Abstract:
A control system for electrical devices in a vehicle has output/relay modules with processing and memory capability. The output/relay module is programmable to store configuration data corresponding to predetermined states for the various devices to be controlled. The output/relay module has memory capability including a non-volatile component (EEROM). An input module also has processing capability, and includes memory capability. The input module has selector switches for preselecting a variety of device states. The input module further provides a visual indication of the states for these devices. A data bus provides communication between said input and output modules, and a dongle is selectively connected to said relay module data bus for allowing changes to the configuration data stored therein. The dongle is programmable from a personal computer or work station. The control system includes a voltage monitoring system and circuit breakers to protect the system and devices controlled thereby.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]    The present application is related to the following co-pending applications, namely, PCT application number PCT/US01/03941 of Carling Technologies et al. for Apparatus For Electrically Controlling Devices And A Method Of Operating It, filed on Feb. 7, 2001 (Atty. Docket No. 1961-181WO), and U.S. Provisional Application No. 60/310,922 for System and Method For Controlling Electrical Devices, filed on Aug. 8, 2001, (Atty. Docket No. 1961-183), both of which are incorporated herein by reference. 
     
    
     
       SUMMARY OF THE APPARATUS FOR ELECTRICALLY CONTROLLING DEVICES AND A METHOD OF OPERATING IT  
         [0002]    The Apparatus For Electrically Controlling Devices And A Method Of Operating It disclosed in PCT patent application No. PCT/US01/03941 of Carling Technologies et al. provides a control system for electrical devices in a vehicle having output/relay modules with processing and memory capability including non-volatile memory. The output/relay modules are programmable and store configuration data corresponding to predetermined states for various devices to be controlled by the system. The output/relay modules each have outputs including relays coupled to the various electrical devices to be controlled on a vehicle such as lights, motors and pumps. The system provides at least one input module having a microprocessor and a plurality of variable function switches for selecting predetermined states for the electrical devices or relay modules. The input modules have visual indicators for providing the current states of the devices. A data bus provides communication between the input and output/relay modules. A clock provides synchronization for the transmission of serial data via the data bus.  
           [0003]    The system also includes a dongle which can be programmed via a computer to store configuration data for a specific arrangement of the relationship between the input modules, the output/relay modules and the electrical devices to be controlled by the system. Once programmed, the dongle can be coupled to an output/relay module of the control system to configure or reconfigure the non-volatile memory of the system for a specific application.  
           [0004]    The output/relay modules are configured via a jumper provided to function as either a master or slave output/relay such that the control system is extendable for control of any number of electrical devices by configuring a first output/relay module as a master and a plurality of additional output/relay modules as slave modules thereto.  
           [0005]    The system provides for selectively configuring the variable function switches to implement a primary or secondary functions or both primary and secondary functions for controlling the relay modules or electrical devices coupled thereto. The switches include visual indicators for identifying the functional configuration thereof as well as a current status of the electrical devices. The switches can function as momentary or toggle switches and be configured in the following modes: inclusive scroll, exclusive scroll, binary scroll, intermittent, intermittent period increment, intermittent period decrement, as well as clone or timer modes.  
         SUMMARY OF THE INVENTION  
         [0006]    The present invention control system for electrical devices incorporates a control system such as the above-identified Apparatus For Controlling Electrical Devices In Vehicles and includes additional features. The additional features provide improvements to the above-identified system for use in vehicles such as yachts, motor homes, or airplanes wherein numerous electrical devices are utilized in the operation of the vehicle.  
           [0007]    The invention provides a control system for electrical devices in a vehicle including a power supply, a relay module having a microprocessor with a memory and an output for controlling the electrical devices. The relay module is programmable for storing configuration data corresponding to predetermined states for the electrical devices to be controlled. The memory includes non-volatile memory (EEROM) or flash memory. The input module is coupled to the relay module via a data bus and includes a microprocessor and a plurality of variable function switches for selecting predetermined states for the electrical devices. The system includes a jumper for configuring the relay module and a programmable dongle connectable to said relay module for configuring the non-volatile memory.  
