Patent Grant
11578525
The present disclosure relates generally to movable barrier opener systems for opening and closing garage doors, gates, and other movable barriers, in particular to movable barrier opener systems including jackshaft or hoist operators.
Movable barriers, such as upward-acting sectional or single panel garage doors, residential and commercial rollup doors, and slidable and swingable gates, are used to alternatively allow and restrict entry to building structures and property. These barriers are driven between their respective open and closed positions by motors or other motion-imparting mechanisms, which are themselves controlled by barrier moving units, sometimes referred to as “movable barrier operators,” and in the specific case of a door, as “door operators,” and in the even more specific case of a garage door, as “garage door operators.” Garage door operators are effective to cause the DC or AC motor, and accompanying motor drive assembly, to move the associated garage door, typically between its open and closed positions.
Garage door operators and movable barriers create noise during normal operation. For example, the movement of the mechanical portions of the operator and the movable barrier create noise as the barrier moves. Moreover, noise can come from other different parts of the system. For example, the motor drive assembly generally includes steel frame members to which the motor is directly mounted. Generally, the motor of an operator creates vibrations during operation. These vibrations can be magnified by the steel frame members of the drive assembly thereby creating more noise.
Additionally, the operator motor can be attached to drive a belt or chain drive on one side of the motor drive assembly. Driving the belt or chain drive can create a radial load on the motor of the operator. This radial loading can create a force that pulls the rotor off center, creating more vibrations, and increasing the overall the noise level. Furthermore, different components, such as for example, an electrical box, may be mounted to the motor drive assembly. The additional components can amplify the vibrations of the motor and motor drive assembly. Other mechanical interfaces, such as hardware used to disengage the operator for manual operation, can provide additional sources of vibration and noise.
This disclosure is directed to a reduced noise and vibration door operator that addresses these and other shortcomings of conventional systems.
In an example aspect, the present disclosure is directed to an operator having a structural arrangement that may produce less vibration than conventional operators, thereby reducing overall operating noise from the operator. In some example implementations, the operator may include an electric box mounted to a chassis with the chassis including a motor, a drive belt, and drive chain operable to open and close a movable barrier, such as, for example, a garage door.
In an aspect, an operator chassis may include a motor mounted to a metal frame through bearings that are seated within the metal frame. In aspect, the motor may include a double ended shaft, each shaft end being mounted to opposing sides of the metal frame. In an aspect, a belt pulley may be installed over one of the motor shafts, operable to drive a belt and operable to resist axial movements from the motor. In an aspect, vibration dampening washers may be installed between the belt pulley and the bearing. In an aspect, a set collar may be installed over the other motor shaft, operable to resist axial movement from the motor. In an aspect, vibration dampening washers may be installed between the set collar and the bearing. In an aspect, a stud may be installed on the motor and inserted in a slot in the metal frame, the stud being operable to resist rotation of the motor within the frame. In an aspect, the belt pulley may drive a tensioned belt connected around the belt pulley and a transfer belt pulley. In an aspect, the load of the tensioned belt may be supported by the metal frame through the bearings installed over the motor shaft, thereby reducing a radial load on the motor caused by the tensioned belt.
It is to be understood that both the foregoing general description and the following drawings and detailed description are exemplary and explanatory in nature and are intended to provide an understanding of the present disclosure without limiting the scope of the present disclosure. In that regard, additional aspects, features, and advantages of the present disclosure will be apparent to one skilled in the art from the following. One or more features of any embodiment or aspect may be combinable with one or more features of other embodiment or aspect.
The accompanying drawings illustrate implementations of the systems, devices, and methods disclosed herein and together with the description, explain the principles of the present disclosure.
These Figures will be better understood by reference to the following Detailed Description.
