Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The following application is incorporated by reference: U.S. Patent Application Ser. No. 62/018,136, filed Jun. 27, 2014. If there are any contradictions or inconsistencies in language between the present application and the application incorporated by reference that might affect the interpretation of the claims in the present application, the claims herein should be interpreted to be consistent with the language herein. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to motorized systems in general, and, more particularly, to a motorized window-blind system with position calibration, circuit protection, and detection of motor stoppage. 
       BACKGROUND OF THE INVENTION 
       [0003]    Many household devices and appliances enable a user ahead of time to configure them to operate in a customized manner. For example, a smart-switch device can be programmed to control a first light based on one combination of button pushes and a nearby, second light based on another combination. As another example, a coffeemaker appliance can be programmed to make automatically coffee at 7:00 am on some mornings and 9:00 am on others. 
         [0004]    The configuring of some such devices and appliances can be clumsy, however. Some smart switches, for instance, only enable programming by having the user tap in various sequences on the switch itself. Yet, this clumsiness in programming has been addressed somewhat. A software application, or “app”, running on a Bluetooth-enabled or WiFi-enabled smartphone can provide a keyboard on the phone display; the smartphone user configures the device or appliance by using the keyboard, and the app translates these user interactions into commands that are transmitted wirelessly to the device or appliance. 
         [0005]    The aforementioned combination of smartphone, app, and wireless capability has addressed some of the configuring problems and for some types of appliances, but not all. Some appliances require a training procedure such as calibration, including appliances that comprise one or more electromechanical systems such as a motor. In such appliances, the motor might need to be calibrated by operating it across at least one complete cycle of operation. One such application of a motor is in a motorized window blind, which uses a motor to raise and lower the blind, where moving the blind from being fully opened to fully closed to fully opened again constitutes one complete cycle. Calibration on such a device might be necessary in order to determine how to select an intermediate position for the blind, instead of merely allowing the blind to move to its extreme positions—that is, up or down all the way. Another reason for calibration is to support a progress bar when the blind is being moved from one position to another, even from one extreme position to the other. 
         [0006]    In regard to calibrating a motorized blind or similar system, a user is typically prompted to press a button that controls the motor in a first direction, whereupon the blind travels from one extreme to the other extreme. Then, the user releases the button when the blind has stopped travelling, when prompted to do so. The user is then prompted to press a button controlling the motor in the opposite direction and is prompted to release the button when the blind has travelled back to its original position. 
         [0007]    Various difficulties still exist with calibration, however. A first problem with the aforementioned calibration procedure is that it is often perceived as inconvenient to the user. Although the procedure might seem straightforward, it still involves a human user, which inherently makes the calibration process prone to error. 
         [0008]    In addition, the controllers of such motorized systems comprise electronics that can be damaged if the driving motor is not carefully turned on, turned off, or reversed in direction. For example, some motorized window blinds are conventionally driven with a motor that has a double winding and is powered by alternating current (AC) line voltage, or “mains” voltage. The two windings in the motor respectively drive upward motion and downward motion in the window blind. The motor has built-in limit switches that cut off power when the blind reaches the top or bottom position. When the blind is raised and reaches the topmost position, the winding that powers the upward movement is cut off. Similarly, when the blind is lowered and reaches the bottommost position, the winding that powers the downward movement is cut off. Although the limit switches perform these important functions, they can also introduce problems in the controlling circuitry. 
         [0009]    Finally, some of the costs associated the controllers of some prior-art motorized systems are excessive and need to be lowered in order to promote additional acceptance by the consumer of such systems. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention enables a motorized system with improved calibration, circuit protection, and detection of motor stoppage than in some motorized systems in the prior art. The improvements that are disclosed herein can be applied to a motorized window-blind system, which is featured in this specification, as well as to other motorized systems, within households and elsewhere. 
         [0011]    In accordance with the illustrative embodiment of the present invention, a power-switching circuit is disclosed that addresses the problem of certain electronic components being subjected to voltage spikes when the driving motor is turned on, turned off, or reversed in direction. The circuit is disclosed herein that comprises a TRIAC, or “triode for alternating current,” and TVS diodes, or “transient-voltage-suppression diodes,” providing voltage protection to various types of electronic components, including while not being limited to control components of alternating-current (AC) motors. 
         [0012]    In accordance with the illustrative embodiment of the present invention, a controller is disclosed that provides a cost advantage over at least some controllers in the prior art, in particular for those of AC motors. The controller disclosed herein features measurement of voltage that is induced on a secondary winding of a motor, in contrast to or in addition to measuring electrical current that is present at a primary winding of the motor. The controller measures the voltage in order to detect certain events that occur during the operation of the motor, including while not being limited to motor stoppage. 
         [0013]    A calibration method disclosed herein of a motorized system, illustratively a motorized window blind, can account for one or both of the aforementioned protection circuit and event-detecting controller. The disclosed calibration method accounts for human interaction and, in doing so, is intended toward making a calibration process of a motorized household system less prone to human error. 
         [0014]    An illustrative control system comprises: a first terminal of a controller, the first terminal being electrically connectable to a first end of a first winding of a motor having a shaft, wherein voltage being applied via the first terminal to the first end of the first winding in relation to a second end of the first winding results in rotation of the shaft in a first rotation direction; a second terminal of the controller, the second terminal being electrically connectable to a first end of a second winding of the motor, wherein voltage being applied via the second terminal to the first end of the second winding in relation to a second end of the second winding results in rotation of the shaft in a second rotation direction; a third terminal of the controller, the third terminal being electrically connectable to the second end of the first winding and the second end of the second winding; a detector of the controller, the detector being configured to detect a decrease in magnitude of voltage across the second and third terminals when voltage is being applied at the first end of the first winding; and a processor of the controller, the processor being configured to output a first signal based on the detector detecting the decrease across the second and third terminals. 
