Abstract:
An energy saving controller for an air conditioning system comprising a temperature sensor or sensing and measuring the temperature in an area to be controlled, a memory device for storing a first set and a second set of reference temperatures, each set of reference temperatures including a heating reference temperature and a cooling reference temperature, and a controller in communication with the memory device for selecting one of the first and second sets of reference temperatures in the memory and for comparing the selected set of reference temperatures to the measured temperature of the area. The controller is adapted to select one set of reference temperatures when the area is unoccupied by a person and to select the other set of reference temperatures when the area is occupied by a person. The occupancy information is provided to the controller by an occupancy detector. A system switch is provided that communicates with the controller and selects between a heating mode, a cooling mode, and an off mode. The controller is adapted to actuate a heating unit when the heating mode is selected by the system switch and when the measured temperature of the area falls substantially below the heating temperature set point or actuate a cooling unit when the cooling mode is selected by the system switch and when the measured temperature of the area substantially exceeds the selected cooling temperature set point.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 60/008,668, filed Dec. 15, 1995. 
     TECHNICAL FIELD 
     An appendix having a total of 42 pages of a computer program constitutes part of this specification of this invention. 
     This invention relates to thermostat control systems and, more specifically, to a thermostat control system that controls the temperature settings in a room based on the occupancy of the room. 
     BACKGROUND OF THE INVENTION 
     When an unoccupied hotel room, office or dwelling is cooled or heated to personal comfort levels, energy and money are being wasted. Conventional thermostats generally have a set of manual controls, requiring the occupant of the room or dwelling to manually adjust the settings to their needs. If the occupant also happens to be the owner of the premises, chances are that they will make a conscious effort to lower the settings when they leave the premises, as they are acutely aware of the needless costs of running a heating and cooling system when their premises are unoccupied. However, when the occupant of the room, office or dwelling is not the owner and does not have to pay for the cost of heating and cooling, chances are that they may not be quiet as conscientious. In fact, it is fairly safe to say that most non-owner occupants will make minimal or no effort to adjust the thermostat settings when they leave the room or premises unless they are personally responsible for the cost of heating or cooling the room, office, or premises. 
     In most hotels and corporate suites, the cost of heating and cooling is borne by the owner. In any given day, most hotel rooms and corporate suites are left unoccupied from ten to twelve hours. Rooms and suites are generally used primarily during the evening hours. Therefore, if the thermostats in the rooms are left at settings chosen by the occupant for their comfort, a tremendous amount of money and energy is spent needlessly every day. 
     SUMMARY OF THE INVENTION 
     A dual set-point thermostatic controller assembly for controlling gas, oil, or electric heaters with air conditioning is provided. The assembly operates as a conventional household thermostat, sensing the environment&#39;s temperature and activating a switch selected heating or cooling unit. Unlike other thermostatic controllers that operate to maintain an environmental temperature referenced to a single temperature, the thermostatic controller assembly disclosed herein is designed to automatically select one of two reference temperature sets. One reference temperature set is selected when the physical area to be environmentally controlled is occupied. The second reference temperature set is selected when the controlled area is unoccupied. 
     The dual set-point thermostatic controller assembly comprises a thermostat control unit and an occupancy sensing unit. The control unit comprises a micro-controller for controlling and actuating a heating and cooling unit, a set of display devices for displaying the temperature of the room and desired reference temperature, a segment driver that connects the micro-controller to the display devices and drives the display devices in response to the micro-controller, and a memory device, which is programmed to store an occupied reference temperature, an unoccupied reference temperature, and a time delay. The micro-controller receives input from several internal and external sources: temperature sensors, occupancy sensors, a fan switch, a power switch, a system switch, a key switch, a programming switch, and the memory device. 