For promoting an understanding of the principles of the present disclosure, reference will now be made to the implementations illustrated in the drawings and specific language will be used to describe them. It will nevertheless be understood that no limitation of the scope of the disclosure is intended. Any alterations and further modifications to the described devices, instruments, methods, and any further application of the principles of the present disclosure are fully contemplated as would normally occur to one skilled in the art to which the disclosure relates. In addition, this disclosure describes some elements or features in detail with respect to one or more implementations or Figures, when those same elements or features appear in subsequent Figures, without such a high level of detail. It is fully contemplated that the features, components, and/or steps described with respect to one or more implementations or Figures may be combined with the features, components, and/or steps described with respect to other implementations or Figures of the present disclosure. For simplicity, in some instances the same or similar reference numbers are used throughout the drawings to refer to the same or like parts.
With initial reference to
The chassis 104 encloses a jackshaft motor assembly. The electric box 105 encloses a door control module and an operator control module. The jackshaft motor assembly includes, among other components, (i) a motor adapted to move the garage door in the conventional manner known by one of ordinary skill in the industry, and (ii) an absolute position sensor that monitors or measures rotation of the output shaft of the motor and communicates signals based on the measurements indicative of, the extent and direction of rotation of the rotatable output shaft of the motor, and therefore indicative of the extent and direction of travel of the garage door 106 between travel limits.
As best seen in
The jackshaft operator 102 is installed adjacent a garage door 106 and operable to open and close the garage door. The chassis 104 of the operator 102 is shown adjacent the motor drive assembly 110 which may include a torsion tube 112 and one or more cable drums 114 rigidly affixed to the torsion tube 112. These may be rotatably driven by the operator 102. One or more cables 116 may be wound about the cable drums 114 and have their free ends 118 attached at or adjacent a bottom edge 120 of the door 106. In some embodiments, the torsion tube 112 forms a part of or is coaxial with the motor shaft of the operator 102. In other embodiments, the torsion tube 112 may be laterally offset from the motor shaft of the operator 102 and use a chain and sprockets to couple the operator 102 to the torsion tube 112. Rotation of the output shaft of the operator 102 rotates the torsion tube 112 and the cable drums 114. Rotation in a direction to wind the cable around the cable drums 114 results in the door 106 being raised to the open position.
In this embodiment, the torsion tube 112 of the motor drive assembly 110 extends horizontally and is directly coupled to, and adapted to be rotatably driven by, the operator 102 in either a clockwise or counterclockwise direction. A torsion spring 122 extends around the torsion tube 112.
When the operator 102 is instructed by a controller to open the garage door 106, the torsion tube 112 and the connected cable drums 114 are rotated by the operator 102 in a direction so as to wind the cable(s) 116 onto the cable drum(s) 114, thereby lifting the garage door 106 to its open position. When the operator 102 is instructed by the controller to close the door 106, the torsion tube 112 and connected cable drums 114 are rotated by the operator 102 in the opposite direction so that cable(s) 116 may be payed out, thereby permitting the door 106 to be closed. The torsion spring 122 provides a counterbalance to aid in the door 106 being moved to its closed position.
With reference to
A belt transfer pulley 318 is coupled to the belt transfer shaft 310 with a belt 320 that is wrapped around the belt transfer pulley 318 and the motor belt pulley 314. A belt transfer shaft sprocket is coupled to the belt transfer shaft 310 between the sidewalls 302 of the chassis. A jackshaft sprocket 322 is coupled to the output shaft 312 between the sidewalls 302 of the chassis and a chain 324 is wrapped around the jackshaft sprocket 322 and the belt transfer shaft sprocket. As the motor 306 rotates the motor shafts 308, the belt 320 rotates the belt transfer shaft 310 which in turn causes the chain 324 to rotate the output shaft 312. The output shaft 312 being coupled to the torsion tube 112 for operating the garage door 106.
According to some embodiments, belt 320 may be a self-tensioning belt having a loaded tension of up to 100 lbs. In some embodiments, the tension on belt 320 may be between about 60 lbs. and about 100 lbs. Other tension amounts, both higher and lower are contemplated. As will be discussed in more detail below, the load of the belt 320 is carried by side plates 302 instead of the motor shaft 308. In this way, vibrations from the motor 306 caused by a radial load of the belt 320 are reduced. Furthermore, this configuration reduces contact points between the motor 306 and side plates 302. This reduction in vibration and contact points may produce less noise that may result in a quieter system as compared to previous designs.