           [0008]    The present invention control system for electrical devices in vehicles also includes a voltage monitoring system coupled to the microprocessor for monitoring the output voltage of the power supply and providing selective control of the electrical devices. In the event of a low voltage condition, the voltage monitoring system utilizes predetermined priority levels for each of the electrical devices controlled and shuts down the electrical devices accordingly, beginning with the lowest priority devices. The voltage monitoring system also includes a manual override for each of the electrical devices wherein the electrical devices can be shut down manually. The system stores predetermined default parameters for each of the electrical devices controlled that are also utilized in the shut-down procedures.  
           [0009]    The present invention control system includes circuit breakers for protecting the system and electrical devices controlled thereby. The circuit breakers can be auto resettable such that the control system can reset a tripped breaker. Sensors are coupled to the circuit breakers for transmitting signals to indicators provided to communicate the status of the circuit breakers. Both audible and visual indicators can be utilized depending on the priority levels of the devices being controlled.  
           [0010]    Additional features of the control system of the present invention are described in the following detailed description of a preferred embodiment of the invention wherein the control system is adapted for use in a boat. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    [0011]FIG. 1 is a block diagram of an embodiment of the present invention;  
         [0012]    [0012]FIG. 2 is a block diagram of the relay module of the FIG. 1 embodiment shown coupled to a dongle for configuring a relay module for use in a particular application;  
         [0013]    [0013]FIG. 3 is an illustration showing the dongle of the above-identified Apparatus For Electrically Controlling Devices coupled to a computer for storing configuration information for the relay modules;  
         [0014]    [0014]FIG. 4 shows a housing embodying the present invention control system;  
         [0015]    [0015]FIG. 5 is a top view of a button module or operator control module for use with the present invention;  
         [0016]    [0016]FIG. 6 is an illustration of a keypad switch having a removable button for use with the present invention;  
         [0017]    [0017]FIG. 7 is a flowchart of a start-up function for use with the invention;  
         [0018]    [0018]FIG. 8 is a flowchart illustrating the normal operation of an embodiment of the present invention;  
         [0019]    [0019]FIGS. 9A-9C are flowcharts of typical automatic functions of the invention;  
         [0020]    [0020]FIG. 10 is a flowchart illustrating the operation of the voltage monitoring system of one embodiment of the present invention; and  
         [0021]    [0021]FIG. 11 is an illustration showing the interface panel controller of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0022]    Following is a description of a preferred embodiment of the present invention control system for electrical devices that was designed for use in vehicles. Other embodiments of the invention and applications therefor are within the scope of the invention and will be apparent to those skilled in the art upon review of the description and drawings of the invention included herein.  
         [0023]    [0023]FIG. 1 shows the present invention control system for electrical devices generally referred to with the reference numeral  10  as used with the above-identified Apparatus For Electrically Controlling Devices. The operation and features of the Apparatus For Electrically Controlling Devices is described briefly hereinabove and in detail in the above referenced PCT patent application. Thus, the basic operation of the relay/output module generally  12 , button modules  16  and  17  respectively and data bus  22  are not described further herein. However, the present invention improvements to the relay module  12  and button modules  16  and  17  are described following.  
         [0024]    [0024]FIG. 2 is an illustration of the relay module  12  of the present invention coupled to the dongle, generally  201  in the same manner described in the above-identified Apparatus For Electrically Controlling Devices.  
         [0025]    [0025]FIG. 3 is an illustration of the dongle  201  coupled to a computer, generally  251  for storing the configuration data for use in the relay module  12  in the memory of the dongle. This process is described in detail in the above-identified patent application for Apparatus For Electrically Controlling Devices, thus FIG. 3 is included herein for convenience only.  
         [0026]    [0026]FIG. 4 shows a housing  26  for the control system  10  as used in the preferred embodiment of the present invention. The housing  26  has terminals  28  and  30  for coupling the control system  10  to the power supply  32 . The coupler  34  is provided to attach the system to the bus  22 . Manual override switches, generally referred to by the reference numeral  36  are further described hereinbelow.  
