HK1142394B - Adjustable sensor - Google Patents

Description

Adjustable sensor

Cross reference to related applications

This application is a continuation-in-part application of U.S. application No.11/207,729 filed on 27.8.2005 and hereby claiming priority. This application claims the filing date of provisional application No.60/604,543 filed on 26.8.2004, the disclosures of both of which are incorporated herein by reference in their entirety.

Technical Field

The invention relates to an occupancy wall sensor.

Background

Typically, when first installed, newly installed occupancy wall sensors, such as Passive Infrared (PIR) and/or ultrasonic occupancy wall sensors, need to be positioned on a wall or ceiling and then oriented to scan an area of interest to provide a level of protection desired by a user. Often, after being mounted to a wall or ceiling, the sensors must then typically be reoriented several times until they actually scan the desired area. Moreover, when a user needs to change, existing wall sensors may need to be repositioned and reoriented to scan different areas at potentially different viewing angles.

Some sensors today may require special tools to be provided by the manufacturer for use when installing and/or orienting the sensor for the required adjustment. Sometimes tools may not be readily available, particularly when repositioning or reorienting the sensor after a period of time after first being mounted on the wall. Such adjustments are not only difficult to perform, but sometimes result in damage to the sensor when it is mounted to a wall or disassembled and then reassembled.

The key component of the sensor is the PIR lens. It is usually made of a thin, soft plastic material, the surface of which is easily scratched. The lens is typically relatively large to allow the sensor to cover a scanning area or scan a large field of view, and is prone to damage when the lens is mounted on the front surface of the sensor. For example, lenses that are delicate and critical components of the sensor can be easily scratched or damaged during manufacturing, shipping, handling, and installation of the sensor. A scratched or damaged lens may prevent the sensor from operating properly. The lens on the sensor is typically not replaceable.

Another problem with current wall mounted sensors is the lack of a simple way to mount the sensor to a wall or ceiling. Often, and particularly in industrial applications, the sensors will be located 30 feet or more above the ground. Thus, while on a ladder, the installer may have to hold the sensor on his/her head with one hand while trying to mount the sensor to the wall or ceiling with the other hand.

There is a need for a sensor that can be easily and quickly mounted to a wall or ceiling and oriented to scan a desired area, and that has a lens that is quickly and easily replaceable.

Disclosure of Invention

The present invention helps overcome some of the above problems by providing an occupancy sensor that can be quickly and easily installed and oriented to scan a particular coverage or scanning area without the need for special installation tools. The sensor includes a relatively lightweight, integral mounting base that is separate from the body of the sensor and that can be mounted to a structure such as a wall or ceiling without the need for the installer to support the weight of the sensor body. Thereafter, the body of the sensor is mounted into a pedestal, which is mounted to a wall or ceiling, and the sensor body is twist locked to the pedestal to obtain coverage of different scanning areas. Additional adjustment may be made by loosening a threaded fastener, such as a nut, on the back of the sensor body. To help overcome the problem of damaging the lens, the sensor includes a replaceable PIR lens with a snap on lens holder that can be attached to the sensor.

In one aspect of the invention, an occupancy sensor is disclosed that includes a base element adapted to be mounted to a structure such as a wall or ceiling, a PIR sensor and a base neck having a first end and a second end. The first end is connected to the sensor by a ball and socket connector and the second end is connected to the base member by a swivel connector. The ball and socket connector and rotatable connector mechanism provide a combination of two rotational degrees of freedom for improved sensor adjustment. The lens is part of a replaceable lens holder that allows for easy replacement of a damaged lens. The techniques of the present invention are also applicable to other occupancy sensing technologies such as ultrasound and microwave means.

The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they may readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.

