Shutter device and setting method

Abstract

The upper and lower limit positions can be easily set. [Solution] A shutter device comprising: a drive control unit that starts the opening operation of the shutter curtain when a predetermined operation is performed on an operating device, and stops the opening operation and starts the closing operation when the overload state is detected during the opening operation; a first processing unit that sets the upper limit position based on the current position of the shutter curtain when the overload state is detected by the overload detection during the opening operation; and a second processing unit that sets the lower limit position based on the current position of the shutter curtain when the overload state is detected by the overload detection during the closing operation.

Description

Technical Field

[0001] The present invention relates to a shutter device and a setting method.

Background Art

[0002] There is a shutter device that opens and closes a shutter curtain between an upper limit position (fully open position) and a lower limit position (fully closed position) (for example, Patent Document 1). By the way, it is necessary to set the upper limit position and the lower limit position when installing the shutter device.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The upper limit position and the lower limit position of the shutter curtain are set by an operator or a user operating a remote control device while visually observing the position of the shutter curtain to move the shutter curtain to a desired position and registering the current position of the shutter curtain. Therefore, in order to set the upper limit position and the lower limit position for each of a plurality of shutter devices, it is necessary to perform the above operation for each shutter device, which is troublesome for the installer or the user.

[0005] The present invention has been made in view of such circumstances, and an object thereof is to provide a shutter device and a setting method capable of easily setting the upper limit position and the lower limit position.

Means for Solving the Problems

[0006] (1) One aspect of the present invention is a shutter device that performs an opening and closing operation of a shutter curtain between an upper limit position and a lower limit position, including a motor that drives the shutter curtain to open and close, and a shutter control device that performs the opening and closing operation by controlling the motor and executes overload detection to detect an overload state of the motor during the opening and closing operation. The shutter control device starts an opening operation of the shutter curtain when a predetermined operation is performed on an operation device, and when the overload state is detected during the opening operation, stops the opening operation and automatically starts a closing operation. The shutter control device also includes a first processing unit that sets the upper limit position based on the current position of the shutter curtain when the overload state is detected by the overload detection during the opening operation, and a second processing unit that starts the overload detection when the position of the shutter curtain passes a threshold value during the closing operation and sets a position that is separated from the current position of the shutter curtain in the opening direction by a first distance as the lower limit position when the overload state is detected by the overload detection.

[0007] (2) The shutter device according to (1) above, wherein when the overload state is detected by the overload detection during the closing operation, the drive control unit may stop the closing operation of the shutter curtain and move the shutter curtain to the lower limit position set by the second processing unit.

[0008] (3) The shutter device according to (1) above, wherein when the overload state is detected by the overload detection during the closing operation, the drive control unit may stop the closing operation of the shutter curtain and move the shutter curtain in an opening operation by a second distance that is smaller than the first distance.

[0009] (4) A shutter device according to any one of (1) to (3) above, further comprising an output unit that outputs a pulse signal corresponding to the rotation of the motor, and a load detection unit that counts the number of pulses in the pulse signal, wherein the second processing unit may set the lower limit position to a value obtained by subtracting a predetermined number of pulses from the count value of the pulse signal when the overload state is detected by the overload detection during the closing operation.

[0010] (5) In the shutter device of (4) above, the second processing unit may determine that the motor is in an overload state when the amount of change between the pulse width of the pulse signal corresponding to the current count value and the pulse width of the pulse signal corresponding to the count value two or more times earlier exceeds a predetermined value one or more times.

[0011] (6) A setting method for a shutter device to set an upper limit position and a lower limit position of a shutter curtain, the setting method including: an opening operation step for starting an opening operation of the shutter curtain when a predetermined operation is performed on an operating device; a first detection step for performing a first overload detection for detecting an overload state of a motor that drives the shutter curtain during the opening operation; a first stopping step for stopping the opening operation when the overload state is detected in the first detection step; a first setting step for setting the current position of the shutter curtain stopped in the first stopping step to the upper limit position; and a closing step for starting a closing operation of the shutter curtain when the upper limit position is set. This setting method includes an operation step, a second detection step of starting a second overload detection to detect an overload state of the motor when the position of the shutter curtain passes a threshold value during the closing operation, a second stop step of stopping the closing operation when the overload state is detected by the second overload detection, and a second setting step of setting the lower limit position to a position that is a predetermined distance away in the opening direction from the current position of the shutter curtain when the overload state is detected by the second overload detection, thereby setting the lower limit position to a state in which the shutter curtain is fully closed and the deflection of the shutter curtain that occurs in the second stop step is eliminated.