         [0027]    [0027]FIG. 5 shows a top view of an operator control module of the preferred embodiment of the present invention generally referred to by the reference numeral  37 . The operator control module  37  has a plurality of variable function keypad switches  38  for operation of the electric devices of the vehicle (not shown) that are coupled to the control system. Indicator lights,  40 , which are LEDS in the preferred embodiment shown, each correspond to the individual keypad switches  38 . The keypad switches  38 , can have one, two, or any number of indicator lights  40  associated therewith. Audible indicators (not shown) can also be utilized with the control system and activated thereby for indicating the status of certain of the electrical devices. The operation of operator control module  36  is described in detail in the above-described patent application for Apparatus For Electrically Controlling Devices.  
         [0028]    In the preferred embodiment, the operator control module  37  is manufactured such that the module  37  has a membrane for providing a completely sealed unit for long term use in applications involving adverse conditions. The sealed units can be customized using removable switch covers that can include custom legends corresponding to the function of the switch or the device being controlled. The removable switch covers for the keypads provide flexibility for adapting standard keypads for various applications. The switch covers may include translucent etched legends for LED lighting of the customized switches or other means for providing illuminated switches having customized legends and visual indicators for displaying the status of the switches or electrical devices controlled thereby.  
         [0029]    [0029]FIG. 6 shows details of one embodiment of a keypad switch  38  having a removable cover. A contact switch  42  is manually operated by using the button switch  44  which includes a removable cover  46 . The button cover  46  couples to the switch  44  via detents  50  thereon and cooperating openings  52  in the button cover  46 . The button switch  44  has a membrane  45  for sealing the switch and is coupled to a circuit board  48  via anchors  54 . The button cover  46  is removable so that indicia on a top side  56  of the button cover can be easily changed or customized depending on the particular application or electrical device the operator control module  37  or keypad switch  38  is used to control. Additionally this allows the button cover  46  to be color coded to correspond to certain devices or for other purposes.  
         [0030]    Referring to FIG. 7, a flowchart for the start-up procedure for the present invention control system is shown. The reference numeral  58  illustrates that portion of the start-up procedure that includes memory transfer from the dongle  201  and a self-test procedure, both of which are described in detail in the previously identified patent application for Apparatus For Electrically Controlling Devices. In the present invention, the relay modules  12  are initially configured using defaults for the variable parameters associated with the various functions of the relays and the operator control modules. For example the variable functional switches set to provide an intermittent function for a flashing light may be pre-set to activate the appropriate relays at 30 second intervals, wherein an intermittent switch designated to operate a live well on a fishing boat may have a preset parameter for intermittent operation in 10 minute intervals.  
         [0031]    The present invention also provides an ignore ignition feature operable using an input pin on the relay module  12 . Referring again to FIG. 7, the ignore ignition feature is illustrated starting at block  60  wherein a determination is made as to whether or not the ignore ignition feature is activated. If activated, as indicated in block  62 , the control system  10  is operational regardless of the position of the vehicle&#39;s ignition-switch. Alternatively, if the ignore ignition in an inactive position, the vehicle&#39;s ignition switch is checked as shown in block  64 . At block  66  a determination is made as to whether or not the ignition switch is on. If the ignition switch for the vehicle is on, then the control system  10  is activated for normal operation as indicated at block  68 . Block  70  represents the condition wherein the ignore ignition feature is deactivated and the ignition switch is off, thus, the system returns to block  64  and rechecks the status of the ignition switch. The ignore ignition feature is utilized for operating the control system and electrical devices powered thereby when the ignition for the vehicle is in the off position. The ignore ignition feature can also be utilized for individual circuits wherein the appropriate relay modules  12  are configured accordingly. For example, the circuit for a stereo may be configured to operate only when the ignition is on thus ignore ignition would be deactivated. Alternatively, a circuit controlling a bilge pump may be configured to operate regardless of the status of the vehicle&#39;s ignition, thus ignore ignition is activated and the relay  12  would be configured accordingly.  