     The micro-controller operates to select one of the two reference temperature sets by monitoring the occupancy sensor. The occupied reference temperatures, typically chosen by the occupant of the room, is selected by the micro-controller when the physical area to be environmentally controlled is occupied. The unoccupied reference temperatures, typically selected by the owner of the premises, is selected when the controlled area is unoccupied. The micro-controller monitors the temperature sensor, the occupancy sensor, and mechanical switches and determines which reference temperature applies and controls the heating and cooling unit accordingly. 
     The fan switch has one of two positions: an ON position and an AUTO position. In the ON position the fan runs continuously. In the AUTO position, the micro-controller turns on the fan and heating or cooling unit when the environment temperature drops below (in the case of heating) or above (in the case of cooling) the reference temperature setting. 
     The system switch is a three position switch monitored by the micro-controller to determine if the occupant has selected the heating operation, the cooling operation, or has turned the thermostat unit off. If the occupant has selected the COOL switch position, the micro-controller turns on or off the power control switch to control the cooling operation for the controlled environment. Similarly, if the occupant has selected the HEAT switch position, the micro-controller turns on or off the power control switch to control the heating operation to the controlled environment. If the occupant has selected the OFF switch position, the controller does not turn on the heating or cooling unit but continues to monitor and display the current temperature. The controller provides power to the fan, however, if the fan switch is placed in the ON position. 
     The micro-controller determines the heating and cooling operational cycles by comparing the current environmental temperature measurement from the monitored temperature sensor to the applicable reference temperature, in the case of an occupied room to the reference temperature selected by the occupant or in the case of an unoccupied room to the default settings selected by the owner. 
     The key switch has two positions: a counter-clockwise position, the normal operating position for the switch, and a clockwise position. In the counter-clockwise position, the occupied reference temperature settings may be adjusted using the programming switch, as will be described below. A key is needed to move the switch from the counter-clockwise position to the clockwise position, where the unoccupied reference temperatures and a time delay can be programmed into the memory device. The reference temperatures for unoccupied operation can only be programmed when the key is inserted into the key switch and the key switch is in the clockwise position. 
     The programming switch is a three position switch: a neutral center position, an INC (increase) position, and a DEC (decrease) position. To set the unoccupied reference temperature, the system switch is moved to indicate whether the cooling or heating temperature is being adjusted and then the programming switch is held in either the INC or DEC position to either increase or decrease the temperature. To set the unoccupied reference temperature, the key switch is rotated by the key to the clockwise position and then the system switch is moved to indicate whether the cooling or heating temperature is being adjusted. Once the system is designated, the programming switch is held in either the INC or DEC position to either increase or decrease the temperature. To set a time delay, the system switch is moved to the OFF position and the programming switch is moved to either the INC or DEC position to increase or decrease the time delay. 
     The display devices are four digit liquid-crystal displays. The left two digits of the display device indicate the set point temperature currently referenced by the micro-controller. The right two liquid-crystal display digits indicate the current temperature of the environment area controlled by the dual set point thermostatic controller assembly. However, when the key switch is rotated to the clockwise position and the unoccupied reference temperature is being adjusted, the left two digits of the liquid-crystal display device indicates the unoccupied reference temperature as it is increased or decreased and the right two digits of the display device will show two dashes (- -) confirming that the unoccupied reference temperature is addressed rather than the occupied reference temperature. 
     The occupancy sensing unit includes an infrared sensor, which detects the heat emanating from a person&#39;s body. During periods of vacancy, the occupancy sensor will not send a trigger signal to the micro-controller. Without the triggering signal the micro-controller maintains the environmental conditions of the controlled area by use of the programmed set point reference temperatures intended for unoccupied conditions. During periods of occupancy, the micro-controller receives triggering signals from the occupancy sensor and maintains the environmental conditions of the controlled area by use of the programmed set point reference temperatures intended for occupied conditions. 
