Door operator unit

Information

  • Patent Grant
  • 6422965
  • Patent Number
    6,422,965
  • Date Filed
    Thursday, April 20, 2000
    24 years ago
  • Date Issued
    Tuesday, July 23, 2002
    22 years ago
Abstract
A door operator unit includes a drive motor connected to a speed reduction differential planetary gear drive mechanism having a drive unit output shaft for connection to a further door drive mechanism. An electromagnetic brake is interposed between the motor output shaft and the planetary gear drive mechanism and is releasable when energized to allow rotation of the motor output shaft and the drive unit output shaft. A first ring gear of the planetary gear drive mechanism is normally held stationary by a release block and is operable in response to disengagement of the release block to permit rotation of the drive unit output shaft when the brake in engaged to allow manual opening and closing of the door. A torque limiting clutch may be interposed the operator unit output shaft and a second ring gear of the differential planetary gear drive mechanism.
Description




FIELD OF THE INVENTION




The present invention pertains to a motor-driven door operator unit for opening and closing an upward acting door, in particular, and including mechanism to permit manually closing the door under certain conditions.




BACKGROUND




Various types of apparatus have been developed for opening and closing large doors, including upward-acting garage doors and so-called rollup doors. Motor-driven operator units for industrial doors, including upward-acting doors of various types, have been developed which include mechanism for manually or automatically allowing the door to close under certain operating condition.




Various improvements have been sought in door operator units which are motor-driven but which also may be operated when motor power is unavailable or when the door is required to be closed under its own weight or another source of power. However, reliable and versatile operation of door operator units, compact and lightweight construction of such units and the ability to interchange the position of components of the operator unit, depending on the door configuration or application, continue to be problems facing artworkers. It is to these ends that the present invention has been developed.




SUMMARY OF THE INVENTION




The present invention provides an improved door operator unit, particularly of a type for opening and closing upward-acting, sectional and so-called rollup doors of various configurations.




In accordance with one aspect of the present invention, a motor driven door operator unit is provided which includes an improved power transmission mechanism between a drive motor and an operator unit output shaft. In particular, the power transmission mechanism includes a differential planetary gear drive drivenly connected to a drive motor and a remotely controlled brake operably connected to the motor output shaft for controlling rotation of the operator unit output shaft under certain operating conditions.




In accordance with another aspect of the invention, a door operator unit is provided which includes a differential planetary gear drive mechanism having a first ring gear which is normally held stationary to provide suitable speed reduction and torque amplification between a motor output shaft and the operator unit output shaft. A first ring gear member is held stationary during normal operation of the unit under motor power but may be released to rotate under certain operating conditions, such as when it is desirable to manually open or close a door connected to the operator unit. In this regard also, the releasable ring gear may be drivenly connected to a manual or separately driven shaft for driving the operator unit output shaft to rotate in either direction. Still further, the operator unit includes a release mechanism for holding the first ring gear stationary under selected operating conditions and for allowing the first ring gear to rotate, thus allowing rotation of the operator unit output shaft under other operating conditions.




The present invention also provides a door operator unit which includes a differential planetary gear drive mechanism having a first ring gear which may be held stationary or allowed to rotate and a second ring gear which also comprises an output gear of the operator unit. The second ring gear is operably connected to the operator unit output shaft through an adjustable torque limiting clutch whereby the output torque exerted on a door or door drive mechanism connected to the operator unit may be limited, and may be selectively adjusted.




The present invention provides an improved door operator unit drive mechanism which is adapted to include a gear for driving a sensor, such as a door position limit switch, which gear is positively keyed to rotate with the operator unit output shaft to prevent loss of timing between the position of the door and the limit switch.




Still further, an improved operator unit is provided which is adapted to reverse the positions of a manual operator drive shaft and a release mechanism. The operator unit includes an improved arrangement of a manually operated or auxiliary power operated drive shaft, associated drive mechanism and a speed limiting governor.




The present invention includes all of the above-mentioned features in a compact and reliable door operator unit, which will be further appreciated by those skilled in the art upon reading the detailed description which follows in conjunction with the drawing.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view of an industrial type, socalled rollup door drivenly connected to the improved door operator unit of the present invention;





FIG. 2

is a front elevation of the door operator unit shown in

FIG. 1

;





FIG. 3

is a side elevation of the door operator unit shown in

FIGS. 1 and 2

;





FIG. 4

is a perspective view, partially cut away, showing the drive mechanism and related elements of the door operator unit;





FIG. 5

is a detail longitudinal central section view of the drive mechanism output ring gear and torque limiting clutch mechanism for the door operator unit;





FIG. 6

is a central longitudinal section view of the differential planetary gear speed reduction mechanism;





FIG. 7

is a section view taken generally from line


7





7


of

FIG. 3

of the release mechanism for the releaseable ring gear;





FIG. 7A

is a detail perspective view of a cover member for the release mechanism housing;





FIG. 8

is a perspective view of certain components of the release mechanism;





FIG. 9

is a transverse section view through the operator unit taken generally along the line


9





9


of

FIG. 3

; and





FIG. 10

is an exploded perspective view of certain components of the door operator unit including the manual drivetrain members.











DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT




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




Referring to

FIG. 1

, there is illustrated conventional upward acting or rollup type door


12


including a closure member


14


guided for movement between opposed vertically extending guide tracks


16


and


18


for closing a door opening


20


. Upward acting door


14


is of a socalled rollup type and comprises a flexible curtain which is adapted to be wound around a cylinder or drum


22


supported for rotation between spaced apart brackets


24


and


26


suitably supported by a vertical wall


28


, as shown. The drum


22


is drivenly connected to an improved door operator unit in accordance with the invention and generally designated by the numeral


30


. The operator unit


30


includes a drive mechanism housing


32


adapted to be supported on the bracket


24


and may be supported in other configurations and on other structures, not shown. A rotatable output shaft


34


is supported for rotation on the housing


32


and supports a conventional drive sprocket


36


for rotation therewith and drivingly connected to a sprocket


38


connected to the drum


22


by way of a conventional endless chain


40


. Shaft


34


is preferably of hexagonal or other polygonal cross section, as shown, to provide for improved drive connectability to components associated therewith.




As shown in

FIGS. 2 and 3

also, the door operator unit


30


includes an auxiliary drive shaft


42


rotatably supported on housing


32


spaced from output shaft


34


and supporting a handwheel


44


comprising a chain sprocket drivably engaged with an endless link chain


46


in a known manner for rotating shaft


42


to raise or lower the door


14


, when required. Normally, in certain applications of the operator unit


30


, the door


14


will lower itself under, certain conditions to be described hereinbelow but may be required to be raised manually by rotating the handwheel


44


via the chain


46


or by direct engagement of the handwheel by a person attempting to raise the door through the operator unit


30


.




Referring further to

FIGS. 2 and 3

, the operator unit


30


includes an electric drive motor


48


,

FIG. 3

, including a housing


49


directly connected to the housing


32


and operable through suitable drive mechanism to be described further herein to drive output shaft


34


in opposite directions of rotation under command of a control system, major components of which are mounted in a control system housing, generally designated by numeral


50


. As further shown in

FIGS. 2 and 3

, housing


32


includes a suitable transverse mounting flange


33


for mounting the operator unit


30


on the bracket


24


, for example, using conventional mechanical fasteners, not shown.




Referring now to

FIG. 4

, the housing


32


includes an endface


35


opposite the flange


33


and defined in part by a flange


52


for securing motor


48


in assembly with the housing


32


using conventional threaded fasteners


52


a, one shown. Motor


48


may be a conventional induction type electric motor including a rotary output shaft


54


adapted to be drivably connected to a coupling member


56


, including a “sun” gear


58


formed thereon. Sun gear


58


is drivingly connected to a differential planetary gear drive mechanism, generally designated by numeral


60


and disposed in a first cavity


31




a


formed in housing


32


and separated from a second cavity


31




b


by a transverse partition and brake mount


32




a


. Drive mechanism


60


includes a first ring gear


62


supported in housing


32


adjacent a second ring gear


64


comprising an output gear of the planetary gear drive mechanism.




Referring to

FIG. 4

, output shaft


34


is disposed in sleeved relationship within a bearing hub


34




a


which is coupled to a suitable sealed bearing


34




b


supported for rotation in a support plate


32




p


releasably connected to the flange


33


by suitable threaded fasteners


32




f


. Moreover, shaft


34


includes a bearing bore


34




c


for receiving an idler shaft


34




d


which extends within a bore


56




c


of coupling/sun gear


56


,


58


to provide support for the coupling/sun gear and to journal the coupling/sun gear against lateral deflection away from its normal axis of rotation.




A commercially available electromagnetic disc type brake assembly


66


is supported within cavity


31




b


of housing


32


by motor housing


49


and includes a stator member


68


axially movable with respect to shaft


54


and coupling member


56


but non rotatable relative to housing


32


. Brake assembly


66


may be of a type manufactured by API-Deltran, of Amherst, NY as their model BRP-30Y. A brake disc member


70


is mounted on coupling member


56


for rotation therewith and is operable to be engaged by an axially movable brake assembly stator member


68


to arrest rotation of coupling


56


and motor drive shaft


54


when the brake assembly


66


is de-energized. When brake assembly


66


is energized, stator member


68


is operable to release forcible engagement with brake disc


70


to allow same to rotate with motor drive shaft


54


and coupling/sun gear


56


,


58


. Brake assembly


66


includes a stationary back plate


67


forming a support for limiting axial movement of the disc


70


and stator


68


and to provide for engaging the disc


70


to provide the braking action. The coupling


56


includes a portion


56




a


having a non-circular outer surface for slidably engaging a corresponding non-circular bore in brake disc


70


to provide for drivingly-connecting the disc


70


to the coupling


56


but allowing some axial sliding movement between the disc


70


and the coupling/sun gear


56


,


58


.