         [0015]    An illustrative method for controlling a motor by a controller, the motor having i) a shaft, ii) a first winding, and iii) a second winding, the controller having i) a first terminal that is electrically connected to a first end of the first winding, ii) a second terminal that is electrically connected to a first end of the second winding, and iii) a third terminal that is electrically connected to a) a second end of the first winding and b) a second end of the second winding, comprises: applying, by the controller, predetermined voltage via the first terminal to the first end of the first winding in relation to the second end of the first winding such that the motor shaft rotates in a first rotation direction; detecting, by the controller, a decrease in magnitude of voltage across the second and third terminals when voltage is being applied at the first end of the first winding; and generating, by the controller, a first signal based on the decrease detected across the second and third terminals. 
         [0016]    An illustrative method for calibration comprises: receiving, by a controller, a first command to calibrate a motorized device that is mechanically coupled to a shaft of a motor; actuating the motor, by the controller providing voltage at a first winding of the motor, based on receiving the first command, wherein the actuating is such that the shaft rotates in a first direction moving the motorized device from a first position toward a second position; detecting, by the controller, that the motorized device reaches the second position; actuating the motor, by the controller providing voltage at a second winding of the motor, wherein the actuating is such that the shaft rotates in a second direction moving the motorized device from the second position toward the first position; detecting, by the controller, that the motorized device reaches the first position; transmitting a message based on the detecting of the motorized device reaching the first position. 
         [0017]    An illustrative circuit comprises: a first triode for alternating current (TRIAC) having an MT 1  terminal, an MT 2  terminal, and a gate; a first transient-voltage-suppression (TVS) diode having i) a first terminal electrically coupled to the MT 2  terminal of the TRIAC and ii) a second terminal; and a second TVS diode having i) a first terminal electrically coupled to the second terminal of the first TVS diode and ii) a second terminal electrically coupled to the MT 1  terminal of the TRIAC; wherein the first TRIAC conducts electrical current if a predetermined voltage across the second TVS diode is exceeded. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIGS. 1A and 1B  depicts a picture of motorized system  100  in accordance with the illustrative embodiment of the present invention. 
           [0019]      FIG. 2  a schematic diagram of motorized system  200  in accordance with the illustrative embodiment of the present invention. 
           [0020]      FIG. 3  depicts motor  201  of system  200 . 
           [0021]      FIG. 4  depicts controller  204  of system  200 . 
           [0022]      FIG. 5  depicts a block diagram of the salient components of microcontroller unit  401  of controller  204 . 
           [0023]      FIG. 6  depicts some salient operations according to the illustrative embodiment of the present invention, in which a first-position limit and a second-position limit are detected. 
           [0024]      FIG. 7  depicts controller  700 . 
           [0025]      FIGS. 8A and 8B  depict conditions that can occur when powering motor  201  on and off, respectively. 
           [0026]      FIG. 9  depicts a schematic diagram of the salient components of switching unit  403  of controller  204 , in accordance with the illustrative embodiment of the present invention. 
           [0027]      FIGS. 10A and 10B  depict conditions that can occur when a limit switch cuts off a winding. 
           [0028]      FIG. 11  depicts some salient operations of method  1100  according to the illustrative embodiment of the present invention, in which motorized device  203  is calibrated and utilized. 
           [0029]      FIG. 12  depicts the salient sub-operations of task  1101  of method  1100 . 
           [0030]      FIG. 13  depicts the salient sub-operations of task  1103  of method  1100 . 
       
    
    
     DETAILED DESCRIPTION 
       [0031]      FIGS. 1A and 1B  depicts a picture of motorized system  100  in accordance with the illustrative embodiment of the present invention. Motorized household system  100  comprises motor  101 , AC power source  102 , motorized device  103 , and controller  104 , interrelated as shown. As depicted, motorized device  103  comprises a window blind that is driven, operated, and controlled by motor  101  and controller  104 , and has limits of movement in two directions across one dimension—namely, “up” and “down” across a vertical dimension. It will be clear to those skilled in the art, however, after reading this specification, how to make and use embodiments of the present invention in which a type of motorized appliance, device, or object different from a window blind is driven, operated, and controlled, as well as being governed by limits of movement (e.g., rotational, translational, etc.) in one or more directions across one or more dimensions. 
         [0032]    Motor  101  is configured with a double winding and powered by alternating current (AC) line voltage, which is 110 VAC in the United States and 230 VAC in the European Union, for example and without limitation, provided by AC power source  102 . The respective two windings drive upward motion and downward motion in window blind  103 . Motor  101  has built-in limit switches that cut off electrical power when the blind reaches the top or bottom position. When blind  103  connected to motor  101  is raised and reaches the topmost position, as shown in  FIG. 1A , the winding that powers the upward movement is cut off. Similarly, when the blind is lowered and reaches the bottommost position, as shown in  FIG. 1B , the winding that powers the downward movement is cut off. 
         [0033]    The motorized window blind can be controlled remotely via a smartphone or by a smart-home management system. These allow the position of the window blind also to be set at an intermediate position anywhere between being fully opened and fully closed. Accordingly, and as described in detail later, controller  104  is configured to communicate with a controlling application on a smartphone or with a smart-home system that executes the movement of the blinds automatically based on built-in rules, scenes, and presets. Commands are exchanged via a wired or wireless digital connection between the controlling application (in the smartphone or system) and controller  104 . Moving blind  103  to an intermediate position requires controller  104  to track the movement as a proportionate, percentage distance between the topmost and bottommost limit. In doing so, the controller has to know the time it takes for blind  103  to move from the 0% to 100% position and also the time it takes it to move from the 100% to 0% position; this is because the times can differ, in that upward movement usually takes more time than downward movement, owing to gravity. 
