Rail system

Abstract

To provide a rail system that can be used for moving an object or a load such as a panel, a pedestrian, a vehicular access door, a fixed and prefabricated panel, a roller door, a curtain, and the like.SOLUTION: A rail system 10 comprises: a guide rail; a plurality of stationary electromagnets mounted in the guide rail; and a carriage having a plurality of wheels configured to travel along the guide rail. The wheels are magnets. Movement of the wheels along the guide rail is brought about by a fluctuating magnetic field generated by the stationary electromagnets acting on the wheels.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a rail system that can be used to move objects or loads, such as panels, pedestrian or vehicle access doors, fixed and sectional panels, roller doors, curtains, etc. [Background technology]

[0002] Modern use of sectional and roller doors often incorporate automated opening and closing methods for safety, convenience and efficiency. These automated methods often rely on wound spring or counterweight assisted winch systems that use geared rotary motors with cables and / or chains.

[0003] Any discussion of documents, acts, materials, devices, articles or the like included in this specification should not be construed as an admission that any or all of that matter forms part of the prior art or was common general knowledge in the field relevant to this disclosure existing prior to the priority date of each claim of the appended claims.

[0004] Throughout this specification, the term "comprise" or variations such as "comprises" or "comprising" will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps. Summary of the Invention

[0005] According to the present disclosure, there is provided a rail system comprising a guide rail, a number of stationary electromagnets attached to the guide rail, and a carriage having a number of wheels that run along the guide rail. The wheels are magnetic. Movement of the carriage along the guide rail is effected by a fluctuating magnetic field generated by the stationary electromagnets acting on the wheels. The carriage may be configured to be attached to a load or object.

[0006] The rail system may include a plurality of guide rails and a plurality of carriages. The plurality of guide rails may include a first guide rail and a second guide rail, the first guide rail and the second guide rail being spaced apart from one another. The plurality of carriages may include one carriage attached to the first guide rail and one carriage attached to the second guide rail. A load may be attached to the carriage on the first guide rail and the carriage on the second guide rail. The load may move by coordinated movement of the carriage on the first guide rail and the carriage on the second guide rail.

[0007] A plurality (two or more) of carriages may be mounted on the first guide rail. A load may be mounted to each carriage on the first guide rail. A plurality (two or more) of carriages may be mounted on the second guide rail. A load may be mounted to each carriage on the second guide rail.

[0008] Each guide rail may include a brake-engaging surface. At least one carriage mounted to each guide rail may include a brake having a shape configured to engage the brake-engaging surface. When more than one carriage is mounted to each guide rail, each carriage may include a brake having a shape configured to engage the brake-engaging surface of its associated guide rail. The brake of the carriage may engage the brake-engaging surface of the guide rail to limit movement of the carriage when power to the electromagnet is interrupted.

[0009] The brake engaging surface can have a serrated profile. The carriage brake may have a matching serrated profile configured to positively engage the guide rail brake engaging surface. The carriage brake may be in the form of a cam, which may have a serrated braking surface or foot associated therewith.

[0010] Once a brake on the carriage engages a brake-engaging surface on the guide rail to restrict carriage movement, disengagement may be effected by movement of the brake in a direction opposite to the movement that caused the engagement. For example, if downward movement of the carriage causes the brake to engage the brake-engaging surface, then upward movement of the carriage disengages the brake from the brake-engaging surface.

[0011] A load may be an object. A load may be a panel. In the following, the term "panel" is used to refer to various architectural structures suitable for closing or covering openings in buildings, such as for pedestrian and / or vehicular access.

[0012] The rail system may further comprise a load or panel. In this disclosure, various terms including "panel" are used to refer to various architectural structures suitable for closing or covering building openings, such as those for pedestrian and / or vehicular access, and suitable for movement by a guide rail system. For example, terms such as curtain, door, roller door, sectional panel door, full panel door, solid panel door, garage door, etc. are used. For simplicity, in this disclosure, the term "panel" is also used generically and inclusively to collectively refer to these and similar architectural structures. It is understood that the carriage may be configured to be attached to objects or loads other than panels. The carriage may be configured to be attached to objects or containers in which objects can be placed. The rail system may be configured to transport or distribute objects or containers from one location to another.

[0013] The system may include a control system for controlling the supply of energy to the electromagnets. The control system may be powered by an external power source. A backup battery may be provided to provide backup power in an emergency or to provide bulk power during operation of moving the panels.