Transverse partition


32




a


, intermediate the flange


33


and the end face


35


, separates the brake assembly


66


from the differential planetary drive mechanism


60


. Cavity


31




a


may be at least partially filled with a suitable lubricant which is prevented from escaping into cavity


31




b


by a disc like dam


31




c


, FIG.


4


. Referring further to FIG.


4


and also

FIG. 6

, the planetary gear drive mechanism


60


includes a first carrier member


72


and a second carrier member


74


releasably connected to the carrier member


72


by conventional threaded fastener


75


, one shown in FIG.


6


. Carrier members


72


and


74


support plural circumferentially spaced apart compound planet gears


78


for rotation on suitable shafts


80


, as shown by way of example in FIG.


6


. An arrangement of three equally-spaced planet gears


78


is preferred. Compound planet gears


78


each include a first set of gear teeth


82


meshed with cooperating internal gear teeth


84


formed on ring gear


62


and a second set of gear teeth


86


adapted to mesh with internal teeth


88


formed on output ring gear


64


, see

FIG. 5

also. Planet gears


78


also mesh with sun gear


58


in driven relationship thereto. Accordingly, a substantial speed-reducing torque multiplying effect is provided by the differential planetary gear drive mechanism


60


for rotating the output shaft


34


at a reduced speed with respect to the input shaft or coupling


56


and the motor output shaft


54


.




As shown in

FIGS. 4 and 5

, output ring gear


64


includes a transverse cylindrical disc-like hub portion


65


and a central bore


65




a


therethrough which is adapted to receive a torque limiting clutch hub


90


therein, which hub is drivingly coupled to output shaft


34


. In this respect, output shaft


34


has a hexagonal crosssection and is drivenly coupled to hub


90


which has a cooperating hexagonal cross section bore


91


formed therein. Clutch hub


90


is also provided with external threads


93


formed thereon for threadedly connecting the hub to a torque limiting clutch adjustment plate


96


having cooperating internal threads


97


,

FIG. 5

, for threaded engagement with the hub


90


.




Referring further to

FIG. 5

, the torque limiting clutch mechanism connected to ring gear


64


includes spaced apart friction discs


99




a


and


99




b


disposed for forcible engagement with opposite faces of transverse hub


65


. Clutch disc


99




a


is also in engagement with a circular flange


90




a


formed on clutch hub


90


. A gear


100


is mounted on clutch hub


90


, is suitably drivenly connected thereto and is engageable with the other clutch disc


99




b


, as shown. One or more Bellville type springs


102


, two shown in

FIG. 5

, are interposed the gear


100


and the adjustment plate


96


to provide a clutch engagement force acting on a circular web portion


100




a


of gear


100


. The clutch discs


99




a


and


99




b


, the flange


90




a


, the hub


65


and web


100




a


to form a torque limiting clutch assembly. Adjustment plate


96


includes a radially extending threaded bore


96




a


formed therein, as shown in

FIG. 5

, and in which is disposed a setscrew


96




b


having a suitable drive tang


96




d


formed thereon.




If driving torque imposed on ring gear


64


exceeds a limit set by the torque limiting clutch described, the ring gear


64


will slip with respect to the hub


90


, rotationally, to prevent damage to the operator unit


30


as well as other structural components including the drive mechanism between the operator unit and the door closure member


14


and any object which may be caught between the door closure member and the floor of the door opening. However, since limit switch gear


100


is keyed for rotation with clutch hub


90


, and clutch hub


90


is positively engaged with shaft


34


, any slippage of the aforementioned clutch will not result in a loss of timing between a limit switch operably connected to the gear


100


and the position of a door driven by the operator unit


30


. By way of example, as shown in

FIG. 5

, gear


100


is meshed with a pinion


103


which is operably connected to a suitable door position limit switch


105


of a type commercially available from Sanwa Corporation, as Hokuyo model LMP-2, for example.




Referring again to

FIG. 6

, each of the planet gears


78


is meshed with the sun gear


58


at a respective sets of gear teeth


86


on the planet gears. As previously described, in like manner, the gear teeth


82


of the planet gears


78


are meshed with the teeth


84


of the ring gear


62


. As further shown in

FIG. 6

, ring gear


62


has a set of circumferential external teeth


62




a


formed thereon which are adapted to mesh with a ring gear release block


108


,

FIGS. 4 and 7

, having cooperating teeth


110


formed thereon,

FIG. 7

, engagable with teeth


62




a


to prevent rotation of the ring gear


62


with respect to the housing


32


. In this way, when ring gear


62


is held stationary with respect to housing


32


, rotation of motor shaft


54


and coupling/sun gear


56


,


58


will effect rotation of ring gear


64


and output shaft


34


at a pre-determined reduced speed with respect to shaft


54


.