According to the illustrated embodiment, motor shaft 308a is secured to the side panel 302 by a bearing 602, a washer 604, a washer 606, and motor belt pulley 314 while motor shaft 308b is secured to side panel 302 by a bearing 602, a washer 608, and a set collar 610. In this way, the motor 306 is coupled to the side panels 302 using bearings 602. The bearing 602 fits inside an opening 612 formed in the side panel 302 on each side of the motor 306. In some embodiments, a flange on the outer surface of bearing 602 may provide tension holding side panels 302 in alignment and may prevent bearing 602 from sliding through opening 612. An opening in the bearings 602 allows the bearings 602 to fit over the motor shaft 308a, 308b when bearing 602 is seated in opening 612. In some embodiments, the motor shafts 308a, 308b each include a diameter change as a step 614 that provides clearance between bearing 602 and motor 306. In some embodiments, the larger diameter portion between the motor 306 and the step 614 may extend from the body of motor 306 and along the motor shaft 308a, 308a and have a length between about 20 millimeters and about 30 millimeters. In some embodiments, the step 614 prevents the motor 306 from contacting side panels 302 and allows the motor 306 to self-center between side panels 302. That is, the step 614 may abut against the bearings 602 that fit within the openings 612 to thereby maintain the motor 306 central between the side panels 302. In some embodiments, step 614 saves time during assembly of the jackshaft operator 300 allowing motor 306 to self-center and therefore lowers assembly costs. In some embodiments, step 614 is not present.
Mounting the motor 306 on the side of motor shaft 308b is accomplished by placing the washer 608 over motor shaft 308b adjacent to bearing 602 so that bearing 602 is between washer 608 and the motor 306. In some embodiments, washer 608 may be made of a strong, lightweight material that is resistant to friction. In some embodiments, washer 608 may be a nylon washer. Set collar 610 is disposed over motor shaft 308b adjacent to washer 608 such that washer 608 is between bearing 602 and set collar 610 and washer 608 and prevents contact between bearing 602 and set collar 610. In some embodiments, set collar 610 may include a hole to insert a set screw to hold set collar 610 in place on motor shaft 308b. The set screw may be inserted into the hole and tightened until it presses against the motor shaft 308b thereby holding set collar 610 in place. In some embodiments, the set screw may tighten against any portion of the motor shaft 308b. In some embodiments, motor shaft 308b may include a feature specifically designed to receive the set screw, such as for example a groove or a flat surface.
Mounting the motor 306 on the side of motor shaft 308a is accomplished by placing the washer 604 over motor shaft 308a adjacent to bearing 602 so that bearing 602 is between washer 604 and the motor 306. In some embodiments, washer 604 may be a washer that is designed to be located between a rotating surface and a stationary component and support the axial load to prevent movement along a shaft. In some embodiments, washer 604 may be designed to be used in high-wear application. In some embodiments, washer 604 may be a thrust washer. Next, washer 606 is placed over motor shaft 308a adjacent to washer 604 so that washer 604 is between washer 606 and bearing 602. In some embodiments, washer 606 may be designed to cushion joints and dampen vibrations. In some embodiments, washer 606 may be wool felt washers. Following washer 606, motor belt pulley 314 is placed over motor shaft 308a adjacent to washer 606 so that washer 606 is between washer 604 and motor belt pulley 314 such that washers 604, 606 prevent contact between motor belt pulley 314 and bearing 602. In this implementation, the motor belt pulley 314 serves a dual role, first, as a pulley for driving belt 320 and, second, as a set collar for motor shaft 308a. In some embodiments, motor belt pulley 314 may include holes 616 to insert a set screw to hold motor belt pulley 314 in place on motor shaft 308a. The set screw may be inserted into hole 616 and tightened until it pressed against the motor shaft 308a thereby holding motor belt pulley 314 in place. In some embodiments, the set screw may tighten against any portion of the motor shaft 308a. In some embodiments, motor shaft 308a may include a feature specifically designed to receive the set screw, such as for example a groove or a flat surface.
