DESC:FIELD OF THE INVENTION

The disclosure relates to load control devices. More particularly, the disclosure relates to a load control device, such as an electromechanical speed regulator having a plurality of capacitors for controlling a speed of a motor to be driven from a supply voltage of a power source.

BACKGROUND

Ceiling fans are one of the most common appliances seen in households across the world in regions having warm, tropical, or dry climates. Typically, ceiling fans are provided with regulators to help a user to control the speed of the ceiling fan motor. Regulators, as the name suggests, regulate, or control the speed of the fan motor using a combination of resistors, capacitors, and the like depending on the type of regulator being used. Conventionally, regulators are broadly classified into resistive regulators, phase angle-controlled regulators, inductive regulators, and electronic fan regulators.

Resistive regulators typically utilize wire wound resistors with different contact points corresponding to the different speeds of the fan motor. This type of regulator works on a full resistor load between the fan motor (load) and a power source to reduce the fan motor speed to the lowest speed. This means the lowest speed of the fan motor is achieved by allowing current flow through the maximum length of resistive wire. Conversely, when setting the fan motor at the highest speed then the regulator knob allows current flow through the portion of the circuit having minimal resistance. This means there is, in effect, no resistance utilized, and the power source directly supplies current to the fan motor thereby ensuring maximum speed of the fan motor. Although, such regulators are relatively inexpensive, they are bulky, large, and have high power losses. This power loss is caused due to heat loss since heat is generated when current flows through the resistive wires. As such, heat dissipating components or sufficient ventilation may be incorporated into the design. Therefore, an alternative solution capable of reducing power losses without increasing the complexity or size of the regulator is desirable.

Phase angle-controlled regulators employ active semiconductor devices and are commonly known as dimmer switches. The voltage across the semiconductor device is varied to alter the voltage across the fan, eventually, speed is continuously varied. Although, the power consumption of phase-controlled regulators is less in comparison to resistive regulators, phase-controlled regulators are expensive. Moreover, phase-controlled regulators have non-linear speed control producing humming noise during operation. Yet another type of regulator is the inductive type of fan regulator having inductive reactance (inductive coil with various contact points) that is varied to achieve speed regulation. As in the case of resistive regulators, the inductive type regulators also suffer from high power losses.

Electronic fan regulators include both capacitive regulators and dimmers (triac based). Capacitive regulators control the voltage across the fan using one or more capacitors. The voltage across the fan determines the fan speed. Generally, Existing step-type fan regulators (capacitor based) available in the market can regulate the speed of a fan by 4 step or 5 step. Due to fewer speed controls, many times user feels discomfort with the speed of fan. As a conventional solution for higher speed regulation of fans, dimmers (triac based) were used instead of step-type fan regulators (capacitor based). As dimmers are intended to control resistive loads, they stop working after some time when used on fans (inductive load). This results in customer dissatisfaction. A capacitive regulator or load control device capable of higher speed control of fans, is therefore desirable.

SUMMARY

This summary is provided to introduce a selection of concepts, in a simplified format, that are further described in the detailed description of the invention. This summary is neither intended to identify key or essential inventive concepts of the invention and nor is it intended for determining the scope of the invention.

In an embodiment of the present disclosure, a load control device is disclosed. The load control device for controlling the speed of a motor to be driven from a supply voltage of a power source includes a first capacitor, a second capacitor, and a third capacitor adapted to be coupled in series electrical connection between the power source and the motor. A rotary switch is selectively couplable to at least one of the first capacitor, the second capacitor, and the third capacitor to provide six discrete speeds of the motor, such that the rotary switch is further selectively couplable to the motor and collectively bypasses the first capacitor, the second capacitor, and the third capacitor to provide a speed greater than the six discrete speeds of the motor. Although the disclosure discusses an implementation of the load control device in controlling the speed of the motor used in a ceiling fan, it must be appreciated the load control device may be implemented in lighting circuits with minor modifications to the components used. For example, the motor may be replaced by a light source. In such implementations, the load control device may be used for selectively increasing or reducing an intensity of the light source.

To further clarify the advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof, which is illustrated in the appended drawings. It is appreciated that these drawings depict only typical embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:

Figure 1a illustrates a front elevation view of a load control device, according to an embodiment of the disclosure;

Figures 1b illustrate a side view of the load control device shown in Figure 1a, according to an embodiment of the disclosure;

Figure 2 illustrates a block diagram of the load control device connected with a fan, according to an embodiment of the disclosure;

Figure 3a illustrates an assembled view of the load control device, according to an embodiment of the disclosure;

Figure 3b illustrates a top perspective view of a rotary switch of the load control device, according to an embodiment of the disclosure;

Figure 3c illustrates a bottom perspective view of the rotary switch of the load control device according to an embodiment of the disclosure;

Figure 3d illustrates a top view of a circuit board of the load control device, according to an embodiment of the disclosure;

Figure 3e illustrates a bottom view of the circuit board of the load control device, according to an embodiment of the disclosure;

Figure 3f illustrates a top view of a capacitor of the load control device, according to an embodiment of the disclosure; and

Figure 4 illustrates a circuit diagram of the load control device, according to an embodiment of the present disclosure.