         [0034]      FIG. 2  a schematic diagram of motorized system  200  in accordance with the illustrative embodiment of the present invention. System  200  comprises motor  201 , AC power source  202 , motorized device  203 , controller  204 , switch  205 , and mobile station  206 , interrelated as shown. Motor  201 , corresponding to motor  101  in  FIG. 1 , is configured with a double winding and powered by alternating current (AC) line voltage, which is provided by AC power source  202  in well-known fashion, which corresponds to power source  102 . Motor  201  drives (e.g., moves, rotates, etc.) motorized device  203 , which is mechanically coupled to motor  201  in well-known fashion. Device  203 , corresponding to device  103 , is illustratively a window blind. As those who are skilled in the art will appreciate after reading this specification, however, device  203  can be another type of motorized device or appliance—household or otherwise. 
         [0035]    As depicted in  FIG. 3 , a first winding W 1  is energized by voltage that is applied to line  211  relative to neutral line  231 , and a second winding W 2  is energized by voltage that is applied to line  212  relative to neutral line  231 . The two windings drive upward motion and downward motion, respectively, in a motorized device  203 . Motor  201  further comprises limit switches, namely LM 1  and LM 2 , which cut off power when the blind reaches the top or bottom position. When a blind that is mechanically coupled to motor  201  via shaft SH is raised and reaches the topmost position, winding W 1  that powers the upward movement is cut off by limit switch LM 1  when LM 1  senses that rotor RO, which is connected to shaft SH, has stopped rotating in a first rotation direction. Similarly, when the blind is lowered and reaches the bottommost position, winding W 2  that powers the downward movement is cut off by limit switch LM 2  when LM 2  senses that rotor RO has stopped rotating in a second rotation direction. Power should never be applied to both winding W 1  and W 2  at the same time. 
         [0036]    Returning now to  FIG. 2 , controller  204 , corresponding to controller  104 , is a controller module that is configured to perform various functions, including at least some of the tasks described below and in the accompanying figures, including FIGS.  6  and  9 - 11 . Generally speaking, controller  204  communicates with external devices and systems, such as mobile station  206  or a smart home system, for example and without limitation. Additionally, it controls motor  201 , in part as a result of a calibration process and by relying on stored information as described below. Controller  204  also detects the extreme positions in movements of a driven object, such as motorized window blinds, in order to calibrate the motorized device automatically. Controller  204  is described in detail below and in  FIG. 4 . 
         [0037]    As those who are skilled in the art will appreciate after reading this specification, controller  204  can be configured to control movement (e.g., rotational, translational, etc.) in one or more directions across one or more dimensions, and to control a different type and/or a different number of movements of motor  201  and/or device  203  than depicted. 
         [0038]    Switch  205  is an optional “local” wired momentary switch. When pressed “up,” a contact between line  221  and common line  231  is closed as long as the switch is being depressed, and when pressed “down,” a contact between line  222  and common line  231  are closed. The “up” and “down” inputs are considered soft-switch inputs, as they do not switch the current to motor  201 . Instead, they are binary switch inputs provided to a microcontroller that is part of controller  204 , namely microcontroller unit  401  as described below, wherein the microcontroller decides what actions should be executed. Usually, the actions are “up” and “down” but can also be preset selections or scene selections. Also, the microcontroller can discriminate between “short” and “long” presses. For example and without limitation, a relatively long press (e.g., greater than 10 seconds) of both switches could indicate that an auto-calibration sequence is to be initiated, as described elsewhere in this specification. 
         [0039]    Mobile station  206  is a wireless telecommunications terminal that is configured to transmit and/or receive communications wirelessly. It is an apparatus that comprises memory, processing components, telecommunication components, and user interface components (e.g., display, speaker, keyboard, microphone, etc.). Mobile station  206  comprises the hardware and software necessary to be compliant with the protocol standards used in the wireless network or networks in which it operates and to perform or support execution of the processes described below and in the accompanying figures. For example and without limitation, mobile station  206  is capable of:
       i. receiving an incoming (i.e., “mobile-terminated”) telephone call or other communication (e.g., application-specific data, SMS text, email, media stream, etc.),   ii. transmitting an outgoing (i.e., “mobile-originated”) telephone call or other communication (e.g., application-specific data, SMS text, email, media stream, etc.),   iii. controlling and monitoring controller  204 , and/or   iv. receiving, transmitting, or otherwise processing one or more signals in support of one or more of capabilities i through iii.       
 
         [0044]    Furthermore, mobile station  206  is illustratively a smartphone with at least packet data capability provided and supported by the network in which it operates and that is configured to execute a software application (e.g., an “app”) for controlling one or more controllers  204 . In some alternative embodiments of the present invention, mobile station  206  can be referred to by a variety of alternative names such as, while not being limited to, a wireless transmit/receive unit (WTRU), a user equipment (UE), a wireless terminal, a cell phone, or a fixed or mobile subscriber unit. In some alternative embodiments of the present invention, mobile station  206  communicates directly with an intermediate controller (not depicted), which in turn is capable of controlling and monitoring controller  204 . 
         [0045]    Communication between mobile station  206  and controller  204  is enabled by a wireless network that comprises Bluetooth Low Energy (BLE) network. However, as those who are skilled in the art will appreciate after reading this specification, the wireless network can be based on one or more different types of wireless network technology standards, in addition to or instead of BLE, such as Z-Wave, ZigBee, Wi-Fi, Bluetooth Classic, or Thread, for example and without limitation, in order to enable communication between the mobile station and controller. Furthermore, as those who are skilled in the art will appreciate after reading this specification, mobile station  206  and controller  204  in some embodiments can be connected directly and non-wirelessly to each other, at least for some purposes and/or for some portion of time, such as through Universal Serial Bus (USB), FireWire™, or Thunderbolt™, for example and without limitation. 