     In another aspect of the invention, remote sensing units are provided. The remote sensing units communicate with the thermostat control unit using conventional telephone wires. Conventional telephone jacks are mounted to the remote sensing unit and to the control unit so that the remote sensing unit can transmit the triggering signal to the micro-controller. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Figures of a preferred embodiment of the invention are annexed hereto so that the invention may be better and more fully understood, in which: 
     FIG. 1 is a perspective view of the dual set point thermostatic controller assembly of the present invention; 
     FIG. 2 is an exploded perspective view of the thermostatic controller unit of the present invention; 
     FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 2; 
     FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 2; 
     FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 2; 
     FIG. 6 is an exploded perspective view of the sensing unit; 
     FIG. 7 is a cross-sectional view taken along line 7--7 of FIG. 6; 
     FIG. 8 is a cross-sectional view taken along line 8--8 of FIG. 6; 
     FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 6; 
     FIG. 10a is a plan view of the control unit circuit board; 
     FIG. 10b is a plan view of the sensing unit circuit board; 
     FIG. 11 is a block diagram of the dual set point thermostatic controller assembly; 
     FIG. 12 is an electrical schematic of the occupancy sensing unit; 
     FIG. 13 is an electrical schematic of the micro-controller, segment driver and liquid-crystal display portion of the controller unit; 
     FIG. 14 is a flow diagram of the power on sequence of the computer program; 
     FIG. 15 is a flow diagram of the initialization sequence of the computer program; 
     FIG. 16 is a flow diagram of the interrupts sequence of the computer program; 
     FIG. 17 is a flow diagram of the control sequence of the computer program; 
     FIG. 18 is a flow diagram of the process keys sequence of the computer program; 
     FIG. 19 is a flow diagram of the determination of which data to modify sequence of the computer program; and 
     FIG. 20 is a flow diagram of the compressor timer sequence of the computer program. 
    
    
     Other objects and advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings, in which like reference characters are used throughout the drawings to designate like parts. 
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, the dual set-point thermostatic controller assembly generally designated by the numeral 10 comprises a thermostat control unit 11 and an occupancy sensing unit 12. In a first preferred embodiment of the thermostatic controller assembly, thermostat control unit 11 is mounted adjacent the sensor unit 12 on a mounting surface 13 in a room. 
     As best shown in FIG. 10 and 13, control unit 11 comprises a micro-controller chip 14 and power supply 14a that are mounted on a circuit board 15 for actuating relay switches (not shown), which in turn actuate a heating and cooling system (not shown) and a set of display devices 16a and 16b. The display devices display the temperature of the room and desired reference temperature and are connected to the micro-controller through a segment display driver 18. Micro-controller 14 receives power from power supply 14a through a power regulator circuit 17 and input from several internal and external sources: a temperature sensor 19, the occupancy sensor 12, a memory device 20, and a plurality of mechanical switches. 
     Regulator circuit 17 maintains the level of the voltage supply to the micro-controller chip 14 at approximately 3-volts. Regulator circuit 17 is powered by the three 1.5-volt batteries and a standard 60 HZ power supply (not shown). Regulator circuit 17 includes a 60 HZ feed circuit 17a that connects to the 60 Hz supply through system switch 27. System switch 27 and fan switch 26 are both powered by the 60 Hz power supply. By including feed circuit 17a, the micro-controller 14 generally does not draw power from the batteries. As a result, the batteries have a longer life and are only drained when there is a general power failure in the dwelling&#39;s main electrical supply. 
     Temperature sensor 19 provides information about the environment to be controlled and comprises temperature circuit 19a with a thermistor 19b. Thermistors are temperature-sensitive bilateral resistors that exhibit a negative temperature coefficient. In other words, the device exhibits a high resistance at low temperatures and a low resistance at high temperatures. Depending on the temperature of the environment, the thermistor&#39;s resistance values will vary and cause the temperature circuit 19a to generate a high or low input to the micro-controller chip 14. 
