Patent Application
20060049021
The present invention relates to apparatus and related methods and procedures for referencing a rotary drive with the limits of movement required for that drive to take account of a particular application (e.g.; of the movement limits a door opening or closing, or the like).
There are many instances where a drive system requires calibration so as to ensure that the electric motor (or other prime mover) does not continue to drive or drive effectively in its application beyond limits of that application. For example, in the situation with, for example, garage doors, whether of the curtain, tilt or sectional types it is usual (irrespective of whether or not AC or DC motors are being used as the motive force) to provide limits whereby there is a cut-off of the energising power to the motor when the door is either fully open or fully closed.
Frequently such cut-off systems are dependent upon manual inputs by way of screws or the like members that allow the limits to be customised for the particular application.
The present invention relates to apparatus and related procedures and the like that has application inter alia in such applications as the limit control of, for example, garage doors but has more widespread application.
In our New Zealand Patent Specification No. 522300 we disclosed a novel drive system whereby a motor driven worm engages a worm gear and that worm gear in turn has or drives a sprocket or pulley that acts upon an endless drive member (such as a chain or belt) which in turn moves a guided carriage which is directly or indirectly attached to the door, e.g.; a tilt type garage door.
In the aforementioned New Zealand Patent Specification we disclosed an assembly having significant advantages over prior art structures in that a simple moulded member of a suitable plastics material or other suitable material could be provided which could be mounted on a fixed or rotating shaft mounted from chassis components at each end, such moulded member at one end driving the sprocket, pulley or the like and at the other end, or towards the other end, having a worm gear integrally formed therewith adapted to be driven by the worm driveable by a power output shaft from, for example, an AC electric motor. The full disclosure of the aforementioned New Zealand Patent Specification is hereby here included.
It is an object of the present invention to provide apparatus, methods, procedures and the like which will at least meet one of the abovementioned capabilities, or can be used in conjunction with the aforementioned drive system assembly and/or which at least provides the public with a useful choice.
In a first aspect the invention is apparatus adapted for use to reference a cam actuable switch or the like means to the disposition of a drive in a datum range (e.g.; the movement of a member between open and closed conditions under the action of the drive), said apparatus having,
Preferably the drive is rotatable on a rotation axis about which the eccentric member orbits.
Preferably said ring gear includes means to index into an appropriately provided mount which also serves at least in part as a mount for a switch or the like means to be actuated by the cam.
Preferably the cam is mounted from a member rotatable with a member slidingly encompassing the ring gear but which itself is indexable to rotate about the rotation axis under the action of the eccentrically carried spur gear.
Preferably there is a differential in teeth numbers between the spur gear and the ring gear.
Preferably the differential is a low integer and most preferably one or two.
Preferably the teeth number differential is such as to provide a reduction drive from the rotatable drive which carries the eccentric member through to the cam which rotates about the same said rotation axis.
Preferably the eccentric drive is eccentrically extending from a moulded member which includes a worm gear adapted to be driven by a worm.
Preferably said moulded member additionally includes spline or other means adapted to engage a drive, sprocket, pulley, gear or the like adapted to open and/or close a door or the like (such as a garage door).
Preferably the moulded member is a moulded member of the kind defined and preferably one mounted as described in New Zealand Patent Specification No. 522300.
In yet a further aspect the present invention consists in apparatus adapted to rotate a cam (or other datum providing interactive means component) [“cam”] about a rotation axis, said apparatus having,
Preferably said ring gear includes means to index into an appropriately provided mount which also serves at least in part as a mount for a switch or the like means to be actuated by the cam.
Preferably the cam is mounted from a member rotatable with a member slidingly encompassing the ring gear but which itself is indexable to rotate about the rotation axis under the action of the eccentrically carried spur gear.
Preferably there is a differential in teeth numbers between the spur gear and the ring gear.
Preferably the differential is a low integer and most preferably one or two.
Preferably the teeth number differential is such as to provide a reduction drive from the rotatable drive which carries the eccentric member through to the cam which rotates about the same said rotation axis.