Accordingly, with brake assembly


66


applied to prevent rotation of motor output shaft


54


, operator unit output shaft


34


is also braked against rotation when ring gear


62


is held stationary with respect to housing


32


. However, ring gear release block


108


is operable to move out of engagement with ring gear


62


to allow same to rotate freely. Under these conditions, output shaft


34


, ring gear


64


and planet gears


78


will rotate together with ring gear


62


even though shaft


54


and coupling/sun gear


56


,


58


are held stationary by the brake assembly


66


.




Referring further to

FIG. 4

, ring gear release block


108


is supported in a removable housing


112


secured to the housing


32


by spaced apart fasteners


114


, one shown. An elongated lever


116


is pivotally connected to the housing


112


by pivot pin


116




a


and is engageable with an adapter member


117


for moving the release block


108


radially away from engagement with the ring gear


62


. A lever actuated switch


120


,

FIG. 4

, includes a lever actuator


122


engagable with a tang


108




b


formed on the release block


108


.




Referring now to

FIGS. 7

,


7


A and


8


, the ring gear release mechanism further includes spaced-apart coil springs


124


disposed in suitable bores


112




c


formed in housing


112


,

FIG. 7

, and engagable with opposed shoulder portions


108




s


of the release block


108


, as shown. Release block adapter member


117


includes a yoke portion


117




y


and a pin


117




p


for engagement by lever


116


. Release block adapter


117


is also secured to a hub portion


108




h


for moving the release block


108


against the bias of the springs


124


.




A removable housing cover


112




d


is releasably connected to the housing


112


by suitable threaded fasteners


112




t


. As shown in

FIG. 7A

, housing cover


112




d


includes a plurality of circumferentially spaced, axially projecting and axially sloped teeth


128


formed thereon, spaced about a bore


130


formed in the housing cover and adapted to receive a generally cylindrical axially-extending shank portion


117




s


of the adapter


117


. Shank


117




s


also projects into a bore


112




g


formed in housing


112


, FIG.


7


. An indexing hub


132


,

FIGS. 7 and 8

, is journaled on a reduced diameter portion of shank


117




s


between hub


108




h


and a shoulder


117




r


of shank


117




s


,

FIG. 7

, and is provided with plural circumferentially spaced indexing cams


134


formed thereon, as shown in FIG.


8


.




Cams


134


are operable to engage a member


136


disposed in bore


112




g


, suitably supported by housing


32


, and provided with respective sets of cam receiving slots


137


and


139


circumferentially-spaced about a central bore


140


formed in the member


136


. Slots


137


and


139


are engagable with the cams


134


to hold the release adapter


117


and release block


108


in selected positions in and out of engagement with the ring gear


62


, respectively. In other words, when release block


108


is engaged with ring gear


62


cams


134


are disposed in the slots


137


thereby allowing the block


108


to move axially downward viewing

FIG. 7

, into engagement with the ring gear.




However, in response to actuation of lever


116


to move adapter


117


and block


108


against the bias of springs


124


, upwardly, viewing

FIG. 7

, the cams


134


engage the teeth


128


and rotatably index the hub


132


into a position such that, when the lever


116


is released and the springs


124


bias the block


108


toward the ring gear


62


, the cams


134


register in slots


139


thereby holding the block


108


out of engagement with the ring gear. Upon further actuation of the lever


116


to move the block


108


upwardly, viewing

FIG. 7

, the cams


134


again engage the teeth


128


and, due to the axially-sloping sides


128




a


of the teeth


128


, the hub


132


is rotatably indexed to a position such that the cams


134


will register in slots


137


upon release of the actuator handle


116


, thereby allowing the block


108


to re-engage the ring gear


62


to hold same stationary with respect to the housing


32


. Accordingly, beginning with the condition wherein the block


108


is engaged with ring gear


62


, a first actuation of the handle


116


will effect disengagement of the block


108


from the ring gear


62


and a holding of the block in the disengaged position. Upon a second actuation of the handle


116


and release thereof, the block


108


will re-engage the ring gear


62


holding same against rotation with respect to housing


32


.




Under circumstances wherein the brake assembly


66


remains engaged to prevent rotation of shaft


34


, coupling/sun gear


56


,


58


and the output shaft


34


, the output shaft may be allowed to rotate together with all of the elements of the differential planetary gear drive mechanism, except the sun gear


58


, on actuation of the release block


108


to disengage from the ring gear


62


. This disengagement of the release block


108


from the ring gear


62


may take place manually upon manual actuation of the handle or lever


116


or in response to a control signal applied to an actuator, not shown, suitably connected to the lever. Switch


120


may, of course, be associated with a suitable control system for the operator


30


to maintain a count of the number of actuations of the lever


116


and to indicate the condition of the operator, that is, whether or not the ring gear


62


has been released and allowed to rotate or not.