         [0046]      FIG. 4  depicts a schematic diagram of controller  204  in accordance with the illustrative embodiment of the present invention. Controller  204  comprises microcontroller unit  401 , power supply  204 , and switching unit  403 , as well as voltage measurement detectors VM 1  and VM 2 , driver  415 , direction relay  416 , all of each are interconnected as shown. 
         [0047]    Microcontroller unit  401  comprises a programmable microprocessor with program (non-volatile) memory, persistent data (non-volatile) memory, and random access (volatile) memory, along with a communications module. Microcontroller unit (MCU)  401  executes the logic that performs the various procedures as described below and in the accompanying figures. Based on the logic executed, MCU  401  interprets input signals on lines  221  and  222  from respective switch terminals SW 1  and SW 2  within switch  205 , which provides inputs to MCU  401 . In one mode, MCU  401  emulates the switching behavior of SW 1  and SW 2  as if lines  221  and  222  were directly connected to windings W 1  and W 2 , respectively (i.e., driving the windings directly). The SW 1  and SW 2  terminals enable connecting existing motor controller switches, effectively converting an existing “dumb” motor switch into a “smart/connected” motor controller by introducing controller  204 . MCU  401  can sense and execute different set of actions based on how the switches are operated; for example and without limitation, i) a short, single press of a switch can start/stop the motor, and ii) a long (e.g., greater than 5 seconds, etc.) press of a switch or of both switches can initiate the calibration process. The SW 1  and SW 2  terminals are galvanically isolated via optocouplers (omitted for clarity purposes). 
         [0048]    Also, based on the logic executed MCU  401  interprets input signals on voltage detector lines  411  and  412  accordingly. As described below, a signal on line  411  can be used to determine movement or stoppage of motor  201  in one direction by the voltage, or change in voltage, induced on winding W 1  and correspondingly reflected on line  411 ; similarly, a signal on line  412  can be used to determine movement or stoppage of the motor in the opposite direction by the voltage, or change in voltage, induced on winding W 2  and correspondingly reflected on line  412 . 
         [0049]    Further based on the logic executed, MCU  401  provides output signals on lines  413  and  414  accordingly. MCU  401  provides for communication with mobile station  206  via antenna path  419 . Power to MCU  401  is provided via line  418 . 
         [0050]    Power supply  402  converts AC line voltage (or “mains” power) that is provided at line  241 , to a direct-current (DC) voltage suitable for microcontroller unit  401 . Supply  402  provides the DC power to MCU  401  via line  418 . The neutral line in the AC supply corresponds to line  231 . It will be clear to those skilled in the art how to make and use power supply  402 . 
         [0051]    Switching unit  403  is part of a driver circuit that is configured to drive motor  201 , controlling motor  201  in a first direction via line  211  and in a second direction via line  212 . Unit  403  is driven by MCU  401  using signals provided via line  414 . Furthermore, unit is configured to switch AC power on line  241  on or off, to relay  416  via line  417 . Related to this, unit  403  features protection against induced voltage, as described below. Switching unit  403  is described below and in  FIG. 9 . 
         [0052]    Relay  416  is an electromechanical relay that is configured to switch the power signal present on line  417 , to either line  211  or  212 , based on the direction-switching signal present on line  413  and conditioned, if necessary, by driver  415 . In some alternative embodiments of the present invention, relay  416  is a different type of relay than electromechanical. 
         [0053]    Voltage measurement detectors VM 1  and VM 2  detect the voltage level present on lines  211  and lines  212 , respectively, in well-known fashion. In particular, when a voltage is induced on winding W 1 , detector VM 1  detects, relative to ground, the voltage induced at winding W 1  and provides an indicium of the value to MCU  401  via line  411 . Similarly, when a voltage is induced on winding W 2 , detector VM 2  detects, relative to ground, the voltage induced at W 2  and provides an indicium of the value to MCU  401  via line  412 . For example and without limitation, the detector circuit comprising detectors VM 1  and VM 2  can be used to detect the upper and lower limits of a motorized window blind, or the extreme positions of a different type of device  203 , and can enable the calibration process described below. 
         [0054]      FIG. 5  depicts a block diagram of the salient components of microcontroller unit  401  in accordance with the illustrative embodiment of the present invention. In particular, microcontroller unit (MCU)  401  comprises: processor  501 , memory  502 , network interface module  503 , input/output interfaces  504  and  505 , power distribution bus  506 , and electrical ground  507 , which are interconnected as shown. 
         [0055]    Processor  501  is a general-purpose microprocessor that is configured to execute operating system  521  and application software  522 , and to populate, amend, use, and manage database  523 , as described in detail below and in the accompanying figures, including FIGS.  6  and  9 - 11 . In any event, it will be clear to those skilled in the art how to make and use processor  201 . 
         [0056]    Memory  502  is non-transitory and non-volatile computer storage memory technology that is well known in the art (e.g., flash memory, etc.). Memory  502  is configured to store operating system  521 , application software  522 , and database  523 . The operating system is a collection of software that manages, in well-known fashion, MCU  401 &#39;s hardware resources and provides common services for computer programs, such as those that constitute the application software. The application software that is executed by processor  501  enables MCU  401  to perform the functions disclosed herein. Database  523  comprises information relating to current position of motorized device  203 , and also the calibrated time intervals of motorized device  203 &#39;s movements in various directions (e.g., up, down, etc.). 