Drawings

Other aspects, features, and advantages of the present invention will become more fully understood from the following detailed description, the appended claims, and the accompanying drawings in which like elements are represented by like reference numerals:

1A-1D are isometric, front, side, and rear views of an occupancy sensor according to the principles of the present invention;

FIG. 2 is an exploded view of the sensor of FIG. 1;

3A-3C illustrate the sensor of FIG. 1 adjusted to different positions;

FIG. 4A shows another exploded view of the sensor of FIG. 1;

FIG. 4B shows an exploded view of the fastener of the sensor of FIG. 1;

FIG. 5 shows an exchange lens feature of the sensor of FIG. 1;

6A-6B illustrate the sensor mounting structure of FIG. 1;

FIG. 7 is a rear view of another embodiment;

FIG. 8A is another rear view of the embodiment shown in FIG. 7;

FIG. 8B is another rear view of the embodiment shown in FIG. 7;

FIG. 9 is a side cross-sectional view of the embodiment shown in FIG. 7;

fig. 10 is a side view of the embodiment shown in fig. 7.

Detailed Description

An occupancy sensor has a Passive Infrared (PIR) lens holder connected to a universal mounting mechanism that adjusts the scanning or coverage area of the sensor without the use of tools. The mounting mechanism includes a base neck element having a first end for a ball and socket connector for the PIR lens holder sensor body and a second end using a rotatable connector for mounting the base. The ball and socket connector and rotatable connection mechanism provide two rotational degrees of freedom for enhanced sensor adjustment. The lens is part of a replaceable lens holder that allows for easy replacement of a damaged lens. Although one embodiment of the present invention relates to a PIR sensing method, the techniques of the present invention are also applicable to other occupancy sensing techniques such as ultrasonic microwave means or combinations thereof.

Referring to fig. 1A-1D, different views of an occupancy sensor 10 in accordance with the principles of the present invention are shown. The sensor 10 includes a sensor body 12 with a replaceable lens holder 24 and a mounting mechanism including a base neck 16, a nut 18 or other threaded fastener, and a mounting base 14 for mounting the body 12 to a surface or structure, such as a wall or ceiling. The lens holder 24 has a PIR lens with a fixed scan range 82 defined by a scan angle 80, the fixed scan range 82 being used to detect the presence of an occupant in different scan (coverage) areas, e.g., 84, 86, and 88. The mounting mechanism provides fine and coarse adjustment means for adjusting or orienting the position of the sensor body 12 to allow the scanning range 82 to cover different scanning areas 84, 86, 88. For example, the scan range 82 of the sensor 10 is shown covering a scan area 84. However, the sensor body 12 can be easily adjusted to cover the scan areas 86 or 88 (and the overlap area) without having to adjust the scan range 82 or angle 80. The coarse adjustment means is achieved by detaching the base neck 16 from the base 14, rotating the base neck 16 around the mounting base 14 to the desired position and then reinserting the base neck into the base. The fine adjustment means is achieved by loosening the nut 18, rotating the sensor body 12 around the base neck to the desired position and then retightening the nut. By providing a sensor body 12 that is separate from the mounting base 14, an installer can mount and orient the sensor 10 without having to support the weight of the sensor body 12 and without the need for a separate tool. In addition, the replaceable lens holder 24 can be easily removed for replacement of a damaged PIR lens.

Fig. 2 shows an exploded view of the sensor 10 of fig. 1 in accordance with the principles of the present invention. The rear side of the lens holder 24 is mounted to the front side of the frame 26, and a Printed Circuit Board (PCB)28 having a sensor circuit occupying is mounted to the rear side of the frame 26 to form a sensor unit assembly. The sensor unit assembly is mounted within the chamber of the rear cover 22. The front cover 20 is mounted over the sensor unit assembly to form a sealed sensor body 12. The front cover 20 has an opening 21 to expose a front side or lens portion of the lens holder 24. The forward end of the base neck 16 has a spherical member 36 for connection to the cylindrical member 30 extending from the rear side of the rear cap 22 to provide a ball and socket connector. The front end of the base neck 16 is secured to the cylindrical member 30 by a nut 18. The rear end of the base neck 16 has a cylindrical member 40 that fits and is rotatably connected to a cylindrical member 44 extending from the front side of the mounting base 14. A hemispherical base cover 17 is mounted over the mounting base 14 to provide an aesthetic appearance. The components of the sensor 10 may be fabricated from various materials, such as plastic, metal, or combinations thereof.