Referring now to

FIG. 9

, the section view of this drawing figure taken through the housing


32


shows opposed mounting flanges


32




j


and


32




k


which are substantially identical and define openings


32




m


and


32




n


adjacent to ring gear


62


. In the configuration of

FIG. 9

, as shown, release block


108


is disposed in cavity


32




m


and housing


112


is secured to the flange


32




j


. The release block


108


and the housing


112


may, however, be disposed in cavity


32




n


and supported on flange


32




k


to provide for reversing the arrangement of the release block and its support structure. More importantly perhaps, one reason for providing the housing


32


with the opposed flanges


32




j


and


32




k


is to provide for arranging the manual or auxiliary drive shaft


42


supported on either side of the housing


32


. In the arrangement shown in

FIGS. 9 and 10

, shaft


42


is supported in a bore


33




h


by a suitable bearing


42




b


. However, shaft


42


and bearing


42




b


may also be disposed in a bore


33




j


for the arrangement wherein manual operation of the operator unit


30


is carried out by placement of the shaft


42


on the opposite side of housing


32


.




Referring further to

FIGS. 9 and 10

, the manual or auxiliary powered operating mechanism for raising and/or lowering a door connected to the operator unit


30


, includes shaft


42


which is also supported by a two-part housing, including housing members


142


and


144


, FIG.


10


. Housing members


142


and


144


are adapted to be mounted on the flange


32




k


or


32




j


, depending on which side of the housing


32


the shaft


42


is to be disposed. Shaft


42


is also operably connected to a viscous governor unit


146


of a type commercially available and which is also supported by the housing


144


and operable to retard the rotational speed of the shaft


42


if the ring gear


62


is released to rotate under a force imposed on the shaft


34


due to the weight of a rollup door, for example.




Shaft


42


is operably connected to ring gear


62


by a drive gear


148


adapted to be mounted on shaft


42


and suitably connected thereto for rotation therewith by a key


150


. Gear


148


is operable to mesh with an idler gear


152


adapted to be supported on a shaft


154


which may be disposed in a suitable recess


32




s


in cavity


32




m


,

FIG. 10

or, as shown in

FIG. 9

, in a recess


32




t


in cavity


32




n


. Ring gear


62


is adapted to have its teeth


62




a


continually meshed with the teeth of idler gear


152


and idler gear


152


is also meshed with gear


148


drivenly connected to shaft


42


. Accordingly, under circumstances wherein a rollup type door, such as the door


14


, for example, is in an open position and ring gear


62


is released to allow rotation of shaft


34


. Shaft


42


will also be rotated through a drive train comprising the ring gear


62


, idler gear


152


and gear


148


mounted for rotation with shaft


42


. Downward or closing movement of the door


14


will be retarded by the viscous governor


146


.




When it is desired to open the door


14


manually, handwheel


44


is rotated directly, or through endless chain


46


to effect rotation of shaft


34


and the drive mechanism connecting shaft


34


with the door


14


, as long as ring gear


62


is disengaged from release block


108


. As mentioned previously, the location of the manual or auxiliary drive mechanism comprising the shaft


42


, viscous governor


146


, housing members


142


and


144


, gears


148


and


152


and support shaft


154


may all be located on the opposite side of housing


32


and the location of the release block


108


and its actuating mechanism may also be located on the side opposite from that shown in the exemplary arrangement according to drawing

FIGS. 9 and 10

, in particular.




The operation of the door operator unit


30


will now be described. Utilizing a suitable control system, not shown in

FIGS. 1-10

, the motor


48


may be energized substantially simultaneously with energizing the brake


66


to release braking action on disc


70


, so that motor shaft


54


may be rotated in one direction or the other, depending on the operation desired. For example, the motor output shaft


54


, if operated to effect raising the door


14


, would be rotated in one direction while releasing brake


66


and, with ring gear


62


engaged with release block


108


, a reduced speed of output shaft


34


would be obtained to drive sprocket


44


and door drum


22


to raise the door.




With the rotation of output shaft


34


and ring gear


64


, limit switch gear


100


also rotates pinion


103


to effect operation of the limit switch


105


which, upon reaching a pre-determined limit count, is operable to effect shutoff of motor


48


by way of a suitable control system, not shown. Upon shutoff of motor


48


, brake assembly


66


is deenergized and engaged to lock brake disc


70


and shaft


54


as well as coupling/sun gear


56


,


58


against rotation and, with ring gear


62


engaged with release block


108


, shaft


34


is also arrested and locked against rotation. In the event that door


14


should jam, either during opening or closing movement thereof or an overload condition exists, shaft


34


might be arrested or severely retarded in motion. However, to avoid damage to the drive mechanism of the operator unit


30


, ring gear


64


and the differential planetary drive mechanism associated therewith may be allowed to continue to rotate at least briefly, by slipping the clutch formed by the hub


90


, the clutch discs


99




a


and


99




b


and the ring gear hub


65


.




If the torque limit on the clutch is to be adjusted at any time, setscrew


96




b


may be accessed by a suitable socket head wrench, for example, engageable with drive tang


96




d


,

FIG. 5

, through a suitable hole


32




o


,

FIG. 10

, to back the setscrew radially outwardly into engagement with the housing


32


at the hole


32




o


whereupon shaft


34


may be manually rotated in one direction or the other, together with hub


90


, while adjustment plate


96


is held stationary to adjust the biasing force of the springs


102


. Rotation of the shaft


34


and the hub


90


will occur with respect to the adjustment plate


96


which is being held against rotation by the setscrew


96




b


being disposed in the hole


32




o.