The anti-rotation stud 326 may be coupled to and extend from the housing of motor 306. In the illustrated embodiment, the anti-rotation stud 326 is disposed below the motor shaft 308a and extends in a direction parallel to the motor shafts 308a, 308b. It is contemplated that in some embodiments, the anti-rotation stud 326 may be disposed in a different location, such as above or to the side of either of the motor shafts 308a, 308b, such that it may be operable to resist rotation of the body of the motor 306. In the illustrated embodiment, the anti-rotation stud 326 may have a diameter of about ⅝ inch, however other sizes, both larger and smaller, are contemplated. In some embodiments, the anti-rotation stud 326 may be one discrete component. In some embodiments, the anti-rotation stud 326 may include two or more discrete components. In some embodiments, such as the embodiment in
Side panels 302 may include openings as slots 618 for receiving projections as anti-rotation studs 326. In the illustrated embodiment, the slots 618 extend from a bottom edge of side panels 302 upward to opening 612 to form one continuous opening having a narrow slot connected to a round head or opening 612. In some embodiments, slots 618 may be cut shorter than illustrated, being distinct and separate from openings 612. The slots 618 may have a width smaller than the bearing 602, and therefore the bearing is still maintained in the opening 612. In some implementations, the width of the opening in slots 618 may be about the same size as the diameter of anti-rotation studs 326. In some embodiments, the width of opening in slots 618 is about ⅝-inch. In some embodiments, the slots 618 may be wider than the diameter of anti-rotation studs 326. In some embodiments, slots 618 and anti-rotation studs 326 may be sized so that the anti-rotation studs 326 are press fit into slots 618, with an interference fit. In the illustrated embodiment, slots 618 have an opening of about ⅝-inch and anti-rotation studs 326 have a diameter of about ⅝-inch so that anti-rotation studs 326 are seated securely within slots 618. Although not required to be similar sizes, the secure seating allows the anti-rotation studs 326 to slide into slots 618 with minimal effort.
The slots 618 have inner edges that define their open area or width. The anti-rotation stud 326 may be sized to abut against the inner edges of the slots 618 without otherwise being secured to the side panels 302. Accordingly, the anti-rotation stud 326 may abut the edges of the slot 618 to inhibit or prevent rotation of the motor relative to the side panels without being fixedly secured to the side panel. That is, the secure seating or fit of the anti-rotation stud 326 into the slot 618 may prevents the anti-rotation studs from swinging side to side when motor 306 reverses direction, further dampening noise and vibration. Furthermore, the life of the anti-rotation stud 326 is prolonged because of the minimized impact from the lack of swing. In some embodiments, the slots 618 may be above the openings 614. The anti-rotation studs 326 may be located above the motor shafts 308a, 308b and fit within slots 618 that are above openings 614. In some embodiments, side panels 302 may include additional openings positioned and sized to receive anti-rotation studs 326 position in different configurations along the sides of motor 306.
