Calibration and setup unit for barrier operator control system

Abstract

A setup and calibration unit for a barrier operator is operable to communicate with the operator's own controller. The calibration unit includes a control circuit connected to a visual display and to a set of switches controlled by switch actuators for placing the operator controller in a controller run mode or calibration mode, scrolling through selected actions displayed on the display in one direction or the other, a set/clear function and display backlighting for user interaction with the setup and calibration unit. The setup and calibration unit is particularly adapted for use with upward acting sectional and roll-up doors and other types of barriers movable between open and closed positions by motorized operators. The calibration unit may be operably connected to the operator controller via hard wiring, a radio frequency link or an infrared or visible light transmission link.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view in somewhat schematic form of a barrier and barrier operator adapted for setup and calibration by the setup and calibration unit of the present invention;

FIG. 2 is a perspective view of one embodiment of an operator adapted for use with the setup and calibration unit of the invention;

FIG. 3 is a diagram of a control panel for a barrier operator control system setup and calibration unit in accordance with the invention;

FIG. 4 is a schematic diagram of a major portion of the circuitry for the setup and calibration unit of the invention;

FIG. 5 is a schematic diagram of a further portion of the control circuitry for the setup and calibration unit;

FIG. 6 is a schematic diagram of a portion of a barrier operator control system adapted for use with the unit of the present invention;

FIG. 7 is a somewhat generalized block diagram of an embodiment of the invention wherein communication with a barrier operator and its control microcontroller is carried out by way of radio frequency (RF) communication;

FIG. 8 is a block diagram similar in some respects to FIG. 7 of an embodiment of the invention whereby communication between a calibration unit or device and an operator controller or microcontroller is carried out by IR or visible light spectrum communications; and

FIG. 9 is a block diagram similar to FIGS. 7 and 8 of an embodiment of the invention wherein communication between the calibration unit or device and the operator controller is via hard wiring.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

In the description which follows like elements are marked throughout the specification and drawing with the same reference numerals, respectively. The drawing figures are not necessarily to scale and certain features may be shown in generalized or schematic form in the interest of clarity and conciseness.

Referring now to FIG. 1, there is illustrated a movable barrier 20 which is characterized by way of example as a sectional upward-acting garage door. The barrier 20 is movable between the closed position shown and an open position on spaced apart generally parallel guide tracks 22 and 24. The barrier 20 is adapted to be moved between open and closed positions by a motorized operator, generally designated by the numeral 21, which may be one of several types and includes an elongated support 26 for supporting an operator actuating mechanism, not shown in detail, but connected to an arm 28 which, in turn, is connected to the barrier 20. By way of example also, the support 26 may include spaced-apart barrier position limit switch mechanisms for controlling the limit positions of the door in both an open limit position and a closed limit position. The operator 21 includes a housing or frame 30 supporting a motor 36 connected to the mechanism which is carried by support 26 for moving the arm 28 and the barrier 20 between the limit positions described. Barrier 20 is movable to close an opening in a structure, such as a residential or commercial garage, industrial building or any structure which requires a motorized movable barrier for closing over an opening. The aforementioned building includes a sidewall 39 and a floor 31, as indicated.

Referring further to FIG. 1, the operator 21 may be controlled by various control devices including a wall-mountable control console 38 having one or more push button type switch actuators 40a, 40b and 40c disposed thereon. The wall-mountable control console 38 may be hardwired to an operator controller for motor 36, as indicated at 43, or the control console 38 may communicate with the operator controller by radio frequency transceivers, for example, generally in accordance with the teaching of U.S. patent application Ser. No. 11/301,584 filed on Dec. 13, 2005 by Larry D. Murphy et al. and assigned to the assignee of the present invention.