         [0032]    [0032]FIG. 8 is a flowchart illustrating the normal operation of the preferred embodiment of the invention. FIG. 8 shows the operation of the system starting at block  72 . At block  74 , the cycle begins at one of the keypad switches  38 , wherein a determination is made as to whether or not the switch  37  has been depressed. If the switch has not been depressed the system cycles to the next relay in an infinite loop transversing each of the relays of the system  10 , shown at block  75 . If yes (the keypad switch  37  has been depressed), the block  76  represents a determination as to whether or not the function controlled by the depressed switch is allowed to be changed. This represents a lock-out feature of the control system wherein a function or device is prevented from being turned on or off depending on the status of on or more other functions or devices, (i.e. a port side ballast pump may be “locked-out” while a starboard ballast pump is active).  
         [0033]    If the depressed switch controls a locked-out function, (lock-out active), shown in block  78 , the switch closure is ignored. Next, the backlighting for the locked-out switch is checked at block  80  and adjusted accordingly at block  82 . For example, the backlighting feature for the keypad switches may be configured to be turned off if the function of the switch is locked out. The control system  10  then cycles to the next relay as shown in block  84 .  
         [0034]    If the function controlled by the depressed switch  37  is not locked-out, the control system determines the functional operation of the switch at blocks  86 ,  88 ,  90 ,  92 , and  94  respectively. Upon determination of the function of the switch  37 , the appropriate relay is activated accordingly as shown in blocks  96 ,  98 ,  100 ,  102 , and  104  for controlling the electrical devices.  
         [0035]    Continuing at block  106 , the system makes a determination if the switch has been depressed and held for at least 3 seconds. If no, the cycle advances to the next relay at block  107 . If yes, a determination is made as to whether or not a secondary function is associated with the switch at block  108 . If no, the cycle advances to the next relay at block  107 . If there is a secondary function associated with the depressed switch  37 , the secondary function is activated at block  110 . The system  10  continues at block  112  and checks a flash indicator associated with the secondary function. The flash indicator is activated accordingly at block  114 . The normal operation cycle of the system  10  continues to the next relay at block  116 .  
         [0036]    [0036]FIGS. 9A-9C illustrate the normal operation of some of the automatic or repetitive functions of the preferred embodiment of the control system  10  such as intermittent control (block  118 ), countdown control (block  124 ) and automatic shutdown (block  130 ). If the switch is configured to function intermittently, referring again to block  118 , the system checks the appropriate timer at block  120  and upon reaching a predetermined time interval, the appropriate relay(s) is/are activated at block  122 .  
         [0037]    If the switch is configured in a countdown control (block  124 ), the timer is checked at block  126  and the appropriate relays are deactivated at block  128 . Referring again to block  130 , one embodiment of an automatic shut-down or sleep mode is illustrated. At block  132 , a determination is made as to whether or not an appropriate timer has expired since the last keypad switch  37  was depressed. If yes, the control system or a portion thereof is shut-down at block  134  until the next time a keypad switch  37  is utilized. Alternatively, the control system can be shut-down manually.  
         [0038]    [0038]FIG. 10 illustrates one embodiment of the voltage monitoring system  24  of the control system  10 . The present invention system  10  provides a voltage monitoring system  24  wherein the power supply  32  is continuously monitored and the voltage monitoring system provides selective control of the electrical devices of the vehicle accordingly. In the preferred embodiment, the control system functions properly in a voltage range of between about 9.5 volts to about 15 volts.  
         [0039]    Each of the electrical devices is assigned a priority level that is stored in the memory of the system and utilized by the voltage monitoring system in automatic priority based shut-downs in the event of a low-voltage condition. For example, in the preferred embodiment, a priority level one is assigned to all of the most crucial devices in the vehicle, including any system that needs constant power such as a computer system or water system. A priority level two is assigned to devices that can be turned off, for example entertainment systems or certain power outlets. Additionally, in the preferred embodiment, the least critical devices are assigned a priority level three, for example, some non-emergency light fixtures may be assigned a priority level three.  
         [0040]    The control system  10  provides manual override switches  36  shown in FIGS. 4 and 4A wherein certain functions or electrical devices can be operated manually regardless of the priority level thereof or the status of the voltage monitoring system  24 . These manual override switches  36  are mainly designed for emergencies, however they could be utilized in other situations as well. The FIG. 4A embodiment also shows a main power switch  169  for the control system  10 .  