         [0057]    It will be clear to those having ordinary skill in the art how to make and use alternative embodiments that comprise more than one memory  502 ; or comprise subdivided segments of memory  502 ; or comprise a plurality of memory technologies that collectively store the operating system, application software, and database. 
         [0058]    Network interface module  503  comprises a network adapter configured to enable MCU  401  to transmit information to and receive information from a smart home system or a user device, such as mobile station  206 , for example and without limitation. Module  503  communicates wirelessly via Bluetooth Low Energy (BLE) in accordance with the illustrative embodiment of a present invention. In some other embodiments of the present invention, network interface module  503  can communicate via one or more different types of wireless network technology standards, in addition to or instead of BLE, such as Z-Wave, ZigBee, Wi-Fi, Bluetooth Classic, or Thread, for example and without limitation. In a multiple-protocol configuration, a first network adapter can support a first standard (e.g., BLE, etc.), a second network adapter can support a second standard (e.g., WiFi, etc.), and so on, for example and without limitation. 
         [0059]    As those who are skilled in the art will appreciate after reading this specification, module  503  can comprise one or more of the elements that are depicted in  FIG. 5  as being separate from module  503 , such as processor  501  and/or memory  502 . 
         [0060]    In accordance with the illustrative embodiment, MCU  401  uses network interface module  503  in order to telecommunicate wirelessly with external devices. It will be clear to those skilled in the art, however, after reading the present disclosure, how to make use and use various embodiments of the present invention in which MCU  401  communicates via a different type of wireless network (e.g., personal area network, local area network, etc.), or via a wired protocol (e.g., X10, KNX, etc.) over physical media (e.g., cable, wire, etc.) with one or more external devices, either in addition to or instead of the wireless capability provided by module  503 . In any event, it will be clear to those skilled in the art, after reading this specification, how to make and use network interface module  503 . 
         [0061]    Input/output (I/O) interfaces  504  and  505  are I/O devices that provide, in well-known fashion, the various characteristics needed in order to receive signals from and to transmit signals to the various devices with which MCU  401  interacts. 
         [0062]    Power distribution system  506  provides power from power supply  402  to the various devices that constitute MCU  401 , in well-known fashion. For purposes of clarity, the individual signal lines between bus  506  and their respective devices are not depicted. 
         [0063]    Electrical ground system  507  provides an electrical ground for the devices within MCU  401 , as needed, in well-known fashion. 
         [0064]    Detection of Limits of Motion 
         [0065]    As explained earlier, a motor of a window blind typically comprises two windings, in which one of the windings, when energized, drives the motor in a first direction of rotation and the other winding drives the motor in a second direction. The motor typically has limit switches that cut off power to the motor when the blind reaches its top or bottom position. Most such motors do not have output terminals to expose signals from the internal limit switches; therefore, motorized systems must rely on something else to determine that a motorized device has reached a limit of movement, such as the blind reaching its topmost or bottommost position. In some techniques in the prior art, a controller connected to the motor measures the current being drawn by the rotating motor and determines the moment when the limit switch opens by detecting when the current flow stops. This measurement of current flow requires a relatively expensive sensing circuit. 
         [0066]      FIG. 6  depicts some salient operations of method  600  according to the illustrative embodiment of the present invention, in which a first-position limit (e.g., up-position limit) and a second-position limit (e.g., down-position limit) are detected, not as in the prior art by measuring the change in current flow through a primary winding, defined as the winding that is driving motor  201 , but by measuring the change in voltage in the corresponding secondary winding of the motor. This is based on the observation that applying power to the primary winding of motor  201  results in movement of the motor, which in turn results in an induction of voltage in the secondary winding. As already discussed, a circuit providing the measurement of voltage is described in the previous figures; in particular, voltage measurement detectors VM 1  and VM 2  and MCU  401  in  FIG. 4  make up the voltage measurement and control circuitry. 
         [0067]    In accordance with the illustrative embodiment of the present invention, the actions depicted in  FIG. 6  and the accompanying voltage measurement circuitry in some of the other figures are directed at enabling calibration of a motorized device such as window blinds. However, it will be clear to those skilled in the art after, after reading this specification, how to make and use embodiments of the present invention in which the aforementioned actions and circuitry are applied to other types of systems and/or for other purposes than calibration. 
         [0068]    In regard to method  600 , as well as to the methods depicted in the other flowcharts contained herein, it will be clear to those having ordinary skill in the art, after reading the present disclosure, how to make and use alternative embodiments of the disclosed methods wherein the recited operations, sub-operations, and messages are differently sequenced, grouped, or sub-divided—all within the scope of the present invention. Also, it will be further clear to those skilled in the art, after reading the present disclosure, how to make and use alternative embodiments of the disclosed methods wherein at least some of the described operations, sub-operations, and messages are optional, are omitted, or are performed by other elements and/or systems. 
         [0069]    At task  601 , motorized system  200  comprising motor  201 , motorized device  203 , and controller  204  is provided and powered on. In accordance with the illustrative embodiment, motorized device  203  comprises a window blind capable of being moved up and down; however, it will be clear to those skilled in the art, after reading this specification, how to use embodiments of the present invention in which motorized device  203  is something other than a window blind. 
         [0070]    At task  603 , controller  204  applies a predetermined voltage at the first end of winding W 1  of motor  201  beginning at time t 1 ; that is, voltage is provided via terminal  251  connected to line  211 , wherein the voltage is relative to terminal  253  connected to neutral line  231 . Applying power to winding W 1  results in movement of motor  201  in a first direction (e.g., “up”), which in turn results in the induction of voltage in the opposite winding W 2 . Detector VM 2  is capable of detecting the induced voltage in winding W 2 . 