Advantages of the Invention

[0012] As described above, according to the present invention, the upper limit position and the lower limit position can be easily set.

Brief Description of the Drawings

[0013]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Modes for Carrying Out the Invention

[0014] Hereinafter, the shutter device according to the present embodiment will be described with reference to the drawings.

[0015] FIG. 1 is a diagram showing an example of the schematic configuration of a shutter system 1 including a shutter device according to the present embodiment. The shutter system 1 shown in FIG. 1 includes a shutter device 2 and an operation device 3.

[0016] The shutter device 2 is an electric shutter device that opens or closes an opening such as a window or a door of a building. The shutter device 2 includes a shutter curtain 4 and can open or close the opening by opening and closing the shutter curtain 4 based on an operation signal from the operation device 3.

[0017] The operating device 3 is connected to the shutter device 2 to be operated, either by wire or wirelessly, and can communicate with the shutter device 2 mutually. The operating device 3 is an operating means that can be operated by a user or an operator and is provided with means for inputting an operation signal to the shutter device 2, for example, a remote control device.

[0018] Specifically, when any switch is pressed by the user, the operating device 3 outputs an operation signal, which is a signal corresponding to the switch, to the shutter device 2. For example, when the open switch SWo is operated, the operating device 3 transmits a first operation signal instructing the opening operation of the shutter curtain 4 to the shutter device 2. Also, when the close switch SWc is operated, the operating device 3 transmits a second operation signal instructing the closing operation of the shutter curtain 4 to the shutter device 2. Further, when the stop switch SWt is operated, the operating device 3 transmits a stop signal instructing the stop of the opening operation or the closing operation of the shutter curtain 4 to the shutter device 2.

[0019] Furthermore, when a predetermined operation is performed by the user, the operating device 3 transmits a setting signal to the shutter device 2. For example, the predetermined operation is an operation different from a short press operation of one of the open switch SWo, the close switch SWc, and the stop switch SWt. Specifically, the predetermined operation is a simultaneous press of two or more of the open switch SWo, the close switch SWc, and the stop switch SWt, or a long press of one or more switches. However, the above-described predetermined operation is not limited to the simultaneous pressing of two or more switches or the long pressing of one or more switches among the open switch SWo, the closed switch SWc, and the stop switch SWt. For example, the operation device 3 may include an initial setting button. And the above-described predetermined operation may be a pressing operation of the initial setting button. For example, the initial setting button may be provided on the front surface of the operation device 3 or on the back surface. Further, when the initial setting button is provided on the back surface of the operation device 3, for example, the initial setting button is covered by a back cover, and can be operated by removing the back cover. That is, the initial setting button is provided at a position where it is exposed when the back cover is removed. Also, the initial setting button may be provided in a battery box for storing a battery. In this case, by removing a battery cover configured to be attachable to the main body case of the operation device 3 so as to cover the battery box from the back side of the operation device 3, the initial setting button is configured to be operable by the user. That is, the initial setting button is provided at a position where it is exposed when the battery cover is removed. Here, the operation device 3 may be a portable information terminal such as a smartphone or a tablet terminal. In this case, the above-described predetermined operation may be an initial setting command operation in an application of the portable information terminal (for example, a smartphone application).

[0020] Next, an example of the schematic configuration of the shutter device 2 according to the present embodiment will be described.

[0021] As shown in FIG. 1, the shutter device 2 includes a shutter curtain 4, guide rails 5a and 5b, and a shutter box 6.

[0022] The shutter curtain 4 has a plurality of long slats 4a connected in the vertical direction and a crossbar portion 4b provided at the lowermost end.