Fig. 3A-3C illustrate a mounting mechanism for the sensor 10 for adjusting the scanning or coverage area of the sensor. As described above, the mounting mechanism, including the base neck 16, nut 18, and mounting base 14, provides coarse and fine adjustment means for adjusting the scanning or coverage area of the sensor 10. In fig. 3A, the sensor body 12 is oriented or positioned to provide a scanning range 82 with an angle 80 to cover a particular scanning area. It should be noted that the scan range 82 and the angle 80 typically have a three-dimensional conical profile, but only a two-dimensional sector profile is shown for ease of explanation. Fig. 3B shows how the fine adjustment means can be used to rotate the sensor body 12 in the direction 92 to cover a new scan area with the same scan range 82 as fig. 3A. For adjustment, the nut 18 is loosened by unscrewing the nut from the sensor body 12, the sensor body 12 is twisted or rotated in the direction indicated by arrow 92 to a new position to cover the new scanning area, and the nut 18 is then retightened to fix the new position of the sensor body 12. Fig. 3C shows how the coarse adjustment means can be used to rotate the sensor body 12 in the direction 90 to cover a new scanning area with the same scanning range 82 as fig. 3A. For adjustment, the base neck 16 is detached or pulled from the mounting base 14, rotated in the direction indicated by arrow 90 to a new position to cover a new scanning area and then reattached or reinserted into the mounting base to secure the sensor body 12 in the new position.

FIG. 4A shows the sensor body assembly 12 coupled to the mounting mechanism of the sensor 10 of FIG. 2. As described above, the mounting mechanism, including the nut 18, the base neck 16, and the mounting base 14, provides a fine and coarse adjustment means for the sensor 10. The inner periphery of the cylindrical member 30 of the rear cap 22 is a socket having a hemispherical surface 32 adapted to rotatably receive a ball member 36 of the base neck 16. When the nut is tightened, the ball element 36 is held in place by the nut 18(18a, 18b), and when the nut 18 is loosened, the sensor body 12 is free to rotate about the ball element 36 to provide a fine adjustment means. The nut 18 is formed of a first nut half 18a and a second nut half 18b that may be removably coupled to one another to form a single nut assembly 18.

For example, in one embodiment, FIG. 4B shows first nut half 18a having posts 27a and openings 29a for engaging corresponding openings 27B and posts 29B on second nut half 18B to secure or lock the two halves 18a, 18B together to form a single nut assembly 18. The internal threads 19a, 19b on the inner periphery of the respective nut halves 18a, 18b are adapted to be threaded onto the external threads 31 on the outer periphery of the cylindrical member 30 of the back cover 22. The partial spherical surfaces 23a, 23b on the inner periphery of the respective nut halves 18a, 18b are adapted to rotate with the ball element 36 of the base neck 16 to provide a ball and socket or rotatable connector.

Referring to fig. 4A, the rear end of the base neck 16 allows the sensor body 12 to rotate to one of several different positions and provides a second degree of freedom of movement associated with the coarse adjustment means. The rear end of the base neck 16 has a cylindrical element 40 which cooperates with a cylindrical element 44 in the mounting base 14 to orient and lock the base neck to the cylindrical element 40. The base neck 16 may have a curved portion 34 located midway along the base neck with a particular angle, for example 30 degrees as shown in fig. 3C. In one embodiment, the cylindrical member 40 of the base neck 16 is sized to slide and fit snugly within the cylindrical member 44 of the mounting base 14. The cylindrical member 40 has two snap tabs 38 spaced 180 degrees apart and extending from the periphery of the cylindrical member. The two snap tabs 38 are adapted to mate with 8 pairs of slots 42 evenly spaced on the inner periphery of the cylindrical member 44. This configuration allows the base neck 16 to rotate or swivel to one of 8 different positions in the same plane as the mounting base 14.