     Occupancy sensor unit 12 provides information about the occupancy of the room and includes an infrared sensor 22, a dual operational-amplifier circuit 23, and a dual-comparator circuit 24, all of which are mounted on a circuit board 25. As best shown in FIG. 12, infrared sensor 22 comprises a pyrosensor transistor which sends a triggering signal when heat is detected to the micro-controller chip 14, causing the controller chip 14 to use the occupied reference temperatures. When the infrared sensor 22 does not detect a heat source, the transistor does not send a triggering signal to the micro-controller 14. The micro-controller chip 14 uses the default reference temperatures--the unoccupied reference temperatures set by the owner. 
     Memory device 20 stores information about the desired reference temperatures for an occupied room and unoccupied room and provides the information to the micro-controller chip 14. 
     Generally, there are four reference temperatures: an unoccupied-heating reference temperature, an unoccupied-cooling reference temperature, an occupied-heating reference temperature, and an occupied-cooling reference temperature. Default values are generally provided for all four reference temperatures and stored on the memory device at the manufacturers. As shown in FIG. 13, an EEPROM memory device is used; however, any industry standard memory device can be substituted, as would be understood by a person having ordinary skill in the art. Micro-controller chip 14 operates to select one of the four reference temperatures stored in the memory device 20 by monitoring the occupancy sensor 22, a fan switch 26, and a system switch 27. 
     Fan switch 26 has one of two positions: an ON and an AUTO position. In the ON position the fan (not shown) runs continuously. In the AUTO position, the micro-controller 14 turns on the fan and heating or cooling unit when the environment temperature drops below (in the case of heating) the heating reference temperature setting or above (in the case of cooling) the cooling reference temperature setting. 
     System switch 27 is a three-position switch, with a COOL position, a HEAT position, and an OFF position. If the occupant has selected the COOL switch position, micro-controller 14 will compare the cooling reference temperature to the temperature detected by the thermal sensor 19. If the temperature detected by the thermal sensor 19 is higher than the cooling reference temperature, the micro-controller will actuate the cooling unit by turning on a power switch 28, the position of the system switch directs the current from the power switch to the appropriate heating or cooling unit through lead wire 27a, shown in FIG. 2. Power switch 28 comprises a power switching circuit 28a and a triac 28b which connect to the 60 Hz power supply. Triacs are bidirectional thrysistors that switch from a blocking state to a conducting state for an applied voltage. 
     If the occupant has selected the HEAT switch position, micro-controller 14 will compare the heating reference temperature to the temperature detected by the thermal sensor 19. If the temperature detected by the thermal sensor 19 is lower than the heating reference temperature, the micro-controller 14 will actuate the heating unit by turning on the power switch which in turn sends current through lead wire 27b, as shown in FIG. 2, to the relay switch (not shown) for the heating unit. As described above, the micro-controller chip 14 chooses between the occupied reference temperatures and the unoccupied reference temperatures based on the presence of the triggering signal generated by occupancy sensing unit 12. 
     If the occupant has selected the OFF switch position for system switch 27, the controller 14 will not turn on the heating or cooling unit but will continue to monitor and display the current temperature on the display devices 16a and 16b. The controller 14 will, however, provide power to the fan through the power switch 28 and lead wire 27c, as shown in FIG. 2, which in turn sends power to the fan relay fan relay switch (not shown), if switch 26 is placed in the ON position. 
     A key switch 29 is provided which has two positions: a counter-clockwise position and a clockwise position. In the counter-clockwise position, the occupied reference temperature settings may be adjusted. In the clockwise position, the unoccupied reference temperature settings may be adjusted. However, a key (not shown) is needed to move key switch 29 from the counter-clockwise position, which is the normal operating position for the switch, to the clock-wise position, where the unoccupied reference temperatures and a time delay can be programmed into the memory device 20. The reference temperatures for unoccupied operation can only be programmed when the key switch 29 is in the clockwise position. 
