Patent Grant
8314509
This invention relates generally to movable barrier operators and more particularly to energy management in such an operator.
Movable barrier operators are well understood in the art and include a wide variety of openers for garage doors (with both residential and commercial/industrial variations being available), sliding and swinging gates, rolling shutters, and so forth. Such operators usually include a programmable platform comprising a programmable gate array, a microcontroller, a microprocessor, or the like that controls various operational states of the operator (including movement of a corresponding barrier, light operation, state monitoring, unauthorized entry detection, and so forth). Many operators also include other elements and components including but not limited to a motor and motor controller, a motor RPM detector, one or more wired remote control interfaces that are at least semi-permanently mounted remotely from the movable barrier operator itself, a wireless remote control interface, one or more worklights, and an obstacle detector, to name a few. Such operators also typically include a power supply to provide energy for all of the above components.
In general, movable barrier operators are designed to provide full power at all times to all elements of the system. For example, an obstacle detector (and the circuitry/logic that monitors and responds to the obstacle detector) will frequently be active and fully powered regardless of whether the corresponding barrier is opened or closed. As a result, the average power draw of a typical prior art movable barrier operator over time is often likely to be higher than might genuinely be merited. For example, many movable barrier operators draw more than five watts of power even during a relatively quiescent state such as when the corresponding barrier is fully closed.
Also, the power supply for many movable barrier operators tends to be simplistic and relatively static in operation in that the power supply is designed and built to operate at full capacity and provide full potentially necessary operating power to all components of the movable barrier operator regardless of the genuine need at any given moment for such power. Waste heat production and radiation due to the power supply design (often primarily due in many cases to the power supply transformer) alone can account for a considerable portion of the so-called stand-by energy needs of a prior art movable barrier operator.
The above needs are at least partially met through provision of the movable barrier operator with energy management control and method described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are typically not depicted in order to facilitate a less obstructed view of these various embodiments of the present invention.
Generally speaking, pursuant to these various embodiments, a movable barrier operator that includes a motor and a plurality of additional components has at least a first mode of operation and a second mode of operation. In the first mode of operation, the operator automatically initiates (following at least apparent attainment of a given operational state) one or more actions that configures or otherwise controls one or more components of the movable barrier operator to effect, in part, a particular corresponding level of energy consumption. In a preferred embodiment, this level of energy as provided pursuant to the first mode of operation is sufficient to power at least most of the components in a substantially fully-active mode of operation. In the second mode of operation, the operator automatically initiates (again preferably based on some indicia of an attained operational state) one or more actions that configures or controls the movable barrier operator to effect, at least in part, a reduced corresponding level of energy consumption.
By appropriate selection of the dynamic alterations that facilitate the selection of reduced energy consumption operating states, and by appropriately selecting when to use such operating states, operational efficacy and safety are not unduly compromised while simultaneously achieving considerable power savings over time.
In differing embodiments, various alterations can be introduced for use with various ones of the components to realize the dynamically utilized reduced energy consumption needs of the components and/or overall operator. Varying levels of energy savings are typically possible with, for example, the motor RPM sensor, the movable barrier operator itself, the radio that supports the wireless user interface, the wired remotely disposed user interface, and the obstacle detector, to name a few. In addition, the power supply can be more efficiently designed and/or provided with dynamic reconfigurable functionality to also support immediate and/or average energy usage reductions.
Referring now to
In addition, in this embodiment, a worklight 9 provides light (for example, upon opening or closing a garage door for a short predetermined period of time). Such a worklight 9 can share a common housing with the motor 7 and motor controller 6 or can be remotely mounted. In addition, two or more such worklights can be provided. When multiple worklights are used, such lights can operate in parallel or can respond to differing control strategies as desired for a particular application.
In a preferred embodiment, an RPM detector 8 provides information regarding the mechanical output of the motor 7 to the operator controller 5. In a preferred embodiment the RPM detector 8 will include one or more optical sensors and a light source wherein one moves with respect to the other as a given output member (such as an output drive shaft) rotates. The resultant signals will be synchronized to the rotation of the motor 7 and hence provide the desired RPM information. There are other ways, however, to provide such information and this particular embodiment should be viewed as being illustrative rather than limiting.
A radio 11 (typically comprising a receiver though two-way capability can be provided as appropriate to suit the needs of a given situation) serves to receive wireless remote control signals and to provide such received signals to the operator controller 5.
An obstacle detector 12 of choice couples to the operator controller 5 and serves primarily to detect when an obstacle lies in the path of the moving barrier. The operator controller 5 uses such information to control the movable barrier accordingly (for example, to cause a closing moving barrier to stop or reverse direction upon detecting an obstacle in order to avoid injuring the obstacle or the movable barrier itself). A variety of known obstacle detectors exist. For purposes of this illustration, the obstacle detector 12 is comprised of a photobeam-based obstacle detector.