Preferably the eccentric drive is eccentrically extending from a moulded member which includes a worm gear adapted to be driven by a worm.
Preferably said moulded member additionally includes spline or other means adapted to engage a drive, sprocket, pulley, gear or the like adapted to open and/or close a door or the like (such as a garage door).
Preferably the moulded member is a moulded member of the kind defined and preferably one mounted as described in New Zealand Patent Specification No. 522300.
In yet a further aspect the present invention consists in apparatus adapted to rotate a cam (or other datum providing interactive means component) [“cam”], said apparatus having,
Preferably said ring gear includes means to index into an appropriately provided mount which also serves at least in part as a mount for a switch or the like means to be actuated by the cam.
Preferably the cam is mounted from a member rotatable with a member slidingly encompassing the ring gear but which itself is indexable to rotate about the rotation axis under the action of the eccentrically carried spur gear.
Preferably there is a differential in teeth numbers between the spur gear and the ring gear.
Preferably the differential is a low integer and most preferably one or two.
Preferably the teeth number differential is such as to provide a reduction drive from the rotatable drive which carries the eccentric member through to the cam which rotates about the same said rotation axis.
Preferably the eccentric drive is eccentrically extending from a moulded member which includes a worm gear adapted to be driven by a worm.
Preferably said moulded member additionally includes spline or other means adapted to engage a drive, sprocket, pulley, gear or the like adapted to open and/or close a door or the like (such as a garage door).
Preferably the moulded member is a moulded member of the kind defined and preferably one mounted as described in New Zealand Patent Specification No. 522300.
In still a further aspect the present invention consists in apparatus for providing a physical reference or datum between a rotatable drive to operate over a datum range of multiple rotation(s), said apparatus having said rotatable drive drivingly rotatable directly or indirectly under the action of an electric motor about a rotation axis, an eccentric member carried by the rotatable drive so as to orbit the rotational axis thereof as the rotatable drive rotates,
Preferably the apparatus is apparatus also as otherwise defined herein.
In still a further aspect the present invention consists in a method of limiting a rotatable drive which employs the operative use of apparatus of any of the forms herein before described.
In yet a further aspect the present invention consists in a limit system suitable for use inter alia with, for example, a garage door which limits the rotation of a rotational drive, the rotational drive being referenced by electronic means to a physical datum or reference between the rotational drive and a switch to which the electronic means references thereby, by reference to the actuation and/or non actuation, or both, of the switch of determining whether or not a or one of the limits has been reached.
For example, preferably the mode of operation is substantially as hereinafter described (irrespective of whether or not it uses apparatus hereinafter described) with reference to FIGS. 1 to 12 of the accompanying drawings.
In still a further aspect the present invention consists in related methods and/or apparatus.
In another aspect the present invention consists in a limit protocol for a door opening system where a physical switch or the like established datum ancillary to the drive system for door opening/closing is utilised to establish a drive operation range of the drive system extending to either side of the datum.
Preferably the datum is established reliant upon a physical interaction of a epicyclic including transmission ancillary to the drive but receiving input directly or indirectly of the drive (e.g.; through an eccentric input).
In still a further aspect the present invention consists in related methods and/or apparatus.
As used herein the term “cam” is to be provided with the broadest conceivable interpretation. Whilst preference is hereinafter described by reference to a peripherally outstanding ramp or ramped land other component forms with a physical interactive feature can be utilised. Indeed alternatives to a direct mechanical interaction can be within the scope of the present invention, i.e.; instead of a physical cam interacting with a follower of a switch instead some interactive means component intended to provide an optical, magnetic or electrical interactive relationship can be substituted in the stead of the physical cam/cam follower inter-reaction.
As used herein the term “datum range” contemplates, by way of example, by reference to a garage door, the rotations in whole and in part of a rotatable drive to the extent to which such rotations relate to the limits of movement of the door between any desired fully open or partly open condition and any desired fully closed or partly closed condition. Similar meanings extend to other applications of the limit system whether relating to a door or not.