[0023] The lintel portion 4b is a long member having a rectangular cross-section connected to the lowermost slat 4a. The lintel portion 4b is formed to protrude so as to contact a stop (not shown) or the shutter box 6 when the shutter curtain 4 is in the fully open state (upper limit position Pu). That is, the lintel portion 4b contacts a stop (not shown) or the shutter box 6 when the shutter curtain 4 is in the fully open state. On the other hand, the lintel portion 4b contacts the lower frame of the frame body of the shutter device 2 or the floor surface when the shutter curtain 4 is in the fully closed state (lower limit position Pl). Note that the above-mentioned stop is a parting member of the opening of the shutter device 2 formed by the upward movement of the shutter curtain 4, and may be provided at the lower part of the shutter box 6.

[0024] A pair of guide rails 5a and 5b are provided at both ends in the width direction of the shutter curtain 4 and are erected perpendicular to the bottom surface. The guide rails 5a and 5b regulate the lateral displacement of each slat 4a constituting the shutter curtain 4.

[0025] The shutter box 6 is provided at the upper part of the shutter device 2. This shutter box 6 performs the rewinding of the shutter curtain 4 (during the closing operation of the shutter curtain 4) or the winding (during the opening operation of the shutter curtain 4).

[0026] Hereinafter, an example of the schematic configuration of the shutter box 6 according to the present embodiment will be described. As shown in FIG. 1, the shutter box 6 includes a shaft 7, a motor 8, an output unit 9, and a shutter control device 10.

[0027] The shaft 7 is connected to the upper end portion of the shutter curtain 4 and the motor 8. The shaft 7 is rotationally driven in the forward and reverse directions by the motor 8. In response to the rotation of the shaft 7, the shutter curtain 4 is rewound or wound. The shutter curtain 4 wound around the shaft 7 is configured to be accommodated in the shutter box 6.

[0028] The motor 8 is a drive source that drives the shutter curtain 4 to open and close by rotationally driving the shaft 7, and is composed of, for example, a DC motor. The motor 8 rotates forward, rotates backward, or stops rotating based on a drive signal from the shutter control device 10.

[0029] The output unit 9 has a function of outputting the driving status of the motor 8. The output unit 9 is, for example, an encoder built into the motor 8. The output unit 9 outputs a pulse signal (hereinafter referred to as "position pulse") corresponding to the rotation of the motor 8 to the shutter control device 10. For example, the output unit 9 outputs one position pulse to the shutter control device 10 when the motor 8 makes one rotation. Note that the output unit 9 is not limited to an encoder, and can be arbitrarily selected as long as it can grasp the rotation amount of the winding shaft or the motor 8, such as measuring the rotation angle amount of the motor 8.

[0030] FIG. 2 is a schematic configuration diagram of the shutter control device 10 according to the present embodiment. As shown in FIG. 2, the shutter control device 10 includes a communication unit 11, a drive unit 12, and a control unit 13.

[0031] The communication unit 11 transmits and receives information by communicating with the operation device 3. The communication method of the communication unit 11 is not particularly limited, but in the present embodiment, a wireless communication method such as a short-range wireless communication standard RF4CE (Radio Frequency for Consumer Electronics) or Bluetooth (registered trademark) is used.

[0032] The drive unit 12 drives or stops the motor 8 by generating a drive signal corresponding to a command from the control unit 13 and outputting it to the motor 8.

[0033] The control unit 13 is composed of, for example, a microprocessor such as a CPU or MPU, a microcontroller such as an MCU, and a storage device, and controls the drive of the motor 8 according to the operation of the switch of the operation device 3.

[0034] Based on the operation signal from the operation device 3, the control unit 13 controls the rotation of the motor 8 to execute the opening operation or closing operation (hereinafter simply referred to as "opening / closing operation") of the shutter curtain 4 between the upper limit position Pu and the lower limit position Pl. Here, the upper limit position Pu is the position where the shutter curtain 4 is in the fully open state (fully open position). The lower limit position Pl is the position where the shutter curtain 4 is in the fully closed state (fully closed position).

[0035] When the control unit 13 receives the first operation signal from the operation device 3 via the communication unit 11, it outputs a command (hereinafter referred to as "open command") to the drive unit 12 to cause the shutter curtain 4 to be wound up on the shaft 7 and perform the opening operation. Thereby, the drive unit 12 rotates the motor 8 forward to perform the opening operation of the shutter curtain 4.