Referring still further to FIG. 1, the barrier 20 may be provided with one or more obstruction detectors, such as a beam emitting-type obstruction detector indicated by numerals 42 and 44. This type of obstruction detector may comprise an infrared, visible light or X-ray type radiation beam emitter and cooperating receiver for generating a signal when a beam 45 is interrupted. The obstruction detector 42, 44 may be one of several types known in the art. The barrier 20 may also include a second obstruction detector, generally designated by numeral 47, and mounted on the lower transverse edge of the barrier 20, as indicated in FIG. 1. Obstruction detector 47 is responsive to engagement with an obstruction disposed in the opening closable by the barrier 20 to transmit a signal to the aforementioned operator controller to effect stopping and/or reversing movement of the barrier. Still further, the barrier 20 may be controlled by remote transmitters or transceivers, indicated by numerals 46 and 48, which are adapted to transmit radio frequency signals to the controller for the operator 21 for remote control thereof. The remote control units 46 and 48 may have one or more control switch actuators included therein for use by persons wishing to control movement of the barrier 20, such switch actuators being indicated by numerals 46a, 46b, 48a and 48b, respectively.

Referring now to FIG. 2, there is illustrated in greater detail a major portion of the operator 21, which is exemplary. FIG. 2 illustrates the operator frame or housing 30 which includes spaced-apart support plates 50 and 52 supporting motor 36 and a drive train including a belt drive 53 for driving an intermediate shaft 54 mounted on frame plates 50 and 52 which drives an output shaft 56 by way of a flexible belt or chain drive mechanism 58. Shaft 56 may, as shown, have a chain sprocket 59 drivenly supported thereon and connected to an endless chain which is, in turn, supported by the support 26 and operably connected to the arm 28 in a known manner. A controller for the operator 21 is preferably mounted in a suitable housing 60 forming a part of the frame 30 and having a removable cover 62 to provide access to certain controller features including a setup and calibration unit in accordance with the invention.

Referring briefly to FIG. 6, there is illustrated a schematic diagram of the external wiring and accessory items which are operable to provide control signals to the operator controller, generally designated by numeral 63, including a control signal terminal strip 64 disposed within the housing 60, as illustrated. Certain elements not actually disposed within the enclosure or housing 60 are shown in FIG. 6 for convenience including the wall-mountable controller 38, the obstruction detector 42, 44 and the obstruction detector 47, for example. The controller terminal strip 64 is also operable to be connected to an alternate or further obstruction detector, indicated by numeral 42a, 44a. Still further, other remote operator control devices 66a, 66b, 66c and 66d may be utilized with the controller 63. Radio control signals may also be communicated to the controller 63 via a radio 69 via suitable connections not shown, and which radio is operable to be in communication to the remote control units 46 and 48.

Housing 60 is also adapted to include a built-in controller setup and calibration unit or device in accordance with the invention and generally designated by the numeral 70 in FIG. 3. Setup and calibration unit 70 includes a visual display 72. Push-button type switch actuators include an actuator 74 for a calibrate/run switch, a display backlight intensity switch includes an actuator 76, so-called up and down menu scroll switch actuators 78 and 80 and a set and clear switch actuator 82 may collectively be referred to as calibration unit inputs 83. For convenience, duplicate operator open, close and stop switch actuators 84, 86 and 88 are provided, respectively. The setup and calibration unit 70 may be incorporated in a control system for an operator, as illustrated, or configured as a separate unit which may be temporarily connected to a barrier operator controller or control system by one of several communications links to be described herein. The unit 70 provides ease of setup and calibration for a control system of the type described herein and, advantageously, may be removable therefrom when the operator controller calibration or setup is completed. Thus the cost of the control system for the operator can be reduced accordingly. The calibration unit 70 includes a microcontroller, the display 72 and the switch input or actuators illustrated and described hereinabove. Further details of the control circuitry associated with the setup and calibration unit 70 will now be described in conjunction with FIGS. 4 and 5.

Referring briefly to FIG. 5, electrical power for the calibration unit 70 and communication with the controller 63 may be provided via a connector to the operator 21, generally designated by the numeral 90, or another connector 92 to a device, not shown, such as a controller expansion board or the like. Transient protection circuitry 94 is provided in the circuit of FIG. 5 and twenty-four volt power is provided by circuit components indicated generally at 96. Regulated five volt power for control elements of the calibration unit 70 are provided by circuit elements indicated generally by the numeral 98.