During assembly, the nut halves 18a, 18b are assembled to form the nut assembly 18 and then placed over the ball element 36 of the base neck 16. When the ball element 36 is inserted into the cylindrical element 30 of the back cap 22, the internal threads 19a, 19b of the nut 18 (fig. 4A) engage the external threads 31 of the cylindrical element 30 of the back cap 22. When the nut 18 is tightened to the thread 31, the two part-spherical surfaces 23a, 23B (fig. 4B) push the ball element 36 against the hemispherical surface 32 of the back cover 22. The ball element 36 is locked in place by the three spherical surfaces 23a, 23b, 32 and the sensor body 12 is secured to the forward end of the base neck 16.

Rotation of the sensor body 12 about the ball element 36 provides a first degree of freedom of body rotation, providing a scanning area that can be easily changed by loosening and then retightening the nut. That is, tightening the nut assembly 18(18a, 18b) locks the sensor body 12 to the base neck 16 to fix the new position of the sensor body. Loosening the nut assembly 18 allows the position of the sensor body to be changed to provide a new scan or coverage area.

When the cylindrical member 40 of the base neck 16 is inserted into the cylindrical member 44 of the mounting base 14, the two flexible snap tabs 38 are pushed inwardly toward the center of the opening of the member 40. The cylindrical member 40 can be rotated inside the cylindrical member 44 until the snap tabs 38 engage one of the 8 slots 42, causing the snap tabs 38 to position themselves within the slots to lock the sensor body into one of the 8 positions. The different positions of the base neck 16 provide a second degree of freedom of body rotation. The total rotation of the sensor body 12 is a combination of two rotational degrees of freedom: the first rotational degree of freedom is provided by a ball and socket connector allowing the ball element 36 to rotate about the sensor body 12, and the second rotational degree of freedom is provided by a rotatable connector allowing the base neck 16 to rotate about the mounting base 14.

Fig. 5 shows a detailed view of the replaceable PIR lens holder 24 of the sensor 10 of fig. 1. The lens 50 is secured to the front of the lens holder 24 by ultrasonic welding or other attachment means. A lug 52 with an opening and spaced snap tabs 56 extend from the top and another lug and tab pair extends from the bottom portion (not shown) of the lens holder 24. Two spaced locating pins 54 on the frame 26 are cooperatively positioned with respect to the lugs 52 of the lens holder 24 and are sized to be received by openings in the lugs. Similarly, two spaced apart slots 58 on the frame 26 are cooperatively positioned with respect to the snap tabs 56 of the lens holder 24 and are sized to receive the snap tabs 56. The pin 54 and the lug 52 are keyed for one-way assembly so that it is properly positioned relative to the frame 26 when the lens holder 24 is attached to the frame. The lens holder 24 is attached (snapped) to the frame 26 and the frame is held inside the housing comprising the front cover 20 and the back cover 22. This configuration allows the lens to be properly oriented and easily replaced if necessary. The front cover 20 has a snap tab 46 on the top edge and another snap tab (not shown) on the bottom edge. The rear cover 22 has two corresponding slots 48 on the top and bottom edges. The snap tabs 46 are positioned relative to the slots 48 to allow the covers 20, 22 to be removably connected to one another to form a single assembly sensor body.

In addition, to use PIR sensing technology, the present invention is also applicable to other occupancy sensing technologies such as ultrasound and microwave means. For example, the sensor 10 may be configured to transmit an ultrasound signal and monitor changes in signal return time to detect occupancy. The sensor may also combine PIR and ultrasonic sensing technologies for high precision monitoring with minimal false triggering. The sensor 10 of the present invention may be used in a variety of applications, such as for monitoring conference rooms, lounges, storage rooms, elevator cabs, and garages in commercial and public places. In addition, the sensors may be adapted to monitor hallways, patios, aisles, and backyards in the home.