Once a suitable adjustment has been accomplished, screw


96




b


is re-tightened in engagement with the hub


90


and is moved out of engagement with the housing


32


at the hole


32




o


so that normal operation of the unit


30


may resume. The torque limiting clutch described and shown primarily in

FIG. 5

is a preferred feature for the operator unit


30


but the operator unit may be configured such that the hub


90


is integral with or fixed for rotation with the gear


64


and the torque limiting clutch eliminated in certain applications of the operator unit, if desired.




When, for example, the door


14


is in an open position and it is desired to manually close the door either under its own weight or through operation of the manual or auxiliary opening and closing drive mechanism of the operator unit


30


, the lever


116


may be actuated to move the release block


108


out of engagement with the ring gear


62


. Actuation of the lever


116


to move the block


108


out of engagement with the ring gear


62


will effect holding the ring gear in the disconnected position thanks to the release mechanism described above and illustrated in

FIGS. 7

,


7


A and


8


, in particular. With the ring gear


62


free to rotate, any torque on the shaft


34


sufficient to overcome friction in the operator unit


30


, which is minimal, will allow shaft


34


to rotate since the planetary drive mechanism


60


will be allowed to rotate with respect to the sun gear


58


.




If the weight of door


14


is sufficient to drive the shaft


34


and differential planetary drive mechanism


60


the speed of closing of the door may be controlled by the viscous governor


146


, since this governor is being driven with rotation of the ring gear


62


, idler gear


152


and drive shaft gear


148


, as well as auxiliary drive shaft


42


, during closing motion of the door


14


. The handwheel drive or auxiliary shaft


42


may, of course, be manually rotated in either direction via the hand wheel sprocket


44


and endless chain


46


, or via an alternate power source, not shown, to either open or close the door


14


.




A second actuation of lever


116


will effect disengagement of the hub


132


from the short depth slots


139


in the member


136


and allow the release block


108


to reengage with ring gear


62


so that shaft


34


may not turn independent of rotation of the coupler/sun gear


56


,


58


which, if braked by the brake assembly


16


, will prevent any rotation of output shaft


34


.




Those skilled in the art will recognize that the operator unit


30


may be adapted to operate with various types of doors which are either upward acting or horizontally moving, for example. Sectional doors as well as rollup type doors may be controlled by the operator unit


30


. By providing the arrangement of the differential planetary drive mechanism


60


, the brake assembly


66


, the release mechanism provided by the release block


108


and the torque limiting clutch, described and shown herein, an improved door operator unit has been realized. The operator unit


30


may be constructed using conventional engineering materials and components known to those skilled in the art. Certain commercially available components have been described hereinabove by way of example only.




Still further, although a preferred embodiment has been described in detail, those skilled in the art will recognize that various substitutions and modifications may be made without departing from the scope and spirit of the appended claims.