         [0041]    Additionally, each of the electrical devices has a proper voltage range associated therewith that is also stored in the system&#39;s memory and utilized to shut-down the particular component as necessary in a low-voltage situation to protect the device. Thus, each of the electrical devices has associated therewith parameters as to the safe operating range thereof as well as a priority level for the operation thereof. These parameters are normally preset to standard default values at the time of manufacture of the control system, however they are variable as necessary per the requirements of a certain application.  
         [0042]    Referring again to FIG. 10, one embodiment of the voltage monitoring system  24  starts at block  138 . At block  140 , the voltage of the power supply  32  is compared to the priority level  2  voltage. If the power supply voltage is lower or equal to the priority level  2  voltage, warning indicators are activated at block  142 . At block  144  a shut-down wait period timer is checked and allowed to elapse before the priority level  2  devices are shut down at block  146 . Returning to block  140 , if the voltage of the power supply  32  is above the priority  2  level, the voltage monitoring system  24  compares the power supply voltage to a priority one level at block  148 . If the power supply voltage is above the priority one level, the voltage monitoring system  24  cycles to the start at block  138 .  
         [0043]    Alternatively, if the voltage of the power supply  32  is not above the priority level one voltage, warning indicators are activated at block  152  and the voltage monitoring system advances to block  144  wherein the shut-down timer for priority two level devices is checked prior to shut-down thereof.  
         [0044]    [0044]FIG. 11 illustrates the use of electromechanical switches  160  coupled to the relay module  12  of the control system via an interface panel  162 . The interface panel  162  is provided to couple switches  160  other than the keypad switches  38  on the operator control module  37  to the relay module  12 . Thus, by using the interface panel  162  the control system  10  can function using standard switches. The control system  10  can utilize both the operator control modules  37  and standard switches coupled with the interface panel  162 .  
         [0045]    Referring to FIGS. 1 and 4A, the present invention control system includes overcurrent protection represented generally by the reference number  165  for protecting the system and electrical devices controlled thereby. Circuit breakers  167  are provided in the output circuitry and can be auto resettable such that the control system can reset a tripped breaker. Sensors are coupled to the circuit breakers  167  for transmitting signals to indicators provided to communicate the status of the circuit breakers. Both audible and visual indicators can be utilized depending on the priority levels of the devices being controlled. In the preferred embodiment the circuit breakers  167  are thermal breakers.  
         [0046]    The programmable variable function switches can be programmed to provide each of the functions described in the previously identified patent application for Apparatus For Electrically Controlling Devices as well as other functions such as a wiper mode. The wiper mode eliminates the need for a standard wiper switch on vehicles equipped with the present invention control system for electrical devices. The wiper mode provides all of the standard controls normally used with windshield wipers such as low, high, mist and intermittent modes.  
         [0047]    Other variable functions provided in the present invention control system include a reverse inclusive scroll mode wherein the switch is configured to turn off a series of electrical devices with repeated switch closings. Additionally a reverse binary scroll function is provided to turn off a series of electrical devices according to a decreasing binary count. A dimmer feature has been included in the present control system  10  for use with lighting devices as well as backlights for the operator control modules  37 . Further, the relay module  12  of the present invention can be configured in a fixed on or fixed off mode such that a device can be always on or always off when the control system  10  is operating.  
         [0048]    The preferred embodiment of the present invention also provides configurations for the relay module  12  for the specific control of bilge pumps used in boats. The relay module  12  for use with a bilge can include a manual override as identified above such that the bilge pump can be operated manually if necessary or desired. Additionally, the relay module  12  can be coupled to a float switch and configured to operate automatically based on the status of the switch. Visual indicators and audible warning devices can also be activated by the relay module  12  configured to control a bilge pump.  
         [0049]    While preferred embodiments have been shown and described herein, various modifications and substitutions may be made without departing from the scope of the invention. Accordingly, it is to be understood that the present invention system and method for controlling electrical devices has been described herein by way of example and not by limitation.