         [0071]    When motor  201  stops rotating in the first direction (i.e., when limit switch LM 1  is opened), the secondary induced voltage drops to zero in winding W 2 . By measuring the secondary voltage drop, controller  204  indirectly senses that the limit switch has been activated. Corresponding to this effect, at task  605 , detector VM 2  of controller  204  detects at time t 2  a decrease in the magnitude of voltage across winding W 2  (i.e., across terminals  252  and  253  connected to lines  212  and  231 , respectively). Controller  204  can detect this decrease even as it is still applying voltage across winding W 1 . 
         [0072]    At task  607 , MCU  401  of controller  204  generates and outputs a first signal (e.g., a message, etc.) based on the decrease detected at task  605 . MCU  401  provides a time indication in the first signal based on the elapsed time between t 1  and t 2 . In some embodiments, MCU  401  generates the signal based on the magnitude falling substantially to zero. 
         [0073]    In some embodiments, the generating of the first signal is further based on detecting a decrease in magnitude of current across terminals  251  and  253 , which is caused by limit switch LM 1  shutting off power to winding W 1 . 
         [0074]    At task  609 , controller  204  stops the application of the voltage at the first end of winding W 1  beginning at time t 3  based on the detecting of the decrease in magnitude of voltage across terminals  252  and  253 . In some embodiments, t 3  is based on the first signal. 
         [0075]    At task  611 , controller  204  applies a predetermined voltage at the first end of winding W 2  of motor  201  beginning at time t 4 ; that is, voltage is provided via terminal  252  connected to line  212 , wherein the voltage is relative to terminal  253  connected to neutral line  231 . Applying power to winding W 2  results in movement of motor  201  in a second direction (e.g., “down”, opposite to the first direction, etc.), which in turn results in the induction of voltage in the opposite winding W 1 . Detector VM 1  is capable of detecting the induced voltage in winding W 1 . 
         [0076]    When motor  201  stops rotating in the second direction (i.e., when limit switch LM 2  is opened), the secondary induced voltage drops to zero in winding W 1 . By measuring the secondary voltage drop, controller  204  can indirectly sense that the limit switch has been activated. Corresponding to this effect, at task  613 , detector VM 1  of controller  204  detects at time t 5  a decrease in the magnitude of voltage across winding W 1  (i.e., across terminals  251  and  253  connected to lines  211  and  231 , respectively). Controller  204  can detect this decrease even as it is still applying voltage across winding W 2 . 
         [0077]    At task  615 , MCU  401  of controller  204  generates and outputs a second signal (e.g., a message, etc.) based on the decrease detected at task  613 . MCU  401  provides a time indication in the second signal based on the elapsed time between t 4  and t 5 . In some embodiments, MCU  401  generates the signal based on the magnitude falling substantially to zero. 
         [0078]    In some embodiments, the generating of the second signal is further based on detecting a decrease in magnitude of current across terminals  252  and  253 , which is caused by limit switch LM 2  shutting off power to winding W 2 . 
         [0079]    Generally speaking, by measuring the drop in the induced voltage of the secondary winding, controller  204  is able to sense that motor  201  has stopped, which is caused by a limit switch having been activated. Measuring voltage is easier and requires simpler and less expensive circuitry compared to measuring the current flow through the primary winding in order to determine the power draw on that primary winding driving the motor. 
         [0080]    In some embodiments of the present invention, controller  201  measures the induced voltage of the secondary winding and measures the applied voltage in the primary winding, and correlates the two measurements with each other. In doing so, controller  204  is able to sense whether motor  201  has stopped by itself, which can be caused by a limit switch having been activated, or has stopped as a result of an intentional action, such as by a user pressing a switch to stop the motor. If the applied voltage is still present, for example, then the motor might have stopped by itself, but if the applied voltage is no longer present, then the motor might have been stopped intentionally. 
         [0081]    Protection of the Driver Circuit 
         [0082]      FIG. 7  depicts certain features of an alternative configuration of controller  204 , which alternative configuration is labeled as controller  700 . As with controller  204 , controller  700  is configured to control motor  201  via lines  211  and  212  and is configured to provide AC power provided via line  241  to a particular motor winding via a direction relay, in this configuration labeled as relay  701 . In controller  700 , relay  701  is provided with power via line  702  connected to power relay  703 . Relay  703  is configured to switch the AC power that is provided to the selected winding either on or off. 
         [0083]    As discussed earlier, motor  201  comprises built-in limit switches LM 1  and LM 2 . They open the circuit, effectively cutting off power to their respective winding, whenever the limit positions are reached (e.g., up/down, left/right, etc.), depending on the setup of the device driven by the motor. 
         [0084]    Powering on the motor is associated with two effects: i) the inertia of rotor RO, and ii) the induction of the winding. When powering on motor  201 , the inertia of rotor RO results in a current peak that exceeds the nominal current by a factor of four to ten times. The current oscillates rapidly because of the induction of the winding, as depicted in  FIG. 8A , which is based on a screenshot from an oscilloscope. The figure shows current in the first winding and induced voltage in the second winding. 
         [0085]    When motor  201  reaches the upper or lower limit position, the limit switch cuts off the power to the active circuit. At that moment there is an accumulated energy in the motor and winding. This energy generates (induces) an overvoltage condition in both windings W 1  and W 2 . Overvoltage generated in the second winding makes it especially difficult to use two TRIACs (i.e., one on, the other off) in place of direction switching relay  701 . The phenomenon is depicted in  FIG. 8B , which is based on a screenshot from an oscilloscope. On a 230 VAC motor, induced voltage has been observed as reaching 1500V. As shown in the figure, cutting off power to the first winding results in a high voltage spike in the second winding. Notably, the “hairy” part of waveform is caused by the vibrating switch contacts that are opening. 