     In order to adjust the occupied reference temperature settings and unoccupied reference temperature settings, a programming switch 30 is provided. Programming switch 30 is a three position switch that is spring-loaded to normally remain in a neutral center position. The other two positions are an INC position and a DEC position. In the INC position, programming switch 30 increments the reference temperature at a rate of one count per second. Similarly, when programming switch 30 is held in the DEC position, the switch decrements the reference temperature at a rate of one count per second. As there are four reference temperatures, the micro-controller monitors the position of key switch 29 and the position of the system switch 27 to determine which of the four reference temperatures is to be adjusted. 
     To set a time delay, key switch 29 is rotated by the key to the clockwise position and system switch 27 is moved to the OFF position. As in the case of the reference temperatures, a default time delay can be pre-programmed into the memory at the manufacturing facilities. To adjust the default time delay value, programming switch 30 is moved to either the INC or DEC position. The left two digits of the display device will display the factory set time delay or the previously programmed time delay for three seconds and then will increase or decrease the time until the programming switch is returned to its center position. Once the desired unoccupied reference temperatures and time delay are programmed into the memory device, the key is then rotated back to the counter-clockwise position and removed. 
     The display devices 16a and 16b are four digit liquid-crystal displays. The left two digits of the display device 16a indicate the reference set point temperature currently referenced by the micro-controller. The right two liquid-crystal display digits 16b indicate the current temperature of the environment area controlled by the dual set-point thermostatic controller assembly. During programming of the unoccupied reference temperatures, the micro-controller chip 14 is programmed to drive (through the segment driver 18) the left two digits of the liquid-crystal display device 16a to display the programmed temperature and the right two digits of liquid-crystal display device 16b to display two dashed (- -). Similarly, during programming of the time delay, the micro-controller chip 14 is programmed drive the left two digits to display the factory set time delay or the previously programmed time delay for three seconds and then to increase or decrease the time until the programming switch is returned to its center position. During this sequence the right two digits will display four vertical lines (||||). 
     When the micro-controller 14 detects that the assembly&#39;s internal battery is low, the micro-controller chip 14 drives the left two digits to indicate a LOW BATTERY signal (Lb). In order to detect the level of the battery, a battery monitor circuit 31 is provided. Referring to FIG. 13, battery monitor circuit 31 is a simple circuit having a pair of MOSFETs which connect to the battery and are driven by the battery when the battery is charged, thus allowing current to pass through the circuit and back to the micro-controller chip 14. When the battery&#39;s voltage drops below a specified level, the MOSFETS do not send a current to the controller chip and in response, the micro-controller chip drives reacts to this by driving the left two digits to indicate a LOW BATTERY signal (Lb). Preferably, this operation occurs approximately 60 days prior to the battery terminal voltage actually falling to a level requiring a system shutdown condition. If the assembly&#39;s battery terminal voltage is allowed to fall to a shutdown level the battery monitor circuit will trigger the system to discontinue operations. 
     In order to protect the micro-controller chip 14 and circuit board 15 from the environment, the circuit board 15 is mounted in a housing 32. As best shown in FIG. 2, housing 32 includes a top cover portion 33 and a base 34. Top cover portion 33 is generally rectangular in shape and sized to fit over base 34. Circuit board 15 is mounted to the underside of top cover portion 33 by fasteners 33a which anchor into downwardly projecting bosses 33b. In order to view display devices 16a and 16b and to access key switch 29, cover portion 33 includes apertures 33d and 33e. Apertures 33d are sized to allow an unobstructed view of all four digits of the liquid-crystal display device 16a and 16b. Key switch 29 is mounted in aperture 33e. 