Claims
  • 1. An apparatus comprising a motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and operably connected to said motor output shaft and to an operator output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation, said gear drive mechanism including a sun gear and at least one planet gear operably engaged with said sun gear and with a ring gear; an adjustable torque limiting clutch disposed between said ring gear and said operator unit output shaft and including means for adjusting a limit torque transferred between said operator unit output shaft and said gear drive mechanism; a brake assembly operably connected to said motor output shaft and said drive mechanism for braking rotation of said motor output shaft and said operator unit output shaft; and a release member operably connected to said ring gear and operable in a first position to lock said operator unit output shaft against rotation when said brake assembly is engaged, said release member being movable to a second position to allow rotation of said operator unit output shaft independent of said motor output shaft.
  • 2. The apparatus set forth in claim 1 wherein:said brake assembly comprises an electromagnetic brake unit including a brake member operably connected to said motor output shaft, said brake member being free to rotate with said motor output shaft in response to energizing said brake assembly.
  • 3. The apparatus set forth in claim 2 wherein:said brake assembly is disposed between said motor output shaft and said gear drive mechanism and is operable to lock said motor output shaft against rotation with respect to said housing.
  • 4. The apparatus set forth in claim 1 including:a limit switch gear operably connected to said operator unit output shaft and rotatable therewith.
  • 5. An apparatus comprising a motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and connected to said motor output shaft and to an operator output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation, said gear drive mechanism comprises a differential planetary gear drive including at least one planet gear operably engaged with a sun gear and with a first ring gear, said first ring gear being operable to be non-rotatable with respect to said housing and a second ring gear engageable with said planet gear and rotatable with respect to said housing and operably coupled to said operator unit output shaft; and a release member operably engaged with said first ring gear to prevent rotation of said first ring gear and said operator unit output shaft when said motor is deenergized, said release member being operable to disengage from said first ring gear to allow rotation of said first ring gear and said operator unit output shaft.
  • 6. The apparatus set forth in claim 5 wherein:said release member is engageable with a release member position control mechanism including means for holding said release member in a position disengaged from said first ring gear in response to a first actuation of said release member and said release member being operable to reengage with said first ring gear in response to a second actuation of said release member.
  • 7. The apparatus set forth in claim 6 wherein:said means for holding said release member disengaged from said first ring gear comprises a cam member operably connected to said release member and including cam means thereon engageable with camming teeth on said apparatus for rotatably indexing said cam member so that said cam member may engage cooperating means on said apparatus to hold said release member disengaged from said first ring gear and to permit reengagement of said release member with said first ring gear.
  • 8. The apparatus set forth in claim 5 wherein:said first ring gear is engaged with an auxiliary drive shaft for manual rotation of said operator unit output shaft in at least one direction when said release member is disengaged from said first ring gear.
  • 9. The apparatus set forth in claim 8 wherein:said drive shaft includes a governor operably connected thereto for limiting the rotational speed of said operator unit output shaft when said first ring gear is released from engagement with said release member.
  • 10. The apparatus set forth in claim 8 wherein:said housing includes support means for supporting said release member and said auxiliary drive shaft thereon in selected positions of each and said housing is adapted to reverse the positions of said release member and said auxiliary drive shaft.
  • 11. The apparatus set forth in claim 5 including:a torque limiting clutch disposed between said drive mechanism and said operator unit output shaft for limiting torque imposed on said drive mechanism.
  • 12. The apparatus set forth in claim 11 wherein:said torque limiting clutch includes a first hub operably connected to said operator unit output shaft, a second hub operably connected to said drive mechanism, clutch plate means interposed said hubs, spring means operably engaged with said hubs and said clutch plate means for forcibly engaging said hubs with said clutch plate means and an adjustment member for adjusting the bias force of said spring means.
  • 13. A motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and connected to said motor output shaft and including an output gear drivably connected to an operator unit output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation; a brake assembly disposed between said drive motor and said drive mechanism and operably connected to said motor output shaft for braking rotation of said motor output shaft and said operator unit output shaft, said brake assembly including an electromagnetic brake unit including a brake member operably connected to said motor output shaft, said brake member being free to rotate with said motor output shaft in response to energizing said brake assembly; a release member operably connected to said gear drive mechanism and operable in a first position to lock said operator unit output shaft against rotation when said brake assembly is engaged, said release member being movable to a second position to allow rotation of said operator unit output shaft independent of said motor output shaft; an adjustable torque limiting clutch disposed between said output gear and said operator unit output shaft for limiting torque imposed on said drive mechanism.
  • 14. An apparatus comprising a motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and operably connected to said motor output shaft and to an operator output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation; a brake assembly operably connected to and disposed between said motor output shaft and said drive mechanism for braking rotation of said motor output shaft and said operator unit output shaft, said brake assembly comprising an electromagnetic brake unit including a brake member operably connected to said motor output shaft, said brake member being free to rotate with said motor output shaft in response to energizing said brake unit, said brake assembly being operable to lock a coupler between said gear drive mechanism and said motor output shaft against rotation with respect to said housing, said coupler including a sun gear, said gear drive mechanism comprising a differential planetary gear drive mechanism including at least one planet gear operably engaged with said sun gear and with a first ring gear, said first ring gear being engageable with said at least one planet gear and operable to be non-rotatable with respect to said housing, and a second ring gear engageable with said at least one planet gear and rotatable with respect to said housing and operably coupled to said operator unit output shaft; and a release member operably connected to said gear drive mechanism and operable in a first position to lock said operator unit output shaft against rotation when said brake assembly is engaged, said release member being movable to a second position to allow rotation of said operator unit output shaft independent of said motor output shaft.
  • 15. The apparatus set forth in claim 14 wherein:said release member is operably engaged with said first ring gear to prevent rotation of said first ring gear and said operator unit output shaft when said brake assembly is engaged, said release member being operable to disengage from said first ring gear to allow rotation of said first ring gear and said operator unit output shaft.