         [0086]      FIG. 9  depicts a schematic diagram of the salient components of switching unit  403 , which is intended to address the aforementioned problems, in accordance with the illustrative embodiment of the present invention. Switching unit  403  of controller  204  supports a cascaded relay-TRIAC configuration, wherein TRIAC stands for “triode for alternating current,” in which relay  416  is used to select the direction of motor  201 , as described above, and TRIAC TR 1  is used to switch on or off the AC power provided to relay  416 . 
         [0087]    TRIAC TR 1  as depicted comprises an MT 1  terminal (also referred to as a “T1” terminal or an “A1” terminal), an MT 2  terminal (also referred to as a “T2” terminal or an “A2” terminal), and a gate, as are known in the art. In some alternative embodiments, TR 1  is a different type of thyristor or electronic switching device than a TRIAC, which can conduct current in either direction when it is triggered (i.e., turned on). In regard to configuration, TR 1  in some alternative embodiments is flipped in relation to what is depicted in  FIG. 9 , such that MT 2  is where MT 1  is depicted, and vice-versa. 
         [0088]    Transient-voltage-suppression, or “TVS”, diode D 1 , as is known in the art, has i) a first terminal electrically coupled to the MT 2  terminal of TR 1  and ii) a second terminal. In some embodiments of the present invention, components that are “electrically coupled” are specifically directly and electrically connected. An example of a TVS diode is a Transil™ diode. 
         [0089]    TVS diode D 2  has i) a first terminal electrically coupled to the second terminal of diode D 1  and ii) a second terminal electrically coupled to the MT 1  terminal of TR 1 . In some alternative embodiments, a different type of diode or electronic component used to protect electronics from voltage spikes on connected wires can be used in place of TVS diode D 1  and/or D 2 . 
         [0090]    Resistor R 1  has i) a first terminal electrically coupled to the second terminal of diode D 1  and the first terminal of the diode D 2  and ii) a second terminal electrically coupled to the gate of TR 1 . The ohmic resistance of resistor R 1  is selected such that TR 1  conducts electrical current between the MT 1  and MT 2  terminals if the predetermined voltage across the diode D 2  is exceeded. In some embodiments of the present invention, resistor R 1  has a value of 1000 ohms. 
         [0091]    Opto-triac OPT 1  has i) a light-emitting diode (LED) and ii) a TRIAC that has a) a first terminal electrically coupled to the first terminal of the diode D 1 , b) a second terminal electrically coupled to the second terminal of diode D 1  and the first terminal of the diode D 2 , and c) a gate configured to cause electrical current to be conducted between the first and second terminals of the TRIAC based on light emitted by the LED. Microcontroller unit  401  is electrically coupled to the LED, in this case through resistor R 2 , wherein the microcontroller is configured to switch the OPT 1  TRIAC via the LED. 
         [0092]    AC voltage source  202  is electrically coupled to the MT 1  terminal of TR 1 , and relay  416  is electrically coupled to the MT 2  terminal of TR 1 . 
         [0093]    A theoretical alternative to the cascaded relay-TRIAC configuration of switching unit  403  would be to use two TRIACs, one on each winding. This two-TRIAC approach, however, is problematic because of the induced voltage on the passive winding that occurs when motor  201  stops, such as when a limit switch opens the active winding (i.e., the winding powering the motor). The induced voltage can pierce the TRIAC connected to the passive winding. This TRIAC cannot be protected with TVS diodes D 1  and D 2 , as this will lead to a closing of the seconding winding circuit, causing motor  201  to immediately start to rotate in the opposite direction because the secondary winding will be powered. 
         [0094]    In regard to operation, motor  201  is started by MCU  401  selecting a position of relay  416  according to the intended rotation direction via the appropriate signal being provided on line  413 . After the relay contacts are stable (typically after about 20 milliseconds), voltage for driving opto-triac OPT 1  is applied at line  414 . Opto-triac OPT 1  starts conducting current after the AC voltage crosses zero and causes TRIAC TR 1  to start conducting current. As a result, the power is applied to the motor winding without generating any sparks on relay contacts. In some embodiments of the present invention, the inrush current that TRIAC TR 1  can sustain must be enough to accommodate the inrush current of the stationary motor winding. 
         [0095]    Motor  201  is now rotating at this point, and there are two ways to stop it:
       i. turning off the voltage driving opto-triac OPT 1  that is being applied at line  414 , and   ii. activating a limit switch by the motor reaching the corresponding upper or lower limit position.       
 
         [0098]    In the first case, TRIAC TR 1  stops conducting current when the line AC voltage (i.e., between MT 1  and MT 2 ) reaches zero. No overvoltage condition occurs in this case. 
         [0099]    In the second case, the limit switch cuts off the circuit asynchronously to the line AC. When the contacts of the limit switch are opening, there are many high frequency, high voltage oscillations in both windings when no suppression circuit is present, as depicted in  FIG. 10A . In this case, the voltage can reach upwards of 1500V. The oscillating high voltage forms an electric arc between the opening contacts of the limit switch and hits TRIAC TR 1 . The TRIAC is too slow to suppress the high voltage. The current conducted by the TRIAC can rise at a rate of several amps per microsecond (uS). If the high voltage oscillations rise at a higher rate than about 100V/uS, which they can do, the TRIAC will not conduct the resulting current fast enough. This would lead to piercing the TRIAC. 