     In the preferred embodiment, cover portion 33 further includes a downwardly extending lip portion 33c that slides over the base 34 and a set of downwardly extending tabs 33f which extend from the inner wall of lip portion 33c. As best seen in FIGS. 2-5, the base 34 includes a mounting flange 34a for mounting the unit to mounting surface 13 and an upstanding lip portion 34b. Inner wall 34c of upstanding lip portion 34b includes a set of recesses 33d which provide a slot into which downwardly projecting tabs 33f of top cover portion 33 snap, thus releasably securing top cover portion 33 to base 34. Furthermore, base 34 includes a battery housing 35 and battery contacts 35b for supporting and holding three AAA-batteries 35a, which power the control unit 11, and a set of terminal blocks 36 for connecting the control unit 11 to the external inputs and outputs. However, it can be appreciated that the battery housing 35 can be modified to support other standard batteries provided that the total voltage supply is approximately 4.5 volts. 
     Sensing unit 12 similarly includes a generally rectangular shaped housing 40. As best shown in FIG. 6, housing 40 comprises a base 41 and a cover 42. Base 41 generally includes a mounting flange 41a, for mounting sensor unit 12 to mounting surface 13, and an upstanding lip portion 41b, which provides a compartment 41c for storing a battery 46 and battery leads 46a. 
     Cover 42 includes a downwardly depending lip portion 42a, which slides over upwardly extending lip portion 41b of base 41, and a set of downwardly extending bosses 42b. Sensing unit circuit board 25 is mounted to the underside of cover 42 by a set of fasteners 42c which extend into bosses 42b. Cover 42 is removably secured to base 41 by tabs 42 which extend downwardly from the inner wall of lip portion 42a and engage recesses 41d provided on the inner wall of upwardly depending lip portion 41b of base 41, thus forming a snap-fit connection between the cover portion 42 and base 41. However, it should be appreciated that the top cover portion and base of both housing units can be connected using other conventional methods, as understood by a person having ordinary skill in the art 
     In order for the occupancy sensor to receive infrared signals from an occupant, an window opening 43 is provided in the in the top cover. In order to collect signals over a wide peripheral range, a curved fresnel lens 45 is positioned in the window opening and supported by a set of raised rails 43a, which project outwardly from the top surface of the cover 42. 
     Opening 43 is positioned to align fresnel lens 45 directly above the infrared sensor 22, as lens 45 operates like a wide angled lens for the infrared sensor 22 and directs and focuses the infrared waves onto the transistor 19a of the occupancy sensor 22. The lens 45 preferably has a horizontal viewing angle of approximately one hundred degrees. The lens vertical viewing angle, however, is significantly smaller and extends from a horizontal plane defined by a lower edge of the lens 45 to a few degrees above the horizontal plane. The vertical viewing angle is limited so that the sensor 22 will generally not detect pets that are roaming around on the floor. Preferably, the sensor unit 12 detects human body heat within a nominal range of twelve to fifteen feet and is mounted approximately three feet above the floor level so human occupants that are lying down on a bed or sofa will still be detected. 
     Control unit 11 and occupancy sensor unit 12 connect together by conventional telephone lines (not shown) which connect to the circuit boards 15 and 25 by conventional telephone jacks 49. As will herein after be more fully explained, the jacks and telephone line connections permit several sensing units to be connected to the control unit. The separation between the control unit 11 and sensor 12 is, therefore, limited only by the length of telephone line that is on hand. 
     As illustrated in FIG. 11, an remote sensing unit 50 can be added to thermostatic controller assembly 10. Since there are two jacks 49 mounted on the control unit circuit board 15 and two jacks 49 mounted on the adjacent sensor unit 12, the remote sensing unit 50 can either be connected through a telephone line to the adjacent sensor unit 12 and, therefore, connected in series with the adjacent sensor unit 12 or connected directly to the control unit 11 and, therefore, be connected in parallel with the adjacent sensor unit. If more than one remote sensing unit 50 is needed, the second sensing unit can be serially connected to the first remote sensing unit or connected in parallel to the first remote sensing unit by connecting in series to the adjacent mounted sensor unit. As it can be understood by one having ordinary skill in the art, many other combinations are possible. ##SPC1##