As illustrated, the motor 306 may be suspended via the bearings 602 which are supported by openings 612 in side panels 302, thereby isolating the vibrations of motor 306 from the overall operator chassis. That is, the motor may be supported by the side panels without being fixedly attached to the side panels. Accordingly, the side panels (or the chassis including the side panels 302) may support the motor only through the motor shafts 308a, 308b and the anti-rotation stud 326. That is, in some implementations, only the motor shafts 308a, 308b and the anti-rotation stud engage, even indirectly, the side panels 302. Contact between motor shafts 308a, 308b and side panels 302 is reduced, or eliminated, through the use of the intermediate bearings 602 or other dampening materials. Therefore, vibrations caused by motor 306 and transmitted to side panels 302 are reduced, or eliminated, resulting a noise reduction. Axial movement of motor 306 (e.g., movement in a direction parallel to the motor shafts 308a, 308b is reduced, or eliminated, by the steps 614 which prevent motor 306 from contacting side walls 302. Washers 604, 606, 608, set collar 610, and motor belt pulley 314 further reduce, or eliminate, axial movement of motor 306 and dampen, or eliminate, contact between bearings 602 and set collar 610 and motor belt pulley 314. This reduction in axial movement and metal on metal contact further reduces vibrations and therefore reduces noise produce by jackshaft operator 300. Rotational movement of the body of motor 306 is reduced, or eliminated, by the anti-rotation studs 326 seated in slots 618. As illustrated, the anti-rotation studs 326 further isolate motor 306, reducing vibrations and contact from motor 306 to side panels 302, which further reduces noise. Radial movement of motor 306 caused by belt 320 is reduced, or eliminated, by the use of bearings 602 supporting motor 306. As illustrated, the load of belt 320 is supported entirely by side panels 302 through bearings 602 and belt transfer pulley 318 resulting in little, to no, radial load on motor 306. This reduction in radial load as compared to previous designs further reduces the transfer of vibrations from motor 306 to side panels 302, resulting in less noise. As described above, each mounting component of the motor mount assembly reduces contact between motor 306 and other components within jackshaft operator 300, including side panels 302. The reduced contact reduces vibrations in the chassis overall, and therefore reduces noise in jackshaft operator 300. Individually, the reduction in noise is an improvement over previous designs and together the net reduction in noise provides a better experience for the customer. In addition to the reduction in vibration and noise, there is a reduction in overall parts used resulting in a reduced cost to manufacture and assemble the jackshaft operator 300. As previously mentioned, the improvements discussed with respect to the illustrated embodiments of an exemplary jackshaft operator are applicable to at least hoist operators, trolley operators, and rail drive operators and are within the scope of this disclosure.
Nuts 806 are inserted into holes in brackets 802 for securing electric box 304 to chassis 801. In the depicted embodiment, nuts 806 are isolation well nuts having a dampening (e.g., polymeric or rubber) head, or flange, a dampening body, and a threaded metal insert within the rubber body for receiving a flange, a rubber body, and a threaded insert contained within the rubber body. In some implementations, the dampening flange has a thickness of about ⅛-inch. The dampening flange and dampening body serve to reduce, or eliminate, the transfer of vibrations from the metal of the chassis 801 to the metal electric box 304. In some embodiments, nuts 806 may be different connector designed to physically isolate the electric box 304 from the chassis 801.
As depicted, electric box 304 is made of metal sidewalls 808, metal top and bottom walls 810, and a metal back panel 812. Electric box 304 contains a control board 814 and electronic components 816. The back panel 812 includes holes 818 operable for securing electric box 304 to chassis 801 and holes 820 operable to pass wires from control board 814 and electronic components 816 to motor 306 and brake 316.
Fasteners 822 are operable for coupling electric box 304 to chassis 801 using nuts 806. In the illustrated embodiment, fasteners 822 are screws that are sized to fit within the threaded insert of nuts 806. When fasteners 822 are tightened into nuts 806 the rubber flange swells providing separation between electric box 304 and chassis 801. This separation further isolates the vibration from motor 306 and results in further noise reduction during operation of jackshaft operator 300. In some embodiments, fasteners 822 may be carriage bolts in combination with rubber washers to provide isolation. In some implementations, the electric box is coupled to the chassis 801 (and the brackets 802) only via vibration-dampening coupling elements, such as the nuts 806, so as to preclude metal to metal contact between the electrical box and the chassis.
Although various embodiments of the claimed subject matter have been described above with a certain degree of particularity, or with reference to one or more individual embodiments, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of the claimed subject matter. Still other embodiments are contemplated. It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative only of particular embodiments and not limiting. Changes in detail or structure may be made without departing from the basic elements of the subject matter as defined in the following claims.
The present disclosure is directed to a movable barrier operator which includes a first side panel that has a first opening. The movable barrier operator further includes a second side panel opposite the that has a second opening and a third opening. The second opening is circular and the third opening is a slot that intersects the second opening so that second and third openings are joined. There is a motor for displacing a moveable barrier that is disposed between the first side panel and the second side panel without being fixedly attached to the first side panel or the second side panel. The motor includes a first shaft, a second shaft, and a third shaft. The first shaft extends away from the motor in a first direction and through the first opening. The second shaft extends away from the motor a second direction that is opposite the first direction and extends through the second opening. One of the first or second shafts transmits power from the motor to displace the moveable barrier. The motor further includes a projection that extends in the second direction through the third opening and abuts the inside edges of the third opening in a manner that prevents rotation of the motor relative to the first side panel and the second side panel. The projection includes a dampening bumper that abuts against the inside edges of the third opening. The motor is supported by a first bearing disposed in the first opening of the first side panel and a second bearing disposed in the second opening of the second side panel.
