light fixture  102  to reduce the size of the light fixture housing  39  includes removing the lamp power supply  37 , and powering the lamp  35  using the power supply  15  of the control module  40 . In order to minimize cost and size, and maximize power savings, it is much more efficient to have one power supply that drives the lamp  35  and the components/and or circuitry on the control board  14 . To accomplish this, the modular controller  40  can be modified to further include power out wires  50  ( FIG. 7 ) that connect the power supply  15  to the lamp  35 . In some embodiments, the lamp  35  is a  12  volt halogen lamp. In other embodiments, the lamp  35  can be a light source that uses much less power, such as one employing one or more LEDs. 
         [0045]    In this embodiment, the power supply  15  can be any type of supply including switching mode supply, or one configured to dim the lamp  35  when the mains supply is dimmed from a wall switch. With the lamp supplied by the power supply  15  on the control board  14 , it will also be possible to dim the lamps individually from the microcontroller  42  using signals from the hand-held remote control transmitter  100 . 
         [0046]    Although the window  2  is illustrated here as round and dome shaped, the window is not limited to this configuration. For example, the window can be made in any convenient peripheral shape, and further may be planar or have an irregular thickness. 
         [0047]    Moreover, other structures can be substituted for the window  2  described herein. For example, other embodiments could have knock-out panels for the window, or could use a window that allows reception in multiple axes. 
         [0048]    Although the system and control module  40  described herein include a radio receiver  16 , the control module  40  is not limited to this type of sensor, and the radio receiver  16  can be replaced using another type of sensor. For example, the radio receiver can be replaced by an infrared receiver. In addition, the photodiode  17  can be replaced by another type of laser or optical sensor such as phototransistor, or another type of optical sensor. 
         [0049]    Although the control module  40  described herein includes an LED  18  that can be repositioned within the module housing, the module  40  is not limited to this configuration. For example, in some embodiments, a surface mount LED may be used that bathes light in all directions so that repositioning is not needed. 
         [0050]    In addition, as discussed above with respect to  FIG. 5C , the control module  40  described herein can be arranged in a third physical configuration in which the window  2  is removed from the opening  52 , and an external sensor assembly  46  that includes a photodiode  17  and LED  18  is connected to the connector  19  of the control module  40  using leads  47  that pass through the opening  52 . In some embodiments, however, the control module  40  may be manufactured without the connector  19 , whereby only the first and second physical configurations would be available. In other embodiments, the control module  40  may be manufactured with the connector  19  and without the photodiode  17 , LED  18  that are directly connected to the control board  14 , whereby optical sensing is achieved via the external sensor assembly  46 . 
         [0051]    A selected illustrative embodiment of the invention is described above in some detail. It should be understood that only structures considered necessary for clarifying the present invention have been described herein. Other conventional structures, and those of ancillary and auxiliary components of the system, are assumed to be known and understood by those skilled in the art. Moreover, while a working example of the present invention has been described above, the present invention is not limited to the working example described above, but various design alterations may be carried out without departing from the present invention as set forth in the claims.