Further, skilled artisans will appreciate that elements in the drawings are illustrated for simplicity and may not have been necessarily been drawn to scale. For example, the flow charts illustrate the method in terms of the most prominent steps involved to help to improve understanding of aspects of the present invention. Furthermore, in terms of the construction of the device, one or more components of the device may have been represented in the drawings by conventional symbols, and the drawings may show only those specific details that are pertinent to understanding the embodiments of the present invention so as not to obscure the drawings with details that will be readily apparent to those of ordinary skill in the art having benefit of the description herein.

DETAILED DESCRIPTION OF FIGURES

For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiment illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations and further modifications in the illustrated system, and such further applications of the principles of the invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the invention relates. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skilled in the art to which this invention belongs. The system, methods, and examples provided herein are illustrative only and not intended to be limiting.

The term “some” as used herein is defined as “none, or one, or more than one, or all.” Accordingly, the terms “none,” “one,” “more than one,” “more than one, but not all” or “all” would all fall under the definition of “some.” The term “some embodiments” may refer to no embodiments or to one embodiment or to several embodiments or to all embodiments. Accordingly, the term “some embodiments” is defined as meaning “no embodiment, or one embodiment, or more than one embodiment, or all embodiments.”

The terminology and structure employed herein is for describing, teaching and illuminating some embodiments and their specific features and elements and does not limit, restrict or reduce the spirit and scope of the claims or their equivalents.

More specifically, any terms used herein such as but not limited to “includes,” “comprises,” “has,” “consists,” and grammatical variants thereof do NOT specify an exact limitation or restriction and certainly do NOT exclude the possible addition of one or more features or elements, unless otherwise stated, and furthermore must NOT be taken to exclude the possible removal of one or more of the listed features and elements, unless otherwise stated with the limiting language “MUST comprise” or “NEEDS TO include.”

Whether or not a certain feature or element was limited to being used only once, either way, it may still be referred to as “one or more features” or “one or more elements” or “at least one feature” or “at least one element.” Furthermore, the use of the terms “one or more” or “at least one” feature or element do NOT preclude there being none of that feature or element, unless otherwise specified by limiting language such as “there NEEDS to be one or more . . .” or “one or more element is REQUIRED.”

Unless otherwise defined, all terms, and especially any technical and/or scientific terms, used herein may be taken to have the same meaning as commonly understood by one having ordinary skills in the art.

Reference is made herein to some “embodiments.” It should be understood that an embodiment is an example of a possible implementation of any features and/or elements presented in the attached claims. Some embodiments have been described for the purpose of illuminating one or more of the potential ways in which the specific features and/or elements of the attached claims fulfil the requirements of uniqueness, utility and non-obviousness.

Use of the phrases and/or terms such as but not limited to “a first embodiment,” “a further embodiment,” “an alternate embodiment,” “one embodiment,” “an embodiment,” “multiple embodiments,” “some embodiments,” “other embodiments,” “further embodiment”, “furthermore embodiment”, “additional embodiment” or variants thereof do NOT necessarily refer to the same embodiments. Unless otherwise specified, one or more particular features and/or elements described in connection with one or more embodiments may be found in one embodiment, or may be found in more than one embodiment, or may be found in all embodiments, or may be found in no embodiments. Although one or more features and/or elements may be described herein in the context of only a single embodiment, or alternatively in the context of more than one embodiment, or further alternatively in the context of all embodiments, the features and/or elements may instead be provided separately or in any appropriate combination or not at all. Conversely, any features and/or elements described in the context of separate embodiments may alternatively be realized as existing together in the context of a single embodiment.

Any particular and all details set forth herein are used in the context of some embodiments and therefore should NOT be necessarily taken as limiting factors to the attached claims. The attached claims and their legal equivalents can be realized in the context of embodiments other than the ones used as illustrative examples in the description below.

Embodiments of the present invention will be described below in detail with reference to the accompanying drawings.