[0014] According to the present disclosure, a method is provided for operating (e.g., opening and closing) an autostereoscopic or prefabricated panel, roller door, or curtain by incorporating a lift mechanism into a guide rail that is a common component of such panels (e.g., doors, etc.) The lift mechanism includes a number of fixed electromagnets attached to the guide rail and a number of carriage wheels (which are magnetic).

[0015] According to the present disclosure, such a configuration can allow for fewer installation components and therefore less installation time, which can lower maintenance costs and allow for quieter operation as well as improved aesthetics.

[0016] According to an embodiment, the invention includes a fail-safe mechanism in the form of a braking system that is activated in the event of a component failure or interruption of the power supply. Such a system can increase safety.

[0017] The rail system may be configured to lift a load or panel vertically. For example, a pair of guide rails may be arranged vertically with the panel extending vertically between them. Movement of the carriage along the pair of guide rails may raise the panel vertically or lower the panel vertically. The rail system may be configured to move a load or panel horizontally. For example, a pair of guide rails may be arranged horizontally with the panel extending horizontally between them. Movement of the carriage along the pair of guide rails may move the panel horizontally. The system may be configured to combine vertical and horizontal portions in the guide rails, with movement of the carriage along each of these portions moving the panel accordingly. The rail system is not limited to only vertical and horizontal configurations. It is understood that the guide rails may be arranged at an angle to a vertical or horizontal plane to arrange the system to be able to move the panel in any direction.

[0018] The embodiments disclosed herein may be applicable to domestic, commercial, and industrial applications with scalable designs to suit the varying weights, travel speeds, and environments of the application. [Brief description of the drawings]

[0019] [Figure 1]1 is a schematic cross-sectional view of a guide rail according to an embodiment of the present disclosure. [Diagram 2] 2A-2B are schematic diagrams of guide rails having a bent configuration, according to an embodiment of the present disclosure. [Diagram 3] 3A-3B are schematic diagrams of a guide rail having a straight configuration, according to an embodiment of the present disclosure. [Figure 4] FIG. 2 is a schematic side view of a carriage according to an embodiment of the present disclosure. [Diagram 5] 5A and 5B are schematic cross-sectional views of a guide rail and a carriage according to an embodiment of the present disclosure. [Figure 6] FIG. 2 is a schematic diagram of the control logic of the components of a guide rail system according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] According to one embodiment, a rail system (or assembly) is provided for positioning and movement of loads (or objects) such as panels (e.g., single and split panel doors, roller doors, or curtains) in a vertical plane, a horizontal plane, or other planes at angles to the vertical and horizontal planes. The rail system incorporates a magnetic drive and positioning system. The rail system includes at least one guide rail and at least one carriage. Each guide rail incorporates a series of electromagnet arrays (fixed electromagnets) that are disposed within the guide rail and sequentially provide magnetic attraction and repulsion to move a carriage incorporating permanent magnets along the guide rail with variable force and velocity in response to commands from a control system.

[0021] According to one embodiment, a carriage is provided that incorporates permanent magnets forming wheels. The carriage may be configured to connect to a load or object. For example, in one embodiment, the load (or object) is in the form of a panel, a roller door, or the like. The carriage is mounted to a guide rail and driven via electromagnets incorporated into the guide rail. The load may be positioned or moved via interaction of the carriage's wheels and the electromagnets in the guide rail.

[0022] According to one embodiment, the rail system includes an integrated automatic mechanically operated braking system that can maintain the carriage and thereby the load or object (panel, roller door, etc.) in a fixed position in the absence of interruption of the specific operation or power supply of the rail system. For example, if the load is a roller door, the braking system ensures that the roller door stays in any intended position without the need for a constant drive signal and prevents the roller door from moving in any direction in the event of loss of power to the door control or drive system. In an emergency, the system can be manually overridden, allowing the carriage to move and the roller door to open.

[0023] For example, if the load is a door, the rail system may be suitable for many panel materials and may be adaptable to various widths and heights of panels, roller doors, curtains, and the like.

[0024] According to one embodiment, the rail system is component based with the selection and quantity of components based on the specific application. The components may be manufactured to a scale where physical characteristics other than size may remain consistent throughout the light, medium, and heavy duty versions of the system. The force capacity is not particularly limited and may be set according to the specific application. For example, without intending to limit the scope of this disclosure, it may range from 500 to 4000 Newtons. The operating speed may also vary depending on the specific application and may range from 0.1 m / sec to 4 m / sec as a non-limiting example.