Referring momentarily to
In this embodiment the operator controller 5 also couples to a wired remotely disposed user interface 14 via a remote controller interface 13. The remotely disposed user interface 14 typically includes one or more user assertable buttons and often include one or more display elements (such as one or more light emitting diodes 15). The buttons serve to permit a user to signal the operator controller 5 to, for example, move the movable barrier, to switch on or off the worklight 9, or to facilitate some other communication (for example, to place the operator controller 5 into a so-called vacation mode of operation). There are various known ways to facilitate the provision of such a user interface 14. For purposes of this illustration, and referring momentarily to
As already noted for some of the above specific elements, all of these components are well understood in the art. This understanding includes knowledge regarding a variety of ways to facilitate the realization of each described function. Additional description has therefore not been provided for these various components. In addition, there are other components that can be utilized in conjunction with such an operator controller, including Bluetooth-style data link modules, carbon monoxide detectors, smoke detectors, and so forth. It should be clearly understood that the embodiments described below are compatible with and suitable for use with such other components as well as the specific components and elements that are generally depicted in
All of the above components, including the operator controller 5 itself, utilize electricity. Some (such as the motor 7 and the worklight 9) utilize standard 110 volt alternating current. Others (such as the obstacle detector 12 and the user interface 14) utilize, in this embodiment, 28 volts direct current. Yet others (such as the operator controller 5 and the RPM detector 8) utilize, in this embodiment, 5 volts direct current. Such electricity can be provided in a wide variety of ways, including through use of multiple independent power supplies. More typically, however, a single power supply 16 serves to supply the power needs of all the components in the system. So configured, in this embodiment, the power supply 16 couples to a standard source 17 of alternating current. The AC power is made available via the power supply 16 to those elements that require it. That AC power is also processed to yield both the 5 volt and the 28 volt DC power signals noted above.
As already noted, a typical movable barrier operator will have a power supply that provides full power at all times and all of the components will be operating in a full power stand-by mode as well. This does not mean, of course, that all of the components utilize maximum power at all times. For example, the motor 7 only draws full power when it is operating. But, as an example, the RPM detector 8 in a prior art configuration will draw full power even when the motor 7 is quiescent and there are no revolutions to detect. Pursuant to these embodiments, various components are configured to have at least two energy usage personalities. That is, when the operator controller 5 operates in a first mode of energy consumption operation, at least one of these components will operate using a first energy usage personality. Similarly, when the operator controller 5 operates using a second mode of energy consumption operation, that same component will operate using a second energy usage personality. With reference to
As noted above, the operator controller 5 comprises a programmable platform. Pursuant to these embodiments, the operator controller 5 is programmed to select from amongst a plurality of energy management operating modes as a function, at least in part, of the operational status of one or more elements of the system itself and/or the movable barrier. Generally speaking, and with reference to
The information received 50 by the operator controller 5 can comprise, for example, information regarding one or more operational states of the movable barrier operator system. Such information could reflect, for example, that the movable barrier is at a particular position and/or is stationary at either of a fully opened or a fully closed position. The monitored operational state can further include, in a preferred embodiment, a temporal aspect as well. For example, the information can specifically reflect that a given stationary position of the movable barrier has been continuously maintained for at least a predetermined period of time (such as a specific number of seconds or minutes). When the movable barrier is at a fully opened or especially at a fully closed position, the operational state of the system often comprises a quiescent state, and especially so when the stationary position has been continuously maintained for a period of time.
Each operating mode as is selectable by the operator controller 5 pursuant to this approach can have a corresponding level of energy consumption. Through this process, the operator controller 5 establishes a level of operability that is appropriate and commensurate with the likely needs of the system at a given point in time. More particularly, the operator controller 5 further selects operating modes that tend to result in a reduced level of energy consumption for at least some levels of maintained activity. In general, little or no reduction in energy consumption during high levels of usage are especially expected through this approach. Since most moving barrier operator systems spend most of their time in a fully or partially quiescent operating state, however, considerable opportunity exists for energy savings during such periods.
As one illustrative example, consider the above process as applied to an obstacle detector 12. As already described, the obstacle detector 12 in this embodiment includes two pairs 12A and 12B of photobeam elements that are positioned within the opening 21 that is governed by the movable barrier. The obstacle detector 12 serves an important safety purpose. In this regard, when the operator controller 5 receives 50 information indicating that the movable barrier is moving from an open to a closed position, a first mode of energy consumption operation 52 that comprises, in this example, normal full energization and operation of the obstacle detector 12 is appropriate to ensure that this feature is fully enabled. Once the movable barrier has moved to a fully closed position, however, and further has remained in that position for a predetermined period of time (such as, for example, five minutes), this information as received 50 by the operator controller 5 can be used to select instead a second mode of energy consumption operation 54. In this embodiment, pursuant to the second mode of energy consumption operation, one pair 12B of the photobeam elements can be switched off, thus saving 50% in energy utilized to power the photobeam operation. This energy savings is achieved at the expense of now providing only one pair of photobeam elements, of course. By ensuring that such a selection only occurs when the movable barrier is fully closed, however, such a compromise will be quite reasonable for many applications.
