Data processing: generic control systems or specific application – Specific application – apparatus or process – Mechanical control system
Utility Patent
1998-04-14
2001-01-02
Lee, Thomas C. (Department: 2787)
Data processing: generic control systems or specific application
Specific application, apparatus or process
Mechanical control system
C361S733000
Utility Patent
active
06169937
ABSTRACT:
BACKGROUND OF THE INVENTION
Control units are frequently designed for controlling any of a variety of different operating systems. One example is certain types of thermostats available now which can be configured to control a variety of different HVAC units. HVAC systems have at least three major variants: those with heating only, those with both heating and air conditioning, and those with air conditioning only. Where heating is required, the heating units have a further set of variants—forced air or hydronic; combustion, resistance heating, or heat pump; one two or three stages. Where heat is provided by a furnace there are the further variants of natural gas, propane, or fuel oil types of fuel. There are variants of air conditioning units as well. Most of these combinations of variants require a different control algorithm in the thermostat. For example, where there is temperature setback in the control algorithm, the slower response of hydronic systems may require a substantially different algorithm than does a forced air system. Or the use of a heat pump for both air conditioning and heating will require an algorithm different from a conventional furnace and air conditioner.
In the past, a number of different approaches have been used to configure the thermostat for a particular system. One approach is to use the keyboard of the thermostat to enter the particular variants manually. Another is to have switches accessible to the installer who then sets the switches to properly configure the thermostat to the heating unit characteristics. These switches may be screws which are turned to make or break contacts or simply DIP switches which are set by shifting the position of small slides or levers.
I have found that either keyboard entry or switch setting tends to result in configuration errors by the installers. Making this observation is not meant to suggest incompetence on the part of installers. Contrariwise, it simply reflects the human tendency of making mistakes when performing any type of programming task, even the most simple. Considering the number of variables present, setting the configuration of a thermostat control algorithm is not a simple task. The problem is complicated by the fact that there is no prompt and unequivocal feedback which confirms that the configuration is correct, or indicates when it's not. That is, the system may seem to operate correctly during a few minutes of observation, but then fail when an anomaly occurs which wasn't present during the observation interval. Further, there is a certain amount of time required to set a number of different switches or firmware flags which adds to overall installation cost.
Accordingly, there is a need for a mechanism different from those available now for configuring control units such as thermostats to match the requirements of the operating (HVAC) systems which they control. Such a mechanism should be easy to implement and should be as cheap or cheaper than those now in use.
I have noted that certain control units, notably thermostats, use a separate base (called a subbase in thermostat nomenclature) to mount the control system. In thermostat systems, the subbase is attached to the wall of the room whose temperature is to be controlled. In most subbase arrangements the wires from the HVAC unit(s) are connected to terminals on the subbase. The subbase has built-in connections between these terminals and contacts or connectors in the subbase designed to mate with cooperating contacts or connectors on the thermostat body itself. These connectors are arranged so that the act of mounting the thermostat body on the subbase automatically connects the thermostat electrically to the HVAC wires through the subbase. Experience shows that attaching the subbase is relatively easy. The thermostat body mounts with a detent or latch mechanism to the subbase which can be overcome when removing the thermostat body. The thermostat body covers the subbase, concealing the mounting screws and providing a finished appearance to the installation. These subbases are relatively cheap to produce, and the convenience in mounting the thermostat body more than compensates for the additional cost of the subbase.
BRIEF DESCRIPTION OF THE INVENTION
Applicant has developed a system by which control units such as thermostats can by using the proper one of a number of different subbases be configured to control any of a number of different operating system configurations without complicated programming. Such a control unit provides a control signal suitable for controlling any one of a plurality of different operating systems after configuration according to my invention. The particular operating system receives a control signal generated by operation of the control unit by processing one of a plurality of data sets comprising at least one of instructions and data parameters recorded within and processed by the control unit and assigned to said system.
Such a control unit comprises a base for supporting a controller such as a thermostat. This base has a preselected mechanical attachment structure, a first connector half having a plurality of first conductor halves, and a first memory unit recording one of a plurality of possible predetermined digital values. Each value has associated with it a predetermined one of the instruction sets. The first memory unit is operatively connected to the first conductor halves in the first connector half so that the digital value is available on the conductor halves.
The controller has a second connector half for mating with the first connector half and has a plurality of second conductor halves forming electrical connection with the first conductor halves when the connector halves are mated. The controller has a housing for mating with the base's mechanical attachment structure and when so mated being held by the base with the second connector half mated with the first connector half. The controller further includes i) a second memory unit in which is recorded each of the instruction sets, ii) a processor having a data port and processing data sets provided in an data signal from the memory unit, and iii) a selector unit connected to the first memory unit through the connected conductor halves in the mated connector halves. The selector unit receives through the connected conductor halves, the digital value recorded in the first memory unit. The selector unit is connected to the second memory unit to receive therefrom a memory signal encoding the instructions and data values encoded in the data sets. The selector unit provides to the processor's instruction port a data signal encoding the instructions and data parameters in the data set associated with the digital value received from the first memory unit. In this way, the control unit supplies control signals to the operating system which are compatible with the configuration of the operating system.
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Honeywell International , Inc.
Lee Thomas C.
Leonard Robert B.
Wang Albert
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