[0025] According to one embodiment, the rail system includes a pair of guide rails spaced apart from each other such that the distance between the guide rails is constant along the guard rail. The guide rails may be straight or curved, or a combination thereof, depending on the application and location. The guide rails may include curved or straight sections connected by bends. For example, a vertically extending straight section may be connected to a horizontally extending straight section connected by a bend (see, for example, Figures 2A and 2B). Carriages fixed to the moving panel or curtain are attached and inserted into the guide rails in the number required for the application.

[0026] According to one embodiment, the rail system may include a single guide rail disposed substantially in one plane (e.g., disposed substantially horizontally). For example, the rail system may be configured to move a curtain, the rail system may be disposed above a window, a door opening, or along a ceiling. In such cases, the guide rail may include straight portions, curved portions, or a combination thereof.

[0027] According to one embodiment, a control system incorporating a battery backup is installed adjacent to the guide rail(s) to provide controlled energy to the guide rail electromagnets, which are energized with various currents and sequences to initiate carriage movement.

[0028] According to one embodiment, each carriage has a linkage, bracket, point of attachment, or the like (hereinafter referred to as a "linkage") configured to connect to a load or object.

[0029] According to one embodiment, each carriage incorporates a brake mechanism that engages the guide rail during braking. For example, the brake mechanism may be in the form of a sawtooth cam mechanism that positively engages a corresponding brake engagement surface in the form of a sawtooth profile incorporated in the guide rail (see Figs. 4, 5A and 5B). The brake mechanism of the carriage may be provided on the linkage. For example, with respect to the vertical configuration shown in Figs. 3A and 3B, when a panel connected to the carriage attempts to move in a downward direction without a direct force from the carriage, the sawtooth cam feature engages with the brake engagement surface of the guide rail to stop any downward movement. According to this embodiment, the cam disengages only when an upward force is applied to the linkage by the carriage. This ensures that no uncommanded downward movement of the load (e.g., panel or curtain) occurs. In the event of an obstruction in the downward movement of the load (e.g., panel or curtain), the sawtooth cam feature engages with a sawtooth profile on the guide rail to prevent further movement.

[0030] According to one embodiment, to enable downward movement (see, for example, the configuration shown in Figures 3A and 3B), the carriage first moves upward to disengage the cam brake mechanism, and the speed of movement is adjusted such that the cam lock (brake mechanism) remains disengaged under command.

[0031] According to one embodiment, a system of electronics housed within the control unit uses current sensing and power loops to provide precise energization of stator electromagnets that induce infinitely variable movements in the carriage fixed magnets. Using a loop feedback system, each guide rail and the carriage that travels thereon can be precisely positioned to avoid any misalignment of the load, panel or curtain, and can maintain relative positioning at any point of movement.

[0032] According to one embodiment, the electronic control system has a self-calibration system that takes into account external factors such as wind, ice and other factors, as well as anomalies such as friction variables due to age and maintenance. In this embodiment, a non-volatile memory of events and parameters forms part of the control system to provide a service history and generate alarms and service requests via a basic display.

[0033] According to one embodiment, integrated dry contact triggering and on-board RF and Bluetooth® communications provide users of the system with several external control and monitoring solutions.

[0034] According to one embodiment, the control and operating system is designed to operate from a 24 Volt DC external power supply, the size of the power supply depending on the operating frequency of the system and the size of the unit (small, medium or large model).

[0035] Hereinafter, an embodiment will be described with reference to the drawings.

[0036] 1 is a cross-sectional view of a guide rail 12 of a rail system 10 according to one embodiment. In this embodiment, the guide rail 12 is fixed to a receiving structure (e.g., a wall) 14 via an "L" shaped bracket 16, which allows for mounting via screws 17 on a flush or vertical surface. The guide rail 12 is made up of two non-ferrous metal or polymer guide rail sections 12A, 12B connected via screws 18 spaced at intervals along their length. In this embodiment, a gap or clearance 19 exists between guide rail sections 12A, 12B on the side of the guide rail 12 opposite the receiving structure 14. The electromagnets (stator magnets) 20 are formed from ferrous bobbins 22 attached to the guide rail sections 12A, 12B, which house electromagnetic stator coils in the form of copper induction coils 24 wound around the bobbins 22. Each coil 24 is connected through an embedded PCB backplane (not shown), which interconnects to other rail sections or final controls via a multi pin connector 26. A sawtooth damping profile 28 and nylon guide inserts 30 form part of a damping system 32. The guide rail 12 is manufactured in modular sections, which can be connected end to end, and may include as many, few or no stator electromagnets as required by each application, depending on their location within the range of travel of the panel or curtain.