[0036] Also, when the control unit 13 receives the second operation signal from the operation device 3 via the communication unit 11, it outputs a command (hereinafter referred to as "close command") to the drive unit 12 to cause the shutter curtain 4 to be unwound from the shaft 7 and perform the closing operation. Thereby, the drive unit 12 rotates the motor 8 in reverse to perform the closing operation of the shutter curtain 4.

[0037] Also, when the control unit 13 receives a stop signal from the operation device 3, it outputs a command (hereinafter referred to as "stop command") to the drive unit 12 to stop the operation of the shutter curtain 4. Thereby, the drive unit 12 stops the rotation of the motor 8 and stops the opening / closing operation.

[0038] When the control unit 13 receives a setting signal from the operation device 3, it shifts to the setting mode for setting the upper limit position Pu and the lower limit position Pl. In the setting mode, the control unit 13 performs an opening / closing operation by controlling the motor 8 and executes overload detection to detect an overload state of the motor 8. Then, when the control unit 13 is in the setting mode and an overload state of the motor 8 is detected during the opening operation of the shutter curtain 4, the upper limit position Pu is set based on the current position of the shutter curtain 4, and when an overload state of the motor 8 is detected during the closing operation of the shutter curtain 4, the lower limit position Pl is set based on the current position of the shutter curtain 4.

[0039] Hereinafter, the functional units of the control unit 13 for executing the processing of the setting mode according to the present embodiment will be described with reference to FIG. 3. FIG. 3 is a functional block diagram of the control unit 13 for executing the return processing of the shutter control device 10 according to the present embodiment.

[0040] Hereinafter, the functional units of the control unit 13 according to an embodiment of the present invention will be described.

[0041] The control unit 13 includes a drive control unit 14, a load detection unit 15, a processing unit 16, and a storage unit 17.

[0042] When a predetermined operation is performed on the operation device 3, the drive control unit 14 outputs an open command to the drive unit 12 to start the opening operation of the shutter curtain 4. Then, when an overload state of the motor 8 is detected by overload detection during the opening operation, the drive control unit 14 outputs a stop command to stop the opening operation and outputs a close command to the drive unit 12 to start the closing operation of the shutter curtain 4. When an overload state of the motor 8 is detected by overload detection during the closing operation, the drive control unit 14 outputs a stop command to stop the closing operation.

[0043] The load detection unit 15 detects the load applied to the motor 8 (hereinafter referred to as "motor load"). The load detection unit 15 according to the present embodiment includes a counter 151 and a load measurement unit 152.

[0044] The counter 151 counts the number of pulses of the position pulse. Note that the count value n of this number of pulses corresponds to the current position of the shutter curtain 4.

[0045] The load measurement unit 152 measures the motor load based on the position pulse output from the output unit 9. Specifically, for example, the load measurement unit 152 measures the pulse width An of the position pulse output from the output unit 9 as the motor load for each position pulse (for each count value n of the counter 151). For example, the pulse width An is the pulse width of the position pulse when the motor 8 makes one rotation.

[0046] Here, the position pulse has a larger pulse width as the rotation speed of the motor 8 decreases, and a smaller pulse width as the rotation speed of the motor 8 increases. That is, when the shutter curtain 4 reaches the upper limit position Pu and the flange portion 4b contacts the magsa or the shutter box 6, a load is applied to the motor 8, and the motor 8 enters an overload state. Therefore, the rotation speed of the motor 8 decreases, and the pulse width of the position pulse increases. Also, when the shutter curtain 4 reaches the lower limit position Pl and the flange portion 4b abuts against the floor surface or the lower frame, and then the closing operation continues, the flange portion 4b is in a state of pressing against the floor surface or the lower frame. As a result, a load is applied to the motor 8, and the motor 8 enters an overload state. Therefore, the rotation speed of the motor 8 decreases, and the pulse width of the position pulse increases. Note that when the shutter curtain 4 reaches the lower limit position Pl and the flange portion 4b abuts against the floor surface or the lower frame, and then the closing operation continues, deflection occurs in the slats from below. As a result, a load is applied to the motor 8, and the motor 8 enters an overload state. Therefore, the rotation speed of the motor 8 decreases, and the pulse width of the position pulse increases.