Referring now to FIG. 4, in particular, the calibration unit 70 includes a control circuit comprising a microcontroller 100 which may be of a type commercially available such as a model PIC16F876 available from Microchip Technology, Inc. of Chandler Ariz. While microcontroller 100 may be a preferred embodiment of a calibration unit control circuit, such could be characterized by another programmable logic device, an application specific integrated circuit (ASIC) or a discrete logic circuit, for example. For convenience herein the further discussion will use the term microcontroller for the control circuit 100. Microcontroller 100 is operably connected to a connector set 101, 102 to provide communication to the visual display 72. Power for the backlighting of the display 72 is supplied via circuit components indicated generally at 104 and 104a in FIG. 4. A connector 105 provides for connection to apparatus, not shown, for programming microcontroller 100. A timing circuit for the microcontroller 100 is indicated at 106 and a temperature sensor for adjusting the operation of the display 72, if such is an LCD type, is indicated generally at 108. A bias circuit for the display 72, if of an LCD type, is indicated at 110. Connections 111 and 111a are provided for communication between microcontroller 100 and controller 63, see FIG. 5 also, and connections 111 and 111a may be connected to a remote or directly connected transceiver, not shown, for operation of the calibration unit 70 remotely.

Operation of the calibration unit 70 to set various operating parameters of the controller 63 is advantageous in that it provides for ease of calibration and setup of operation of the controller but may be removable after the calibration or setup operation is complete. Thus the control system for the operator 21 does not require the additional cost of having the calibration capability. Moreover, communication between the calibration unit 70 and the controller 63 can be a serial or parallel hardwired, digital link accessed via a plug-in connector, as shown, via a radio frequency link, as described above, or via an infrared, visible light or other radiation spectrum link. Moreover, the display 72 is operable to communicate information to an operating technician, including information pertaining to current operator status, calibration status, and other explanatory information. The calibration unit 70 also may prompt an operating technician to take certain actions via a single or multi-character numeric or alphanumeric display or by a series of indicators, such as discrete LEDs arranged in a vertical or horizontal row or other matrix. As indicated above, the switch actuators provide input for calibration versus the normal run mode of the operator, menu scrolling functions, backlight activation and function-set or clear commands. Although discrete electromechanical switch actuators are indicated by the numerals 74, 76, 78, 80 and 82, see FIG. 3 also, the switch actuators could be of types associated with DIP switches, conductive rubber buttons, rotary switches, capacitive input devices, touch screen input devices, or other input devices including other types of electromechanical switches or devices that serve the same purpose.

As mentioned above, the operating protocol for the set up and calibration unit 70 includes a normal run mode and a calibration mode whereby, in the calibration mode, a calibration of several features may be carried out wherein the scroll keys allow the operating technician to quickly cycle through the available sequence of features. Still further, the set/clear switch actuator 82 allows the operating technician to alter the parameter that is currently selected and the display 72 will indicate the current parameter setting within the operator controller or other accessory connected thereto.

Selected calibration procedures will now be described. If it is desired to set the controller 63 for the operator 21 to require constant contact of the switch actuators 40a and 40b, for example, the calibration unit is operated as follows. Switch actuator 74 is actuated to enter the calibration mode, followed by actuation of switch actuator 82 until the display 72 reads, for example, “OPEN MODE-C-STP” followed by actuation of switch 78 or 80 until the display reads “CLOSE MODE”, followed by actuation of switch actuator 82 until the display reads “CLOSE MODE-C-STP” followed by actuation of switch actuator 74 to return to the operator run mode.

Consider that the barrier position limit switches are similar to those described in U.S. patent application Ser. No. 10/989,479, filed Nov. 16, 2004 by Angiuli et al. and assigned to the assignee of the present invention. Alternatively, the barrier position limits may be determined by other mechanical or electrical sensors or substantially electronically by the controller 63 using input signals from the operator drive motor or a sensor connected thereto, for example. The first step would, typically, be to verify that the open and close operating modes are set to constant contact. This step is followed by actuation of switch actuator 74 until the operator 21 is in the run mode. Then the switch actuator 84 or 40a may be actuated to move the barrier to the desired open position followed by release of the aforementioned switch actuator. At this time, the limit switch mechanism itself, if of the type first referred to above, may be manipulated appropriately to set the limit position. Then, the switch actuator 40b or 86 may be actuated to move the barrier to within two inches of the floor 31, for example, and the limit switch mechanism or limit switch itself positioned accordingly.