The above example is intended to be illustrative only, of course, and there are other ways to achieve an energy savings in the same situation. For example, the periodicity or duty cycle for energizing the photobeams elements 12A or 12B can be reduced. Instead of continuous or near-continuous energization, the elements can be strobed on a less frequent basis. In this and other ways as will occur to one skilled in the art, the energy consumption operating mode of the obstacle detector 12 is controlled while simultaneously assuring that the operability and efficacy of the overall system is not unduly compromised.
In a simple system where only two operating modes are available for consideration, again, the first mode is likely to represent a full-power mode suitable for use during ordinary operations. The second mode, however, can be used to modify the energy consumption of any given component of the system or any combination of components. For example, and referring now to
The Operator Controller
The operator controller 5 can be configured to toggle itself between an ordinary mode of operation and a so-called sleep mode of operation. During a sleep mode of operation, the processing platform that comprises the operator controller 5 can power down significant portions of its relevant circuitry and then only intermittently re-power such circuitry to respond to any system needs that may have arisen in the meantime. As another example, significant portions of the processing platform can be powered down and left powered down. A remaining portion of the platform can serve to receive signals that indicate when processing requirements now exist and to interrupt and awaken the remaining circuitry to tend to the task at hand. Such operating modes are generally well understood in the art for microprocessors and the like though used uniquely here to facilitate the energy management of a movable barrier operator system.
The Radio
The radio is ordinarily on at all times and available to receive remote control transmissions from a corresponding wireless remote control user device as well understood in the art. The operator controller 5 could be configured to receive 50 information regarding the fully open status of the movable barrier, which status has been maintained for at least a predetermined period of time (such as, for example fifteen minutes). A second mode of operation 54 could configure the radio 11, under such conditions, to enter an intermittent mode of operation. For example, the radio receiver could be cycled on and off for brief intervals in accord with a predetermined duty cycle, such as fifty percent. So configured, energy consumption for the radio would drop during a period of time when a wireless transmission from a user is statistically somewhat less likely (at least for some applications and installations).
As another example, the radio 11 could be configured, pursuant to a second mode of operation, to effect a local squelch function (whereas in ordinary course, the squelch function may be handled by the operator controller 5). Doing this, of course, would possibly increase the energy requirements of the radio 11, but would permit the operator controller 5 to be relieved of this function. Accordingly, this offloading of functionality might then more readily permit a complete (possibly intermittent) powering down of the operator controller 5 into a sleep mode as suggested above. So configured, it can be seen that the functionality of one component can be modified in order to effect a corresponding change in functionality elsewhere in the system along with a commensurate reduction in energy consumption. (Whether such a shifting will result in an overall reduction in energy consumption for a given system will of course vary with respect to the system itself.)
The Remotely Disposed User Interface
As noted above, during ordinary (first mode) operation, this interface 14 can illuminate display elements such as one or more light emitting diodes 15. For example, such a display can be provided in order to provide a location beacon to aid a user in finding the interface 14 under darkened circumstances. By using information regarding available light (such as can be obtained through use of, for example, a photocell circuit as well understood in the art), the operator controller 5 can receive 50 information regarding ambient light and use this information to select a second mode of operation 52 wherein such a light emitting diode 15 is powered down (this being based upon the supposition that such a beacon is not especially helpful when the interface 14 is otherwise readily viewable given present lighting conditions).
As another example, it was disclosed above that a particular switch closure sensing mechanism is used in many such interfaces 14 wherein a 28 volt pulse is repeatedly sent to the interface 14 such that the remote controller interface 13 can thereby actively sense the closure and identity of a given switch. Upon receiving 50 information that indicates a particular operational state (such as, for example, that the movable barrier is and has been fully closed for at least a predetermined period of time), the operator controller 5 can effect a second mode of operation 52 that utilizes an alternative, less energy-consumptive switch sensing mechanism. For example, whereas the primary mode of operation provides for actively sensing a closed circuit, a second mode of operation can instead more passively detect charging of the capacitors 33 and 35 in the interface circuit as described earlier. Sensing switch closure in this fashion is not as rapid or necessarily as accurate as the use of active sensing, but the energy expenditure required for the second mode of operation is also considerably reduced. By limiting use of the less operationally optimum but more energy efficient second mode of operation to circumstances where actual usage of the interface 14 is less likely, overall energy management is served without significant impairment of the overall operation of the system.