Figure 1a illustrates a front elevation view of a load control device 100, according to an embodiment of the disclosure. Figure 1b illustrates a side view of the load control device 100 shown in Figure 1a, according to an embodiment of the disclosure. As used herein, “the load control device 100” refers to a regulator adapted to selectively control speed of a load connected to the regulator. The load, referred to herein, is an AC motor 101 shown in Figure 2 of a fan, for example, a ceiling fan, etc. Although the disclosure discusses an implementation of the load control device 100 in controlling the speed of the motor 101 used in a ceiling fan, it must be appreciated the load control device 100 may be implemented in lighting circuits with minor modifications to the components used. For example, the motor 101 used herein may be replaced by a light source. In such implementations, the load control device 100 may be used for selectively increasing or reducing an intensity of the connected light source. The load control device 100 has a square planar base 110 with a housing 108 extending from a rear end of the square planar base 110. In an exemplary embodiment, the square planar base 110 has approximately a length and a width of 46mm. The housing 108 extends from the rear end of the square planar base 110 away from the square planar base 110 such that the distance between a front face of the square planar base 110 and the rear end of the housing 108 is around 46mm. A speed selector 109 is disposed on the front face of the square planar base 110. In an embodiment, the speed selector 109 is adapted to engage with a rotary switch 106 (shown in Figures 2 and 3a) to select a discrete speed from seven discrete speeds of the motor 101. In an embodiment, a cut-out portion may be defined in the square planar base 110 to expose a portion of the rotary switch 106 for engaging with the speed selector 109. The speed selector 109 is adapted to toggle between the OFF position and the seven speed positions of the rotary switch 106 discussed in detail in the detailed description of Figure 4.

Figure 2 illustrates a block diagram of the load control device 100 connected with the motor 101 of the fan, according to an embodiment of the disclosure. The load control device 100 for controlling the speed of the motor 101 is configured to be driven from a supply voltage of a power source 102 when the switch SW1 is closed. The load control device 100 includes a first capacitor 103, a second capacitor 104, and a third capacitor 105 adapted to be coupled in series electrical connection between the power source 102 and the motor 101. The rotary switch 106 is selectively connected to at least one or a combination of the first capacitor 103, the second capacitor 104, and the third capacitor 105 to provide the seven discrete speeds of the motor 101. When the switch SW1 is in the open position, the supply voltage is cut off across the motor 101 thereby switching OFF the motor 101 of the fan.

Figure 3a illustrates an assembled view of the load control device 100, according to an embodiment of the disclosure. Figure 3b illustrates a top perspective view of the rotary switch 106 of the load control device 100, according to an embodiment of the disclosure. Figure 3c illustrates a bottom perspective view of the rotary switch 106 of the load control device 100 according to an embodiment of the disclosure. Figure 3d illustrates a top view of a circuit board 107 of the load control device 100, according to an embodiment of the disclosure. Figure 3e illustrates a bottom view of the circuit board 107 of the load control device 100, according to an embodiment of the disclosure. Figure 3f illustrates a top view of a capacitor of the load control device 100, according to an embodiment of the disclosure. The load control device 100 includes the first capacitor 103, the second capacitor 104, and the third capacitor 105 mounted on a first side of the circuit board 107. The rotary switch 106 is mounted on a second side of the circuit board 107. As exemplarily illustrated in Figures 1a-1b, the housing 108 encloses the entire assembly including the rotary switch 106, the first capacitor 103, the second capacitor 104, the third capacitor 105, and the circuit board 107.

Figure 4 illustrates a circuit diagram of the load control device 100, according to an embodiment of the disclosure. The load control device 100, disclosed herein, for controlling the speed of the motor 101 to be driven from a supply voltage of the power source 102, includes the first capacitor 103, the second capacitor 104, and the third capacitor 105 adapted to be coupled in series electrical connection between the power source 102 and the motor 101 of the fan. In an embodiment, the power source 102 is an AC power supply and the motor 101 is an AC motor. In an embodiment, the first capacitor 103 has a capacitance of 4µF, the second capacitor 104 has a capacitance of 2.2µF, and the third capacitor 105 has a capacitance of 3.3µF. Further discharge resistors R4, R5, and R6 are connected in parallel to the first capacitor 103, the second capacitor 104, and the third capacitor 105, respectively. The rotary switch 106 is selectively connected to a combination of one or more of the first capacitor 103, the second capacitor 104, and the third capacitor 105 to provide six discrete speeds of the motor 101. Furthermore, the rotary switch 106 is selectively couplable to the motor 101 and collectively bypasses the first capacitor 103, the second capacitor 104, and the third capacitor 105 to provide a seventh speed greater than the six discrete speeds of the motor 101. This means using the combination of the first, the second, and the third capacitors 103, 104, 105 the load control device 100 can provide 7 speed control of the motor 101 of the ceiling fan. In an embodiment, the rotary switch 106 is a two-pole seven position switch having nine pins used to provide an OFF position plus seven discrete speeds of the motor 101.