Setting a limit switch overrun in the barrier closing mode may be accomplished by pressing switch actuator 74 to enter the calibration mode and then switch actuator 80 to scroll to a selected preset limit overrun condition which may be in increments indicated as 0 to 9, for example. Switch actuator 82 is then actuated until the display 72 reads the desired value (0 to 9). Switch actuator 84 is then actuated to open the barrier a few feet then release the switch actuator. Switch actuator 86 is then actuated to close the barrier 20 until the operator 21 stops the barrier. A bottom edge seal should be appropriately engaged with the floor 31. If not, the previous steps for setting the limit overrun are carried out until the desired limit overrun position is reached and the process is then followed by actuation of the switch actuator 74 to return to the so-called run mode.

Activation of an obstruction detector, such as the obstruction detector 42, 44, may be carried out with the calibration unit 70 by actuating switch 74 to place the unit and the controller 63 in the calibration mode. Switch actuator 80 is then actuated until the display 72 reads “ODC STB”, for example. Switch actuator 82 is then actuated until the display reads “ODC STB ON” and the switch 74 is then actuated to return the system to the run mode. To deactivate the obstruction detector 42, 44 the same set of steps is carried out until the display reads “ODC STB OFF”.

Additional features which may be set up or calibrated with the calibration unit 70, include setting a midstop position for the barrier 20 between full open and closed positions. Setting a midstop position is carried out by actuation of switch actuator 74 to enter the calibration mode, actuation of switch actuator 86 to close the barrier to the down limit and actuation of switch actuator 80 until the display 72 reads “MIDSTOP CLEAR”. The barrier 20 is then moved toward an open position by actuation of switch actuator 84 until the desired midstop position is reached and the switch actuator is released. Switch actuator 82 is then actuated until display 72 reads “MIDSTOP SET” followed by actuation of switch actuator 74 to return to the run mode of the controller 63. The midstop position may be cleared by actuation of switch actuator 74 and switch actuator 80, then actuation of switch actuator 82 until the display reads “MIDSTOP CLR” followed by returning to the run mode through momentary actuation of switch actuator 74.

The controller 63 may include a maximum run time feature which requires that the barrier 20 move from one limit to another within a preset time period. Typically, upon installation of an operator 21 and controller 63, the maximum run time is established automatically by the controller 63 by measuring the open and close run times during initial runs of the operator in the run mode. A factory set value may be added to this measured value and the resulting sum stored as the maximum run timer value for a given direction of travel. If the maximum run time is exceeded in a subsequent “normal” cycle of operation, the operator 21 stops and may reverse if the barrier is moving toward the closed position. The maximum run time feature may provide that the operator 21 not respond to any further commands following a maximum run time being exceeded until a reset operation is carried out by the calibration unit 70, which may be accomplished by actuating any of the switch actuators or keys of the calibration unit, except actuators 84, 86 and 88. Alternatively, the controller 63 may also be operable to restore full function to the operator 21 by cycling electrical power off and then back on to operator 21. The controller 63 may include a feature whereby factory default values for the maximum run timers may be restored. Switch actuator 74 may be actuated, for example, to enter the calibration mode followed by actuation of switch actuator 80 to reach the position on the display which reads “MAX RUN TMR-SET”, followed by actuation of the set/clear actuator 82 until the display reads “MAX RUN TMR-CLEAR”. This action will set the maximum run times to a default value. The controller 63 may then be returned to the run mode by actuation of switch actuator 74.

Once the limit switch operation and obstruction detector operation modes have been set, the operator 21 may be placed in the so-called momentary contact operating mode wherein only momentary contact of the switch actuators 40a, 40b or one of actuators 66a, 66b, 66c and 66d, or one of actuators 84 and 86 are required to carry out the operation desired. Actuation of switch actuators 74, 80, 82, and then 74 are carried out. For example, switch actuator 74 is actuated to enter the CAL/RUN mode and then switch actuator 80 is actuated until the display reads OPEN MODE-(X) displaying a present setting. Switch actuator 82 is actuated until the display reads MOM then momentary contact will cause the door to open to its limit position. After setting the opening mode the switch actuator 74 may be actuated to return to the operator run mode.

Setting of the door or barrier closing mode is displayed and carried out in somewhat the same manner including actuation of switch actuator 74, 78 or 80 until the display reads CLOSE MODE-(X) to display the present setting followed by actuation of switch actuator 82 until a desired operating mode “C-STP” or “MOM” is displayed followed by pressing switch actuator 74 to return to the operator run mode.