[0037] 2A and 2B show an example of a configuration of the guide rail 12 in a rail system 10 for moving a garage door (not shown), e.g., a sectional garage door with multiple panels. In such a configuration, a second guide rail 12 (not shown) is provided on the opposite side of the door opening in a corresponding configuration. FIGS. 2A and 2B show a bent configuration in which a first portion 34 of the guide rail 12 is vertical and a second portion 36 of the guide rail 12 is horizontal. The first portion 34 is connected to the second portion 36 via a bend 38. FIG. 2A shows a schematic arrangement of the carriage 40 in the vertical first portion 34 as it would be for a garage door in a fully closed position. FIG. 2B shows an arrangement of the carriage 40 in the horizontal second portion 36 as it would be for a garage door in a fully open configuration. The guide rail 12 incorporating the electromagnet 20 may be configured in a bent configuration (see FIGS. 2A and 2B) or in a straight configuration (see FIGS. 3A and 3B). FIGS. 2A, 2B, 3A and 3B show the location and size of the electromagnet embedded in the guide rail 12, as well as depict the carriage 40 including a permanent magnet in the form of a wheel 42, shown in a fully closed position (FIGS. 2A and 3B) and a fully open position (FIGS. 2B and 3A). Note that these figures show cutaway views illustrating examples and are non-specific with respect to the location and amount of coils (electromagnets) and / or carriage. If the guide rail 12 is bent (as in FIGS. 2A and 2B), the bends 38 may be standard components that fit between standard guide rails 12 to guide the carriage and maintain the electrical circuit.

[0038] FIG. 4 is a schematic side view of the carriage. According to this embodiment, the rotor function of the rail system includes magnets in the form of circular rare earth high strength magnets that also function as wheels 42 of the carriage 40. Depending on the application, additional magnets (wheels) 42 may be added to the carriage 40. The wheels 42 are connected by a dolly 44 that includes a main connector 46 and extension arms 48. The main connector 46 and extension arms 48 are connected using pin and clip arrangements 62 that are formed from a non-ferrous material and also connect to the wheels 42. The extension arms 48 and additional wheels 42 are shown in dashed lines to indicate that they may be optional and may be included to increase the size and carrying capacity of the carriage 40. Further extension arms 48 and wheels 42 (not shown) may be added to further increase the length and carrying capacity of the carriage 40. The main connector 46 includes connecting plates 47 and incorporates a cam 50 and a keyed central pin 54 as part of the braking system 32. The cam 50 may be configured to be attached to a load or object 64 (in this embodiment, a garage door) to be moved by the rail system 10 by having a point of attachment, bracket, linkage, or connector to which the load or object is attached. In this embodiment, the cam 50 includes a rod 56 that extends from the cam 50 through the gap 19 between the guide rail sections 12A, 12B.

[0039] FIG. 5 is a schematic cross-sectional view of the guide rail 12 according to one embodiment. FIG. 5A shows a cross-section through the guide rail 12 and the cam 50 (connection plate 47 not shown) of the main connector 46 of the dolly 44 of the carriage 40. FIG. 5B shows a cross-section through the guide rail 12 and the wheels 42 of the carriage 40. The magnets (rare earth magnets in this embodiment) forming the wheels 42 of the carriage 40 are arranged so that the poles of the magnets interact with the electromagnetic stators 20 on the guide rail. The magnet wheels 42 are sized according to the application and the size of the load to be moved by the rail system 10, the guide rail 12, the magnet wheels 42, etc. The loads can be configured for small, medium and large loads. The wheels 42 are guided by grooves 58 formed in the guide rail 12. The wheels 42 can have a nylon outer ring 60 depending on the application. The wheels 42 are retained by a non-ferrous pin and clip arrangement 62. The primary connector 46 incorporates a rigid rod 56 for mounting a load or object 64 (e.g., roller door, door, curtain, etc.), a cam shaped casting 50 as a body incorporating the cam mechanism, and a braking foot 66 formed on the rod 56. The braking foot 66 has a sawtooth profile 68 that corresponds and matches the sawtooth braking profile 28 on the guide rail 12. The primary connector 46 is connected to the cam 50 by a large pin and clip arrangement 70. The connection to the load 64 is made via a specific bracket 72 suited to the particular application. In this embodiment, the bracket 72 is connected to the rod 56 at one end and to the load 64 by a screw 74. The central pin 54 rotates the cam 50 a few degrees depending on the load of the object 64 connected to the carriage via the rod 56.As a result, when a load of an object (e.g., a garage door) 64 is applied to the carriage 40 under normal operation, the cam 50 is rotated and the rod 56 is positioned such that the brake foot 66 of the carriage 40 and the sawtooth brake profile 28 on the guide rail 12 do not engage, allowing the carriage 40 to move relative to the guide rail. However, if a malfunction causes the carriage to not support the load of the object (e.g., both the carriage and the object are falling together without resistance), the cam 50 rotates in the opposite direction and the rod 56 is positioned such that the brake foot 66 of the carriage 40 and the sawtooth brake profile 28 on the guide rail 12 engage, thereby acting to prevent both the carriage 40 and the object 64 from moving relative to the guide rail 12.