[0047] Therefore, the load measurement unit 152 calculates the pulse width An of the motor 8 as the motor load by measuring the pulse width of each position pulse (for each count value n). The load measurement unit 152 associates the count value n with the motor load and outputs it to the processing unit 16. That is, the load measurement unit 152 outputs the count value n and the pulse width (motor load) An of the position pulse corresponding to the count value n to the processing unit 16. Further, the load measurement unit 152 associates the position information n with the pulse width An of the position pulse corresponding to the position information n and stores it in the storage unit 17 as load information.

[0048] In the setting mode, the processing unit 16 sets the upper limit position Pu and the lower limit position Pl by detecting an overload. Specifically, the processing unit 16 includes a first processing unit 161 and a second processing unit 162.

[0049] The first processing unit 161 performs overload detection (hereinafter referred to as "first overload detection") during the opening operation of the shutter curtain 4 in the setting mode. When the first processing unit 161 detects an overload state of the motor 8 by the first overload detection, it sets the upper limit position Pu based on the current position of the shutter curtain 4. For example, the first processing unit 161 may set the count value n at the time when the overload state of the motor 8 is detected by the first overload detection as the upper limit position Pu. For example, the first processing unit 161 may reset the count value n at the time when the overload state of the motor 8 is detected by the first overload detection to "0", and set the count value n reset to "0" as the upper limit position Pu. The first overload detection is a process of determining whether the motor 8 is in an overload state based on the motor load output from the load detection unit 15. For example, when the motor load or the change rate of the motor load exceeds a predetermined threshold value th1, the first processing unit 161 determines that the motor 8 is in an overload state.

[0050] Here, in the first overload detection, the first processing unit 161 does not detect the overload state of the motor 8 at the position (upper limit position Pu) where the flap portion 4b abuts against the magsa or the shutter box 6, but at the position where the shutter curtain 4 is further wound up by performing the opening operation of the shutter curtain 4 from the upper limit position Pu (hereinafter referred to as the "winding-up position"). The deviation ΔH1 between the winding-up position and the upper limit position Pu is represented by the count number n1 of the position pulses between the winding-up position and the upper limit position Pu, and can be obtained in advance according to experiments, the size of the shutter curtain 4, etc. Therefore, the first processing unit 161 may obtain the upper limit position Pu from the winding-up position using the known deviation ΔH1. For example, the first processing unit 161 may set the upper limit position Pu by subtracting or adding the count number n1 from the count value n when the overload state of the motor 8 is detected by the first overload detection.

[0051] For example, when a predetermined operation is performed on the operation device 3, the drive control unit 14 outputs an open command to the drive unit 12 to start the opening operation of the shutter curtain 4. Then, when the overload state of the motor 8 is detected by overload detection during the opening operation, the drive control unit 14 outputs a stop command to stop the opening operation. At this time, the current position of the shutter curtain 4 is the winding-up position. Therefore, the drive control unit 14 lowers the shutter curtain 4 at the winding-up position by the count number n1 and then stops it. Then, the first processing unit 161 may reset the current position of the shutter curtain 4 that has been closed by the count number n1, that is, the current count value n, to "0", and set the count value n reset to "0" as the upper limit position Pu. The drive control unit 14 automatically executes the closing operation when the upper limit position Pu is set. However, if the deviation ΔH1 is acceptable, the shutter curtain 4 at the winding-up position may not be lowered by the count number n1, and the winding-up position may be set as the upper limit position Pu.

[0052] The second processing unit 162 performs overload detection (hereinafter referred to as "second overload detection") during the closing operation of the shutter curtain 4 in the setting mode. Then, when the second processing unit 162 detects an overload state of the motor 8 by the second overload detection, it sets the lower limit position Pl based on the current position of the shutter curtain 4. For example, the second processing unit 162 may set the count value n when the overload state of the motor 8 is detected by the second overload detection as the lower limit position Pl. The second overload detection is a process of determining whether the motor 8 is in an overload state based on the motor load output from the load detection unit 15. For example, when the motor load or the change rate of the motor load exceeds a predetermined threshold value th2, the second processing unit 162 determines that the motor 8 is in an overload state. Note that the first overload detection and the second overload detection may be overload detections by the same method or may be overload detections by different methods.