The movable barrier further includes a belt pulley that is coupled to the first shaft. The belt pulley receives a belt to drive the movable barrier and prevents movement of the motor in the first direction. A washer is disposed around the first shaft adjacent to the belt pulley on one side and the first bearing on the other side. The washer dampens vibration between the first bearing and the belt pulley. A set collar is coupled to the second shaft by a set screw to prevent movement of the motor in the second direction. A washer is disposed around the second shaft adjacent to the set collar on one side and adjacent the second bearing on the other side. The washer dampens vibration between the second bearing and the set collar. The movable barrier operator further includes a first bracket and a second bracket coupled to the first side panel and the second side panel. An electric box is coupled to the first and second brackets by only a dampening connector.
The present disclosure is further directed to a movable barrier operator which includes a chassis having a first side and an opposing second side. The first side includes a first opening and a second opening disposed below the first opening. The second side includes a third opening disposed opposite the first opening. A motor for displacing a moveable barrier includes a first shaft, a second shaft, and a stud. The first shaft extends in a first direction through the first opening. The second shaft extends in a second direction, that is opposite the first direction, through the third opening. The stud is disposed below the first shaft and through the second opening to prevent rotation of the motor relative to the first side and the second side. The chassis may include a fourth opening in the second side that is disposed below the third opening. The motor may include a second stud that is disposed below the second shaft and through the fourth opening. The chassis may support the motor only through the first shaft, the second shaft, and the stud. The stud may prevent rotational motion of the motor relative to the chassis.
The movable barrier operator may further include a bearing, a washer, and a belt pulley. The bearing is disposed within the first opening. One side of the washer is disposed adjacent the bearing and the washer may include a compressible material. The belt pulley is disposed adjacent the other side of the washer. The first shaft is disposed through the bearing, the washer, and the belt pulley. The first shaft may include a step at a proximal end of the shaft that extends a first distance towards the distal end of the first shaft. The first distance may be between 20 mm and 30 mm. An electric box may be coupled to the chassis through an isolation nut that includes rubber.
The present disclosure is further directed to a movable barrier operator that includes a chassis including a first side panel and an opposing second side panel. A first bracket is coupled to the first side panel and the second side panel and a second bracket is coupled to the first side panel and the second side panel. A first bearing is disposed within the first side panel. A second bearing disposed within the second side panel. The movable barrier operator further includes a motor that displaces a moveable barrier. The motor includes a first shaft and a second shaft. The first shaft may extend in a first direction along a first axis. The second shaft may extend in a second direction, opposite the first direction, along the first axis. The motor is disposed within the operator chassis and is suspended from the first bearing and the second bearing. An electric box is coupled to the operator chassis. The motor may include a stud the extends through an opening in the first side panel. The stud abuts against the edges of the opening without being fixed to the first side panel.
The movable barrier operator may further include a first washer, a second washer, a belt pulley coupled to the first shaft. A belt is wrapped around the belt pulley to drive so that the pulley drives the belt and the belt drives the movable barrier. The belt pulley may be disposed around the first shaft and adjacent to and contacting the second washer. The second washer may be contacting the first washer. The first washer may be contacting the first bearing. An electric box may be coupled to the operator chassis using a connector that includes a dampener.
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| Number | Date | Country |
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| 2018217332 | Nov 2018 | WO |
| Entry |
|---|
| The Chamberlain Group, Inc., Premium Series 3240 1/2 HP Screw Drive Garage Door Opener, 2007 LM 3240 06/07, Elmhurst, IL, (publication date unknown). |
| Number | Date | Country | |
|---|---|---|---|
| 20220259913 A1 | Aug 2022 | US |