  • 16. The apparatus set forth in claim 15 wherein:said release member is engageable with a release member position control mechanism operable for holding said release member in a position disengaged from said first ring gear in response to a first actuation of said release member and said release member being operable to reengage with said first ring gear in response to a second actuation of said release member.
  • 17. The apparatus set forth in claim 16 wherein:said position control mechanism comprises a cam member operably connected to said release member and including cam means thereon engagable with camming teeth on said apparatus for rotatably indexing said cam member so that said cam member may engage cooperating means on said apparatus to hold said release member disengaged from said first ring gear and to permit reengagement of said release member with said first ring gear.
  • 18. The apparatus set forth in claim 15 wherein:said first ring gear is engaged with an auxiliary drive shaft for manual rotation of said operator unit output shaft in at least one direction when said release member is disengaged from said first ring gear.
  • 19. The apparatus set forth in claim 18 wherein:said auxiliary drive shaft includes a governor operably connected thereto for limiting the rotational speed of said operator unit output shaft when said first ring gear is released from engagement with said release member.
  • 20. The apparatus set forth in claim 19 wherein:said housing includes support means for supporting said release member and said auxiliary drive shaft thereon in selected positions of each and said housing is adapted to reverse the positions of said release member and said auxiliary drive shaft.
  • 21. An apparatus comprising a motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and operably connected to said motor output shaft and to an operator output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation; a brake assembly operably connected to said motor output shaft and said drive mechanism for braking rotation of said motor output shaft and said operator unit output shaft; a release member operably connected to said gear drive mechanism and operable in a first position to lock said operator unit output shaft against rotation when said brake assembly is engaged, said release member being movable to a second position to allow rotation of said operator unit output shaft independent of said motor output shaft; and a torque limiting clutch disposed between said drive mechanism and said operator unit output shaft for limiting torque imposed on said drive mechanism, said torque limiting clutch including a first hub operably connected to said operator unit output shaft, a second hub operably connected to said drive mechanism, clutch plate means disposed between said hubs, spring means operably engaged with said hubs and said clutch plate means for forcibly engaging said hubs with said clutch plate means and an adjustment member for adjusting the bias force of said spring means.
  • 22. The apparatus set forth in claim 21 including:a locking mechanism operably connected to said adjustment member and operable to lock said adjustment member in a predetermined position thereof for generating a predetermined bias force by said spring means.
  • 23. The apparatus set forth in claim 22 wherein:said adjustment member is threadedly engaged with said first hub and operable to be in a selected position with respect to said first hub for providing a predetermined bias force imposed on said torque limiting clutch by said spring means.
  • 24. A motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and connected to said motor output shaft and to an operator unit output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation; a brake assembly interposed said drive motor and said drive mechanism and operably connected to said motor output shaft for braking rotation of said motor output shaft and said operator unit output shaft, said brake assembly including an electromagnetic brake unit including a brake member operably connected to said motor output shaft, said brake member being free to rotate with said motor output shaft in response to energizing said brake assembly; a release member operably connected to said gear drive mechanism and operable in a first position to lock said operator unit output shaft against rotation when said brake assembly is engaged, said release member being movable to a second position to allow rotation of said operator unit output shaft independent of said motor output shafts; and a torque limiting clutch disposed between said drive mechanism and said operator unit output shaft for limiting torque imposed on said drive mechanism, said torque limiting clutch including a first hub operably connected to said operator unit output shaft, a second hub operably connected to said drive mechanism, clutch plate means interposed said hubs, spring means operably engaged with said hubs and said clutch plate means for forcibly engaging said hubs with said clutch plate means and an adjustment member for adjusting the bias force of said spring means.
  • 25. A motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and connected to said motor output shaft and to an operator unit output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation; a brake assembly interposed said drive motor and said drive mechanism and operably connected to said motor output shaft for braking rotation of said motor output shaft and said operator unit output shaft, said brake assembly including an electromagnetic brake unit including a brake member operably connected to said motor output shaft, said brake member being free to rotate with said motor output shaft in response to energizing said brake assembly; a release member operably connected to said gear drive mechanism and operable in a first position to lock said operator unit output shaft against rotation when said brake assembly is engaged, said release member being movable to a second position to allow rotation of said operator unit output shaft independent of said motor output shaft, said release member being engageable with a release member position control mechanism including means for holding said release member in a position disengaged from a member of said drive mechanism in response to a first actuation of said release member and said release member being operable to reengage with said member of said drive mechanism in response to a second actuation of said release member; and a torque limiting clutch disposed between said drive mechanism and said operator unit output shaft for limiting torque imposed on said drive mechanism.
  • 26. The apparatus set forth in claim wherein:said means for holding said release member disengaged comprises a cam member operably connected to said release member and including cam means thereon engageable with camming teeth on said apparatus for rotatably indexing said cam member so that said cam member may engage cooperating means on said apparatus to hold said release member disengaged and to permit reengagement of said release member with said member of said drive mechanism.
  • 27. An apparatus comprising a motor driven door operator unit for moving a door between open and closed positions, said operator unit comprising:a drive motor including a motor output shaft; a speed reduction drive mechanism including a housing, a gear drive mechanism supported in said housing and operably connected to said motor output shaft and to an operator output shaft, said drive motor being operable to drive said operator unit output shaft at a reduced speed in opposite directions of rotation, said gear drive mechanism comprising a planetary gear drive including at least one planet gear operably engaged with a sun gear and with a ring gear, said ring gear being operable to be non-rotatable with respect to said housing, a release member operably connected to said gear drive mechanism and operable in a first position to lock said ring gear against rotation, said release member being movable to a second position to allow rotation of said ring gear and said operator unit output shaft; and an auxiliary drive shaft operably connected to said ring gear and drivably connected to said operator unit output shaft through said ring gear when said release member is in said second position.
  • 28. The apparatus set forth in claim 27 including:a governor operably connected to said auxiliary drive shaft for limiting the rotational speed of said operator unit output shaft when said release member is in said second position.
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