Still additional features which setup and calibration unit 70 may display, or carry out, include an operator cycle count. Controller 63 is operable to store data regarding the number of cycles the barrier 20 has been operated through and this information may be displayed by way of the unit 70 by actuation of switch actuator 74, 78 or 80 until the display reads “CYCLES-(#)”. This action is followed by restoring the operator controller 63 to the run mode. Essentially the same steps are utilized to determine the version number of the firmware used in the controller 63, the particular type of operator in use and to display a selected number of error codes which may be stored in the operator controller 63. For example, to aid in trouble-shooting operational problems, the operator 21 may be provided with a memory that stores the last ten error events by storing the last ten error codes in sequence. Once ten error codes are stored, the oldest code is erased to make room for the newest code. These codes may be displayed on the display 72 in the calibration mode of operation and the display may flash the number of the error code and the code itself followed by a description of the error code.

The controller 63 may also include a run code memory that stores the last ten run events in sequence and which may be displayed on display 72 in the calibration mode by flashing the number of the run code and a description of the code itself. Any number of operator run codes and error codes, may of course, be programmed into the microcontroller 100 for display by the display 72 when the calibration unit is connected to the controller 63 and the status of the operator 21 is ascertained. The two digit run codes and error codes are typically stored in the microcontroller 63 and may be transferred to the microcontroller 100 for display on the display 72.

Referring now to FIG. 7, there is illustrated a modified operator 21m which is similar in many respects to the operator 21 and includes the operator controller or microcontroller 63, and a radio frequency transceiver 130 operably connected thereto. Power for transceiver 130 may be furnished from the same source as that which powers microcontroller 63. FIG. 7 also illustrates a modified calibration unit or device 70m which includes the calibration display 72, the calibration unit or device controller 100 and the calibration input means 83. Calibration device microcontroller 100 is operably connected to an RF transceiver 132 whereby the calibration unit or device 70m may carry out all communications necessary to calibrate and control the operator 21m via radio frequency signals. A battery 133 furnishes power to microcontroller 100 and transceiver 132.

FIG. 8 illustrates an operator 21n and a calibration unit or device 70n both similar in several respects to the operator 21m and the calibration unit 70m, but including I/R (Infrared) transceivers 134 and 136 operably connected, respectively, to the controller 63 and the controller or microcontroller 100 whereby the calibration unit 70n may conduct all communications via the transceivers 134 and 136 with the operator controller 63 by way of infrared or visible light signal transmission. A battery 133 provides power to microcontroller 100 and transceiver 136.

Viewing FIG. 9, a modified operator 21p and a modified operator calibration unit 70p are illustrated and are substantially like the other embodiments described herein but include communication bus hardware 138 and 140, respectively, whereby communication between the operator 21p and the calibration unit 70p is carried out by so called hard wiring. Power for calibration unit 70p may be provided by a power supply for operator 21p, not shown in FIG. 9, and via suitable conductors associated with communication bus hardware 138, 140.

The construction and use of the barrier operator setup and calibration units 70, 70m, 70n and 70p is believed to be understandable to those of ordinary skill in the art from the foregoing description. Moreover, other functions which the calibration units of the invention may be capable of setting or adjusting include direction of barrier movement, maximum and minimum barrier velocity in opening and closing modes, acceleration/deceleration rates (as the barrier approaches limit positions, for example), date and time of a real-time clock used to determine event timing, service intervals for the barrier and/or operator, timing and operating parameters for automatic operation features and timing of activating visual and/or audio warning devices, and determining the type of barrier being controlled followed by adjusting operator control parameters, accordingly. Although preferred embodiments of the calibration unit and methods of operation of same have been described in detail herein, those skilled in the art will also recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.

Claims

1. A calibration unit for a barrier operator, said barrier operator including a motor and an operator controller for receiving control inputs from said calibration unit, said calibration unit including: a control circuit;a visual display operably connected to said control circuit;calibration input means operably connected to said control circuit including a set of input switch actuators, said switch actuators including a set/clear switch actuator, a calibrate/run switch actuator and at least one menu switch actuator for selecting a calibration step or steps for carrying out various settings of said operator controller;said calibration unit being operably in communication with said operator controller by way of at least one of a radio frequency link, a hardwire link and one of an infrared and visible light signal link.