[0053] Here, in the second overload detection, the second processing unit 162 does not detect the overload state of the motor 8 at the position (lower limit position Pl) where the lintel portion 4b contacts the floor surface or the lower frame, but at a position where the shutter curtain 4 is further pushed into the floor surface or the lower frame by performing the closing operation of the shutter curtain 4 from the lower limit position Pl (hereinafter referred to as the "pushing-in position"). That is, the shutter curtain 4 at the pushing-in position is bent from below, and a deviation ΔH2 occurs between the pushing-in position, which is the position where the overload state of the motor 8 is detected by the second overload detection during the closing operation, and the lower limit position without such bending. The deviation ΔH2 between the pushing-in position and the lower limit position Pl is represented by the count number n2 of the position pulses between the pushing-in position and the lower limit position Pl, and can be obtained in advance according to experiments or the size of the shutter curtain 4, etc. Therefore, the second processing unit 162 can obtain the lower limit position Pl from the pushing-in position using the known count number n2. For example, the second processing unit 162 may set, as the lower limit position Pl, a value obtained by subtracting the count number n2 (ΔH2) from the count value n when the overload state of the motor 8 is detected by the second overload detection. However, if the deviation ΔH2 is within an acceptable range, the second processing unit 162 may set the count value n when the overload state of the motor 8 is detected by the second overload detection as the lower limit position Pl. Note that the count number n2 corresponds to the "first distance" of the present invention. Thus, the second processing unit 162 may set, as the lower limit position Pl, a position that is separated from the current position of the shutter curtain 4 in the opening direction by a first distance when the overload state of the motor 8 is detected by the overload detection during the closing operation. Here, the opening direction is the direction in which the shutter curtain 4 operates by the opening operation of the shutter curtain 4, and in the present embodiment, it is the direction in which the shutter box 6 is arranged.

[0054] The storage unit 17 stores the information on the upper limit position Pu and the lower limit position Pl set by the processing unit 16. Note that when the processing unit 16 receives a setting signal and the storage unit 17 already stores the information on the upper limit position Pu and the lower limit position Pl, the stored information on the upper limit position Pu and the lower limit position Pl may be deleted. For example, when a predetermined operation is performed on the operating device and the upper limit position Pl and the lower limit position Pu are already set, the first processing unit 161 may execute an initialization process for initializing the settings of the upper limit position Pl and the lower limit position Pu. In that case, after the initialization process, the opening operation of the shutter curtain 4 may be started. Also, in the storage unit 17, in the setting mode, information in which the position information n and the pulse width An of the position pulse corresponding to the position information n, that is, load information, are associated is stored for each position information n. For example, the storage unit 17 is a non-volatile memory such as a ROM (Read Only Memory), an HDD (Hard Disk Drive), or an SSD (Solid State Drive).

[0055] Next, a method for setting the upper limit position Pu and the lower limit position Pl of the control unit 13 according to the present embodiment will be described with reference to FIGS. 4 and 5. FIG. 4 is a flowchart of the method for setting the upper limit position Pu and the lower limit position Pl according to the present embodiment. FIG. 5 is a diagram for explaining the method for setting the upper limit position Pu and the lower limit position Pl according to the present embodiment. In the following description of the above setting method, the first overload detection and the second overload detection are overload detections by different methods. Further, the deviation ΔH1 is assumed to be negligibly small.

[0056] First, when the control unit 13 receives a setting signal from the operating device 3, it shifts to the setting mode. When shifting to the setting mode, the control unit 13 executes an initialization process (step S101). Then, the control unit 13 (drive control unit 14) executes the opening operation of the shutter curtain 4 (step S102). Here, during the opening operation of the shutter curtain 4, the control unit 13 increments the count value n of the position pulses with the counter 151.

[0057] When the opening operation of the shutter curtain 4 starts in step S103, the first processing unit 161 executes a first overload detection for determining whether the motor 8 is in an overload state based on the pulse width An corresponding to the count value n (step S103). For example, the first processing unit 161 acquires the pulse width An corresponding to the count value n for each count value n, and determines whether the pulse width An or the change rate of the pulse width An is equal to or greater than a threshold value th1. Then, when the first processing unit 161 determines that the pulse width An or the change rate of the pulse width An is equal to or greater than the threshold value th1, it determines that the motor 8 is in an overload state. On the other hand, when the first processing unit 161 determines that the pulse width An or the change rate of the pulse width An is less than the threshold value th1, it determines that the motor 8 is not in an overload state. When the first processing unit 161 determines that the motor 8 is not in an overload state, it determines again whether the motor 8 is in an overload state based on the pulse width An with the count value n = n + 1. Therefore, the process of step S103 is continued until it is determined that the motor 8 is in an overload state during the opening operation.