Referring to fig. 6A-6B, a mounting base 14 is provided for mounting the sensor 10 to a wall, ceiling, or other structure or surface. The mounting base 14 has openings 64 for receiving screws for attachment to a wall, ceiling or electrical junction box. Once the mounting base 14 is attached, a cable 66 (fig. 6B) or other wire from inside the wall or ceiling may be pulled through the central opening of the cylindrical member 44 and attached to the terminals of the sensor body 12. The cylindrical member 40 of the base neck 16 is inserted into the cylindrical member 44 of the mounting base 14. The leading ends of the two catches 38 are chamfered at approximately 45 degrees and the trailing ends are chamfered at approximately 30 degrees to allow the base neck 16 to be easily inserted into and removed from the cylindrical member 44. The base neck 16 is detached from the mounting base 14 by having the two snap tabs 38 clear the shoulders of the slot 42. When the cylindrical member 40 on the base neck 16 is inserted into the cylindrical member 44, a shoulder on the base neck 16 engages the top end of the cylinder to define the penetration depth. The base neck 16 can be rotated slightly to allow the two snap tabs 38 to engage the nearest two of the eight slots 42 to lock the sensor body 12 in place. To complete the installation, referring to fig. 6B, the base cap 17 is placed over the cylindrical member 40 and advanced until the lip 62 engages the groove 60 on the cylindrical member 40 to form a secure connection.

Fig. 7 is another example of an embodiment including an adjustable base 100 for a base neck 116 that is substantially similar to neck 16 but modified to include a base body 110. Base body 110 is substantially spherical and has apertures 112 and 114 for receiving arms 120 and 130. Arm 120 is connected at a first end to base cover 140 by a first extension arm 124 and extends upwardly in a substantially L-shaped manner to a substantially vertical connecting portion 126.

The arm 130 is connected at a first end to a base cover 140 and has a first extending arm portion 134 and a substantially vertical connecting portion 136. Although designed to be manufactured from any suitable material, in one embodiment, all of these components are manufactured from a plastic material so that the arms 120 and 130 can be temporarily moved when the adjustable base 100 is snapped into the arms. Because base body 110 is substantially spherical, it has a rounded surface that causes arms 120 and 130 to flex laterally to receive body 110 when base body 110 is pressed down into those arms. Once the body 110 is fully depressed into the base cap 140, the arms 120 and 130 snap into the respective apertures 112 and 114 shown in FIG. 8B. In this manner, the connecting portions 126 and 136 snap into the respective apertures 112 and 114 such that the base body 110 is rotatable about the axis formed by the connecting portions 126 and 136.

Base body 110 also includes two locking elements 150 and 160 (see fig. 8A and 8B). The locking elements 150 and 160 may be formed in any manner, but in this case are formed as ramp-like projections having a substantially triangular cross-section extending outwardly from the body 110. The body 110 has two locking elements 150 and 160 so that the base body 110 can be semi-fixedly locked in at least two different positions. In the first position, neck 116 is rotated about connecting portions 126 and 136 until neck 116 contacts base cap 140. During this rotation, the locking element 150 is squeezed through the base cap 140 by moving the base cap 140 such that the locking element 150 is squeezed through (pop through) the base cap 140. At this point, the locking element 150 is positioned outside of the base cap 140 and is held in place by friction and mechanical interference with the base cap 140 (see fig. 9). In this position, the arm 116 is locked against further movement in the first direction by the arm 116 contacting the body 140. The arm 116 is also semi-fixedly locked in the other direction by the locking element 150.

To rotate pivot arm 116 back, the user must use additional force to force locking member 150 through and past base cover 140 by moving base cover 140. The resistance to movement is provided substantially by the structural rigidity of the base cap 140. Base body 110 also has some minimal flexibility and therefore can also flex during this movement.

Alternatively, in the relative position, the user may push arm 116 in the opposite direction such that locking element 160 pops through base cover 140 and then extends outside of base cover 140, as shown in fig. 10. In this position, neck 16 is semi-fixedly locked, as described above, such that neck 16 is effectively held in this position, with further rotational movement prevented at one end by arm 116 pressing against base cover 140, and a second end by locking member 160 pressing against cover 140, similar to that shown in fig. 9. As described above, the neck 116 may be unlocked from this position by the user moving the neck 116 back so that the locking element 160 snaps through the cap 140, thereby releasing the neck 116 to move back to the unlocked position.