2. The calibration unit set forth in claim 1 wherein: said calibration unit is mounted on a structure comprising part of said operator.

3. The calibration unit set forth in claim 1 wherein: said calibration unit is provided as a separate device including said display, said control circuit and said calibration input means and operably associated with said operator controller by way of one of said links.

4. The calibration unit set forth in claim 1 wherein: said control circuit is operable for controlling said operator in a normal run mode and a calibration mode by way of said switch actuators to alter a selected parameter presently selected and indicated on said display.

5. The calibration unit set forth in claim 4 wherein: said control circuit provides for display of indicia on said display to verify that a barrier open and close operating mode of said operator are set to one of constant contact by switch controls for controlling said operator controller and momentary contact of said switch controls for controlling said operator controller.

6. The calibration unit set forth in claim 4 wherein: barrier position limit controls may be set by pressing at least one of said switch actuators to a selected preset limit condition indicated on said display.

7. The calibration unit set forth in claim 4 wherein: said barrier operator includes an obstruction detector and said calibration unit is operable to activate and deactivate said obstruction detector by actuation of selected ones of said switch actuators.

8. The calibration unit set forth in claim 4 wherein: said control circuit is responsive to actuation to one of said switch actuators to enter a calibration mode and to set a midstop position of said barrier between barrier open and closed limit positions.

9. The calibration unit set forth in claim 4 wherein: said control circuit is operable to provide for a maximum run time of said motor settable or resettable by actuation of at least one of said switch actuators.

10. The calibration unit set forth in claim 4 wherein: said control circuit is operable to query said operator controller to determine the number of cycles of at least one of opening and closing of said barrier as carried out by said barrier operator.

11. The calibration unit set forth in claim 4 wherein: said control circuit includes means operable via said calibration unit for displaying on said display a selected one of plural error codes stored in said operator controller.

12. The calibration unit set forth in claim 4 wherein: said control circuit is operable to query said operator controller to display a selected number of operating events carried out by said operator.

13. A method for setting operating parameters of a motorized barrier operator, said operator including a motor and an operator controller for receiving control inputs, said method including: providing a calibration unit, said calibration unit including a control circuit, a visual display operably connected to said control circuit, and calibration input means operably connected to said control circuit including a set of input switch actuators for selecting one or more steps for carrying out various settings of said operator controller; andoperably connecting said calibration unit to said operator controller by way of at least one of a radio frequency link, a hardwire link and one of an infrared and visible light signal link.

14. The method set forth in claim 13 including: mounting said calibration unit on a structure comprising part of said operator.

15. The method set forth in claim 13 including: providing said calibration unit as a separate device including said display, said control circuit and said calibration input means, and operably connecting said calibration unit to said operator controller by way of one of said links.

16. The method set forth in claim 13 including the steps of: controlling said operator in a normal run mode and a calibration mode by way of said switch actuators to alter a selected parameter presently selected and indicated on said display.

17. The method set forth in claim 13 including the step of: displaying indicia on said display to verify that one of a barrier open and closed operating mode of said operator is set to one of constant contact by switch controls for controlling said operator controller and momentary contact of said switch controls for controlling said operator controller.

18. The method set forth in claim 13 including the step of: setting barrier position limits by pressing one or more of said switch actuators to provide a selected limit condition indicated on said display.

19. The method set forth in claim 13 including: providing said barrier operator with an obstruction detector and activating and deactivating said obstruction detector by actuation of at least one of said switch actuators.

20. The method set forth in claim 13 including: causing said control circuit and said operator controller to enter a calibration mode and to set a midstop position of said barrier between barrier open and closed limit positions.

21. The method set forth in claim 13 including: providing a maximum run time of said motor by actuation of at least one of said switch actuators.

22. The method set forth in claim 13 including: querying said operator controller to determine the number of cycles of at least one of opening and closing of said barrier as carried out by said barrier operator.

23. The method set forth in claim 13 including: displaying a selected number of error codes stored in said operator controller on said display.

24. The method set forth in claim 13 including: querying said operator controller to display a selected number of operating events carried out by said operator.