[0040] It will be appreciated that in order to maintain efficiency of the magnetic interaction between the electromagnets in the guide rail and the permanent magnets in the wheels, it is preferable to use non-ferrous or non-magnetic materials for the other components of the system (e.g., guide rail 12, connecting plate 47, pins, clips, screws, etc.).

[0041] FIG. 6 shows a schematic diagram of an embodiment of the control logic of the electronic drivers and controller. In this embodiment, the operation of the rail system 10 is controlled by an electronic control system 76 to provide power to the stator 20 to ensure smooth movement of the load 64 (panel, door, curtain, etc.). This can be affected by environmental factors, physical interference, and power fluctuations. In this embodiment, the control system 76 is powered by an external 24 volt power source 78. The external 24 volt power source 78 is sized based on the size and duty of the rail system equipment. A battery 80 is installed to provide power as emergency backup power 81 and bulk power 82 during operation of the mechanisms of the rail system. A control circuit 83 receives external operation signals 84 including dry contact inputs, RF signals (remote control), etc. On-board Bluetooth® connectivity 86 for control and monitoring functions is also possible.

[0042] In this embodiment, the control system 76 provides electrical energy to a group of stationary electromagnets (electromagnetic coils) 20 in the guide rail 12 in a specific sequence and at variable energy levels to generate a varying magnetic field that acts on the carriage's magnet wheels 42 so that the carriage 40 moves along the guide rail 12, thereby moving the load 64 connected to the carriage 40. In a configuration in which a pair of guide rails 12 is used to move the load 64 (such as the garage door example mentioned above), a constant feedback loop 86 compares the energy consumption in corresponding sections of each guide rail 12 to ensure that the carriages 40 operate in unison. Additional pulse counters can also provide position data from position sensing 88 and load data from load sensing 90 associated with each guide rail 12 to provide position, load, speed and warning signals. In FIG. 6, the guide rails 12 are designated "LHS" for the left guide rail 12 and "RHS" for the right guide rail 12. The control system 76 includes a programmed calibration sequence used for initial setup, which may be performed routinely, or when parameters are sensed to be outside of operational set points, or if operation is interrupted or disturbed. A solenoid activated lock mechanism 92 may be provided to prevent manual movement of the load 64 (e.g., lifting a garage door, moving a panel or curtain).

[0043] Those skilled in the art will appreciate that numerous variations and / or modifications can be made to the above-described embodiments without departing from the broad general scope of the present disclosure.

Claims

1. A rail system for moving a load, comprising: A guide rail and A plurality of fixed electromagnets attached to the guide rail; a carriage configured to move along the guide rail and connect to the load, the carriage having a plurality of permanent magnets; movement of the carriage along the guide rail is effected by a varying magnetic field generated by the fixed electromagnet acting on the permanent magnet of the carriage; A rail system wherein the guide rail is oriented such that movement of the carriage along the guide rail moves the load vertically.

2. At least a first portion of the guide rail is oriented at an angle relative to a horizontal plane, The rail system of claim 1 , wherein movement of the carriage along the guide rail raises or lowers the load relative to the horizontal plane.

3. At least a second portion of the guide rail is oriented at an angle relative to a vertical plane; The rail system of claim 1 or claim 2, wherein the carriage moves substantially horizontally along the second portion of the guide rail.

4. The rail system of claim 1, further comprising a load connected to the carriage.

5. The guide rail defines a travel path, The rail system of claim 1 , wherein the permanent magnet of the carriage is disposed within the path of travel.

6. The rail system of claim 1, further comprising a plurality of wheels attached to the carriage.

7. The rail system described in claim 6, wherein at least one of the plurality of permanent magnets is one of the plurality of wheels.

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