         [0100]    To prevent the TRIAC from being pierced, the two TVS diodes, which conduct current much faster than a TRIAC can, serve to suppress the fast-rising, high voltage. In the illustrative embodiment, when the voltage across MT 1  and MT 2  terminals exceeds 420V, TVS diodes D 1  and D 2  start conducting the current, thereby preventing any further rise of the voltage. The diodes, however, cannot suppress the entire energy accumulated in the motor—their junctions would evaporate if called upon to do so. To prevent this, a second-stage circuit (sometimes referred to as a “crowbar”) is implemented in switching unit  403 , in which resistor R 1  powers TRIAC TR 1 &#39;s gate, the TRIAC starts conducting the current and takes over the load from diodes D 1  and D 2 , protecting the diodes from overheating.  FIG. 10B  reflects the behavior of switching unit  403  in providing the protection described above. In this case, the voltage does not exceed 10V. 
         [0101]    Consistent with its configuration and operation as described above, controller  204 , comprising direction-switching relay  416  and switching unit  403 , is intended to provide at least one or more of the following features:
       i. full control of bi-directional motors up to at least 500 W/230 VAC.   ii. protection against powering both windings W 1  and W 2  simultaneously.   iii. electronic, spark-free powering on and off of motor  201 .   iv. dual-phase suppression of overvoltage when motor  201  is stopped by a limit switch.   v. reduced size of the circuit, in that there is only a single mechanical relay  416  rather than two mechanical relays.   vi. enhanced durability.   vii. no need for a traditional RC overvoltage suppressor.       
 
         [0109]    Automatic Calibration 
         [0110]      FIG. 11  depicts some salient operations of method  1100  according to the illustrative embodiment of the present invention, in which motorized device  203  is calibrated and utilized. A smartphone application executed by mobile station  206  is configured to communicate with the controller  204 , either directly with the controller or indirectly through an intermediary smart-home-control system. Having such an application interacting with controller  204  enables a guided, automatic calibration process. 
         [0111]    At task  1101 , controller  204  calibrates device  203  in accordance with the method described below and in  FIG. 12 . Calibration refers to ensuring that the motorized device is at the position where the user believes it to be. 
         [0112]    At task  1103 , controller  204  utilizes device  203  in accordance with the method described below and in  FIG. 13 . Utilization refers to routine usage of the motorized device by the user. 
         [0113]    As those who are skilled in the art will appreciate after reading this specification, either or both of tasks  1101  and  1103  can be repeated in any combination of repetitions. 
         [0114]      FIG. 12  depicts the salient sub-operations of task  1101 . At task  1201 , controller  204  receives a command from mobile station  206  to calibrate motorized device  203 , which is mechanically coupled to shaft SH of motor  201 . 
         [0115]    Based on receiving the command, at task  1203  controller  204  actuates motor  201  in order to move motorized device  203  to a first position (e.g., window blinds in the full down position, etc.). 
         [0116]    Based on receiving the command, at task  1205  controller  204  actuates motor  201  by providing voltage at a first winding of the motor. The actuating is such that the shaft rotates in a first direction moving motorized device  203  from the first position toward a second position (e.g., window blinds in the full up position, etc.). 
         [0117]    At task  1207 , controller  204  detects whether device  203  has reached the second position. Only if it has does controller  204  proceed to task  1209 . In some embodiments of the present invention, controller  204  detects that the device  203  has reached the second position by measuring voltage on the second winding, as described above and in  FIG. 6 . 
         [0118]    At task  1209 , controller  204  determines and stores the elapsed time in moving from the first position to the second position. In addition, controller  204  stores the second position as the current position of device  203 . 
         [0119]    At task  1211 , controller  204  actuates motor  201  by providing voltage at a second winding of the motor. The actuating is such that the shaft rotates in a second direction moving motorized device  203  from the second position (e.g., up position, etc.) toward the first position (e.g., down position, etc.). 
         [0120]    At task  1213 , controller  204  detects whether device  203  has reached the first position. Only if it has does controller  204  proceed to task  1215 . In some embodiments of the present invention, controller  204  detects that the device  203  has reached the first position by measuring voltage on the first winding, as described above and in  FIG. 6 . 
         [0121]    At task  1215 , controller  204  determines and stores the elapsed time in moving from the second position to the first position. In addition, controller  204  stores the first position as the current position of device  203 . 
         [0122]    At task  1217 , controller  204  transmits a message based on device  203  having reached the first position as detected at task  1213 . In some embodiments of the present invention, controller  204  transmits one or more additional status messages (e.g., when device  203  was brought to the first position initially at task  1203 , when device  203  reached the second position as detected at task  1207 , etc.). 
         [0123]    Control of execution then proceeds to task  1103 . 
         [0124]      FIG. 13  depicts the salient sub-operations of task  1103 . At task  1301 , controller  204  receives a command to move device  203  to a target position (e.g., down from the top by 60%, etc.). 
         [0125]    Based on receiving the command at task  1301 , at task  1303  controller  204  determines whether device  203  is to move toward the first position or the second position, based on comparing the stored current position with the target position that is either received or derived from the received command. 
         [0126]    At task  1305 , controller  204  calculates the amount of time needed for device  203  to move to the target position, based on a selection of i) the stored elapsed-time-toward-first-position of ii) the stored elapsed-time-toward-second-position, wherein the selection is based on the required direction of movement that was determined at task  1303 . The amount of time is also based on the current position. 
         [0127]    At task  1307 , controller  204  actuates motor  201  by providing voltage at a particular winding of the motor. The winding is selected based on the required direction of movement and is energized based on the amount of time calculated at task  1305  to get to the target position. 
         [0128]    At task  1309 , controller  204  transmits a message based on device  203  having reached the target position. In some embodiments of the present invention, controller  204  transmits one or more additional status messages (e.g., a progress indication, etc.). 
         [0129]    It is to be understood that the disclosure teaches just one example of the illustrative embodiment and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the following claims.

Technology Category: h