The opposite end of arm 116 is connected to spherical element 36 which is connected to sensor 10 as described above. This embodiment thus provides further adjustability for the sensor 10 so that the sensor 10 can be positioned in place.

Although the device may be semi-fixedly locked in place, the neck or arm 116 may be repeatedly moved into these two different positions. In addition, base cover 140 may be mounted on a substantially vertical surface, such as a wall, or a substantially horizontal surface, such as a ceiling.

While there have been shown and described and pointed out fundamental novel features of the invention as applied to a preferred embodiment thereof, it will be understood that various omissions and substitutions and changes in the form and details of the methods and devices illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention.

Claims (21)

1. A sensor mounting mechanism, comprising:

a base member adapted to be mounted to a structure; and

a base neck having a first end and a second end, the first end adapted to be connected to a sensor by a ball and socket connector and the second end connected to the base element by a swivel connector, wherein the swivel connector is rotatable about an axis formed by connecting portions (126, 136);

two arms, a first end of the arms being connected to the base element, a second end of each arm being the connecting portion (126, 136), and a second end of the arms being configured to be rotatably connected to the second end of the base neck, the arms being L-shaped.

2. The sensor mounting mechanism of claim 1 wherein the second end of the base neck comprises a body having two apertures configured to respectively receive second ends of the two arms to form a rotatable connector.

3. The sensor mounting mechanism of claim 2 wherein the body is substantially spherical.

4. The sensor mounting mechanism of claim 1 further comprising a locking element for semi-fixedly locking the base neck in the first position.

5. The sensor mounting mechanism of claim 4 further comprising another locking element for semi-fixedly locking the base neck in the second position.

6. The sensor mounting mechanism of claim 4 or 5 wherein the locking element is ramp-shaped to form a friction fit with a base element to lock the base neck in the respective position.

7. The sensor mounting mechanism of claim 1 further comprising a split nut having two partially spherical surfaces and a split internal thread connected to a first end of the base neck to engage threads on the sensor.

8. The sensor mounting mechanism of claim 1 further comprising a threaded fastener for fastening and unfastening the base neck to and from the sensor.

9. The sensor mounting mechanism of claim 8 wherein the threaded fastener is a two-piece nut assembly including a first nut half and a second nut half adapted to form the two-piece nut assembly.

10. The sensor mounting mechanism of claim 1 wherein the base neck has a passage extending therethrough to allow electrical leads to connect from the base member to the sensor.

11. The sensor mounting mechanism of claim 1 wherein the ball and socket connector comprises a ball element on the neck of the base and a socket on the sensor.

12. The sensor mounting mechanism of claim 1 further comprising a base cover for mounting over the base member.

13. The sensor mounting mechanism of claim 1 wherein the sensor comprises a frame and a detachable passive infrared lens holder held to the frame by a snap.

14. The sensor mounting mechanism of claim 13 wherein the sensor comprises a two-piece housing assembly having a front cover and a back cover, wherein the front cover has an opening for exposing a portion of the front surface of the removable passive infrared lens holder, and the back cover is connected to the base neck.

15. The sensor mounting mechanism of claim 13 wherein the frame has a front side for securing the removable lens holder and a back side for securing a printed circuit board having circuitry for the sensor.

16. The sensor mounting mechanism of claim 1 wherein the base neck has a bend between the first end and the second end of the base neck.

17. The sensor mounting mechanism of claim 1 wherein the base neck is a tubular member having a bend between a first end and a second end of the base neck.

18. The sensor mounting mechanism of claim 1 wherein the sensor is a passive infrared sensor having a lens with a rectangular lens having a front convex surface.

19. The sensor mounting mechanism of claim 1 wherein the structure is a pre-existing structure comprising one of a wall and a ceiling.

20. The sensor mounting mechanism of claim 2 wherein the body has a certain minimum flexibility so that flexing can occur.

21. The sensor mounting mechanism of claim 2 wherein the body and the arm are made of a plastic material.