As illustrated in Figure 2, when the ON/OFF switch is in the OFF position, no voltage is supplied across the motor 101 and the motor 101 is switched OFF. When voltage is supplied across the motor 101 of the fan and the second capacitor 104 is connected, which means the speed selector 109 exemplarily illustrated in Figure 1a is rotated to the position marked ‘1’, the load control device 100 provides the first speed of the motor 101. Similarly, when the third capacitor 105 is connected, which means the speed selector 109 is rotated to the position marked ‘2’, the load control device 100 provides the second speed of the motor 101. When the first capacitor 103 is connected, which means the speed selector 109 is rotated to the position marked ‘3’, the load control device 100 provides the third speed of the motor 101. As such, when the rotary switch 106 is coupled to only one of the first capacitor 103, the second capacitor 104, and the third capacitor 105, the load control device 100 provides the first, second, and third speeds of the motor 101.

When the second capacitor 104 and the third capacitor 105 are connected, which means the speed selector 109 is rotated to the position marked ‘4’, the load control device 100 provides the fourth speed of the motor 101. Similarly, when the first capacitor 103 and the second capacitor 104 are connected, which means the speed selector 109 is rotated to the position marked ‘5’, the load control device 100 provides the fifth speed of the motor 101. When the first capacitor 103, the second capacitor 104, and the third capacitor 105 are connected, which means the speed selector 109 is rotated to the position marked ‘6’, the load control device 100 provides the sixth speed of the motor 101.

The load control device 100, disclosed herein, uses the same number of components as regulators having 5-speed capability. For example, the load control device 100 according to the disclosure uses the same number of resistors and capacitors as a conventional regulator having 5-speed capability. In an exemplary embodiment, the load control device 100 is implemented as an electromechanical speed regulator. Existing 5-speed electromechanical speed regulators using capacitors are typically designed as 1M step-type regulators or 2M step-type regulators. In contrast, the load control device 100 according to the disclosure delivers the 7-speed capability while maintaining the dimensions of a conventional 2M electromechanical regulator. This means for the same size and cost increased speed regulation of the motor 101 of the fan is achievable. This improves convenience for the customer without making the load control device 100 prohibitively expensive to use. Further, using capacitors instead of triac-based dimmers ensures humming noise is reduced thereby further enhancing usability of the load control device 100.

While specific language has been used to describe the present subject matter, any limitations arising on account thereto, are not intended. As would be apparent to a person in the art, various working modifications may be made to the method in order to implement the inventive concept as taught herein. The drawings and the foregoing description give examples of embodiments. Those skilled in the art will appreciate that one or more of the described elements may well be combined into a single functional element. Alternatively, certain elements may be split into multiple functional elements. Elements from one embodiment may be added to another embodiment. ,CLAIMS:We claim:

1. A load control device (100) for controlling the speed of a motor (101) to be driven from a supply voltage of a power source (102), the load control device (100) comprising:
a first capacitor (103), a second capacitor (104), and a third capacitor (105) adapted to be coupled in series electrical connection between the power source (102) and the motor (101);
a rotary switch (106) selectively couplable to at least one of the first capacitor (103), the second capacitor (104), and the third capacitor (105) to provide six discrete speeds of the motor (101), wherein the rotary switch (106) is further selectively couplable to the motor (101) and collectively bypasses the first capacitor (103), the second capacitor (104), and the third capacitor (105) to provide a seventh speed greater than the six discrete speeds of the motor (101).

2. The load control device (100) as claimed in claim 1, wherein the load control device (100) is an electromechanical speed regulator.

3. The load control device (100) as claimed in claim 1, wherein the load control device (100) further comprises:
the first capacitor (103), the second capacitor (104), and the third capacitor (105) mounted on a first side of a circuit board (107);
the rotary switch (106) mounted on a second side of the circuit board (107); and
a housing (108) enclosing the rotary switch (106), the first capacitor (103), the second capacitor (104), the third capacitor (105), and the circuit board (107).

4. The load control device (100) as claimed in claim 1, wherein the rotary switch (106) is coupled to only one of the first capacitor (103), the second capacitor (104), and the third capacitor (105) to provide three discrete speeds from the seven discrete speeds of the motor (101).

5. The load control device (100) as claimed in claim 1, wherein the rotary switch (106) is coupled to at least two of the first capacitor (103), the second capacitor (104), and the third capacitor (105) to provide two discrete speeds from the seven discrete speeds of the motor (101).

6. The load control device (100) as claimed in claim 1, wherein the rotary switch (106) is coupled to the first capacitor (103), the second capacitor (104), and the third capacitor (105) to provide one discrete speed from the seven discrete speeds of the motor (101).

7. The load control device (100) as claimed in claim 1, wherein the rotary switch (106) is a two-pole seven position switch having nine pins used to provide OFF plus seven discrete speeds of the motor (101).

8. The load control device (100) as claimed in claim 1, wherein the housing (108) further comprises a speed selector (109), wherein the speed selector (109) is adapted to engage with the rotary switch (106) to select a discrete speed from the seven discrete speeds of the motor (101).