As used herein the term “electronic means” can include any logic system, PLC dependent system, microprocessor dependent system or the like that in preferred forms of the present invention are capable of being utilised to control the limits from the datum preferably established by a physical interaction between the cam and the switch.
As used herein the term “physical datum or reference” can include within its scope interactions of the kind aforementioned which may not be dependent on a physical coming but may instead be of an optical, electrical, magnetic or the like interaction.
In still other aspects the present invention consists in a door or the like limit system controlled by apparatus and/or methods and/or systems in accordance with the present invention.
In still a further aspect the present invention consists in, in combination, any of the apparatus, systems or methods of the aforementioned New Zealand Patent Specification No. 522300 and any of the apparatus, methods and systems of the present invention.
By way of example, apparatus of the aforementioned New Zealand Patent Specification includes
As used herein the term “and/or” means “and” or “or”, or both where the circumstances allow.
As used herein the term “(s)” following a noun means both or either the plural and singular forms of that noun.
As used herein the term “/” between nouns (e.g. as used hereinafter as “opening/closing” means both the opening and closing functions or either.
For the purpose of the use of systems of the present invention in garage door openings reference is drawn to the website of www.merlingo.com/ as demonstrating apparatus and forms appropriate for such control.
A preferred form of the present invention will now be described with reference to the accompanying drawings in which
FIGS. 1 to 5 being as in New Zealand Patent Specification No. 522300,
In a preferred form of the present invention some of the preferred components are as depicted in FIGS. 1 to 7 in which, formed in each instance from plate steel so as to perform their respective functions insofar as the present invention is concerned as well as ancillary functions in respect of control systems etc., are the first chassis component 1, the second chassis component 2 and the third chassis component 3.
The third chassis component 3 carries a pole 15 shown in part which has the function of spacing an idle sprocket from the drive sprocket 9 so that the endless chain can drive a carriage guided by the pole 15, that carriage in any suitable way (including those known) being linked to the door to be opened and/or closed by the apparatus.
As can be seen, the third chassis component 3 has an opening therethrough through which can pass the axle 5 as well as part of the sleeve 4 so that the splined or keyed end region 11 of the sleeve 4 can drivingly be received by the mating spline or key 12 of the sprocket 9. The sleeve also has integrally moulded therewith (e.g.; in nylon or acetyl plastic or phosphorus bronze) (see
As can be seen, provision is made in each of chassis components 1 and 2 for endwise location and fixing (by screws 14 and 13 respectively) of the axle 5, although in other forms of the present invention, any of the forms of end location of the axle member herein described can instead be utilised irrespective of whether or not they are the same at each end.
As shown in
It can also be seen that by having a significant span between the ends of the axle member 5 there is good resistance moment to any stresses placed through the sleeve 14 by the worm 15 against movement of the support for the worm gear. This provides significant advantages over previously constructions.
As will be appreciated any appropriate mount for the ends of the axle member can be provided. For example whilst a axially engaging screw at each end is shown in the drawings, persons skilled in the art will appreciate how, if desired, a frustoconical end region or some equivalent can be received by one or other of the first and second chassis components and some means be provided to locate the other end (whether the same or different). For example, frustoconical, domed or other profiled ends at each end could be appropriately received directly by plates profiled accordingly or thrust washers or the like associated therewith. There is no need for the mounting at each end to involve a screw engagement.
In the arrangement as shown in
The ring gear 19 can be seen with the protuberances or projections 21 adapted to be received in openings of the chassis component 1 whereby the ring gear 19 is precluded from rotation whilst the spur gear 17 is allowed to rotate as it maintains at least some tooth to tooth engagement of an epicyclic nature with the ring gear teeth.
The cylindrical surface 25 of the ring gear 19 bears a location and sliding relationship with the inner cylindrical surface 24 of the cam 23 with its pair of opposed ramps (26) between which there is an outstanding land 26A. One or other of the ramps 26 is preferably the caming surface which bears against an appropriate follower of the switch 27 which, as shown, is preferably mounted in a fixed relationship with the ring gear 17 and chassis component 1 and preferably also the axle 5 into which preferably through the chassis component 1 an appropriate locating screw 14 is engaged.