The Power Supply
A number of improvements can be made with respect to energy efficiency of the power supply and/or its interaction with the remainder of the system. For example, with reference to
During ordinary operation, when all power is to be made available to all components of the system (for example), the switch 72 remains closed and 28 volts and 5 volts remain fully available at all times to all components. During more quiescent modes of operation, however, the second mode of operation 54 can provide for essentially shutting down the 28 volt supply (which will shut down, partially or completely, those components that ordinarily require such a supply to operate in an ordinary fashion). At the same time, however, the energy storage capacitor 74 will be able to maintain a supply of 5 volts at the output of regulator 75 for short periods of time. The voltage monitor 76 can detect when the voltage across this capacitor 74 is falling too low (such as, for example, below 7 volts) and can then close the switch 72. This will permit the building up of voltage across the capacitor 74 and will also result in a still-continuing availability of 5 volts at the output of the regulator 75. The voltage monitor 76 can again cause the switch 72 to open when the voltage across the capacitor 74 reaches or exceeds some predetermined threshold (such as, for example, 12 volts). By toggling back and forth in this fashion, 5 volts remains available to power certain components (or portions of components as the case may be) but the 28 volt components are essentially powered down. As a result, energy requirements are greatly reduced when operating in this fashion. If, in a given embodiment, there are components that require 28 volts that should not be shut down in this fashion, it would be possible to provide two power supplies, wherein one supply continues to provide 28 volts to such components and the other supply operates as just described to reduce power availability to those components where such denial is acceptable and to otherwise provide 5 volt power to the remaining components.
There are a variety of ways by which the switch 72 can be realized. For example, the switch 72 can be comprised of a relatively small low power relay (especially when the pulse rate is relatively slow). The switch 72 could also be realized through appropriate use of an active device such as, for example, a triac. For example, as shown in
Yet other useful and applicable power supply embodiments are possible as well. For example, with reference to
As noted above, more than one power supply may be appropriate in some circumstances to support dynamic reconfiguration for energy management purposes. With reference to
As already noted, various components of the movable barrier operator system can be configured to effect dynamic changes in response to certain operational states to thereby minimize the power requirements of such components. By also modifying the power supply to itself reduce its power provisioning capabilities in tandem with such dynamic alterations to the components, significant energy savings can be attained.
The RPM Detector
The RPM detector 8, at a minimum, expends energy to sense a signal that relates to the position of an object that itself correlates to the position of the output shaft of the motor. Often, the detector 8 will also expend energy to create that signal to be sensed. When the system attains a quiescent state such as occurs when the movable barrier is and has been fully closed for at least some predetermined period of time, a second mode of operation 54 can include reducing the duty cycle of so energizing the detector 8 and/or powering down the detector 8 completely.
The Obstacle Detector
As already described above, a photobeam-based obstacle detector 12 can be configured to permit reduction of the energization cycle and/or complete powering down to accommodate a reduced energy consumption mode of operation. Other embodiments are of course possible. For example, in some embodiments, the remotely disposed wired user interface 14 will include a passive infrared (PIR) device that can detect the presence of a human in the vicinity of the system. To the extent that a system utilizes the obstacle detector 12 to also detect the presence of a person and to trigger the illumination of the worklight 9 in response to such detection, when at least a quiescent condition has been reached where the movable barrier is and has been closed for at least a predetermined period of time, control of the worklight 9 can be left exclusively to the PIR device and the obstacle detector 12 can be relieved of this function. This, in turn, may more readily facilitate the partial or complete powering down of the obstacle detector 12 as already suggested above.
So configured, it can be seen that one or more components of a movable barrier operator system can be configured to operate in at least two different modes of operation, wherein each mode has a differing corresponding energy consumption profile. The mode that requires less energy is frequently less optimum with respect to performance. By matching use of such lower power modes of operation with operational states that present reduced operational challenges, however, a reasonable compromise can be reached as between operational efficacy on the one hand and well managed energy usage on the other.
Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the spirit and scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.
This application is a continuation application of U.S. patent application Ser. No. 12/818,732 filed on Jun. 18, 2010, to be issued as U.S. Pat. No. 7,855,475, which is a continuation application of U.S. patent application Ser. No. 10/227,182 filed on Aug. 23, 2002, now U.S. Pat. No. 7,755,223, each of which is hereby incorporated herein by reference in their entireties.
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| Number | Date | Country | |
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| Number | Date | Country | |
|---|---|---|---|
| Parent | 12818732 | Jun 2010 | US |
| Child | 12964002 | US | |
| Parent | 10227182 | Aug 2002 | US |
| Child | 12818732 | US |