Between the spur gear 17 and the cam member 23 is a rotational drive interaction reliant on a projection from one member being received by the other in such a way as there can be substantially radial relative movement. Preferably this can involve a projection 29 of the spur gear 17 (see
In use therefore any appropriate electronic means can be utilised to provide the outcomes shown as being desirable by
With that datum, any suitable electronic means (whether a simple counter mechanism (PLC) or otherwise can be utilised to calibrate the number of full and/or part rotations allowed each way from that physical reference or datum thereby providing the datum range indicative of rotations on either side of the reference or datum and which accord with the door condition, i.e.; either open at one end or closed at the other.
Persons skilled in the art will appreciate how such a system with a minimum of moving parts reliant upon a small encompassed space reliant on low cost moulded components (e.g.; of any of the plastics previously referred to) can be utilised for limit control datum and/or datum range setting.
Persons skilled in the art also will appreciate how if a DC motor is utilised an override control can be incorporated somewhere in the system. If an AC motor is utilised persons skilled in the art will appreciate how an overload feature can be provided somewhere in the system such that should a door come down on a car or person the power is cut off to the motor in between the limits of the datum range.
Persons skilled in the art however will appreciate how the present invention provides for an effective way whereby a limit protocol of a door opening system (or any equivalent) can provide a physical, optical, magnetic or electrical switch interaction (switch established datum ancillary to the drive system for door opening/closing which can be utilised to establish a drive operation range of the drive system extending to either side of the datum. Less desirable is a circumstance but not outside the scope of the present invention, where the datum provided by the switching mechanism is outside of the datum range itself, i.e.; the rotations allowed are all to one side of the datum range. Nonetheless such possibilities exist and are within the scope of the present invention.
A description of the function and some underlying logic of the door controller limit system in one preferred or optional embodiment will now be described. It may use hardware as disclosed in our New Zealand Patent Specifications 522174 or 522300 filed 22 Oct. 2002 and 25 Oct. 2002 respectively, or indeed any mounting, assembly, subassembly and system we have disclosed by way of publication or use in respect of our MERLIN™ brand door systems.
Operation Before Setup
The manual control button ideally requires to be continuously depressed to move the door. Successive presses result in reversal of door travel direction. This ensures that the door can not accidentally be moved beyond the correct physical end-points of travel.
Set up
To define the limit positions the following process should be performed:
Operation After Setup
A brief press of the manual control button will move the door from one limit to the other. Pressing the manual control button while the door is moving stops the door.
Controller Overview
The following controller inputs, outputs, and parameters are relevant:
From these the controller can infer the position, speed and direction of the door's travel. With knowledge of the motor's torque-speed, and torque-current, characteristics the load placed on the motor can be inferred for any position of the door's travel.
If the controller has been reset, it can not determine whether its stored relative position is correct so it should recalibrate to the reference position. In order to decide which direction to travel first it checks the state of the reference switch and then moves towards the reference point. Once the reference switch has changed state, normal operation resumes. The user will be unaware of this unless they stop the door and try to move the door in the opposite direction before the reference switch changes state. In this circumstance the user will be required to continuously depress the manual control button.
On every uninterrupted operation from a limit position the counter will be set to zero at the reference switch. The counter values for the open and closed limits will be referenced to the newly calibrated reference position. See
Adaptive Travel Adjustment
The motor speed and/or current is stored with door position during setup. If during normal operation within a short distance of the bottom limit the speed and/or current does not match the stored values within some percentage then the physical limit position is judged to have been altered. The new limit position replaces the old limit position counter value.
| Number | Date | Country | Kind |
|---|---|---|---|
| 522578 | Nov 2002 | NZ | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/NZ03/00212 | 9/16/2003 | WO | 8/1/2005 |