[0058] When it is determined in step S103 that the motor 8 is in an overload state, the drive control unit 14 stops the rotation of the motor 8 and stops the opening operation of the shutter curtain 4 (step S104). Then, the first processing unit 161 sets the current position of the shutter curtain stopped in step S104, that is, the current count value n, to "0" (step S105). Here, n = "0" represents the upper limit position Pu. Therefore, setting the count value n to "0" is synonymous with setting the upper limit position Pu.

[0059] When the upper limit position Pu is set, the drive control unit 14 executes a closing operation of the shutter curtain 4 (step S106). Each time the load detection unit 15 acquires a position pulse output by the closing operation of the shutter curtain 4, it counts up the count value n by "+1" (step S107). This count value n corresponds to the distance by which the shutter curtain 4 has descended from the upper limit position Pu. Further, the load detection unit 15 obtains a pulse width An corresponding to the count value n, and outputs the count value n and the pulse width (motor load) An of the position pulse corresponding to the count value n to the processing unit 16 for each count value n.

[0060] In the opening operation of step S106, when the second processing unit 162 passes the threshold value nth shown below, it executes second overload detection based on the count value n and the pulse width An. First, as the second overload detection, the second processing unit 162 obtains a calculated value Bn for each count value n based on the following formula (1) (step S108). Bn = An - A(n - P1) …(1)

[0061] This calculated value Bn is the difference between the current An and the pulse width A(n - P1) before P1 rotations in the motor 8. That is, the calculated value Bn is the difference between the current An and the pulse width A(n - P1) before P1. Here, P1 is a preset fixed value. However, the pulse width A(n - P1) is preferably the count value two or more before, not immediately before n. For example, when the current count value n = 100 and P1 = 50, the second processing unit 162 reads the load information of A 50 from the storage unit 17, and measures the value B 100 = A 100 - A 50 for the count value n = 100.

[0062] Next, the second processing unit 162 determines whether the current count value n is greater than or equal to the threshold value nth. When the second processing unit 162 determines that the current count value n is greater than or equal to the threshold value nth, it determines that the position of the shutter curtain 4 is approaching the lower limit position Pl, and executes the process of step S110. On the other hand, when the second processing unit 162 determines that the current count value n is less than the threshold value nth, it proceeds to the process of step S107. Note that the threshold value nth is set in advance and can be set arbitrarily. For example, the threshold value nth is set in advance by experiments. When the shutter curtain 4 passes the threshold value nth, the second overload detection is started. For example, the threshold value nth may be the minimum number of pulses of the manufacturing limit of the shutter curtain 4, or may be a value for ignoring the data variation at the initial movement of the motor 8.

[0063] When it is determined that the current count value n is equal to or greater than the threshold value nth, the second processing unit 162 determines whether the measured value Bn exceeds the threshold value S (step S110). Then, when the number of times (hereinafter referred to as "determination times") i that the measured value Bn exceeds the threshold value S exceeds the specified number of times ith (1 or more), the second processing unit 162 determines that the motor 8 is in an overload state. That is, when the measured value Bn exceeds the threshold value S continuously (ith + 1) times, the second processing unit 162 determines that the motor 8 is in an overload state. Note that the threshold value S may be a fixed value or a variable linked to the values of the count value n and the measured value Bn.

[0064] Specifically, when the measured value Bn exceeds the threshold value S (step S110: YES), the second processing unit 162 increments the determination times i by 1 (step S111). On the other hand, when the measured value Bn is equal to or less than the threshold value S (step S110: NO), the second processing unit 162 resets the determination times i to 0 (step S112) and shifts to the process of step S107.

[0065] After the process of step S111, the second processing unit 162 determines whether the determination times i exceeds the specified number of times ith (step S113). When the second processing unit 162 determines that the determination times i exceeds the specified number of times ith, it determines that the motor 8 is in an overload state and executes the process of step S114. When the second processing unit 162 determines that the determination times i does not exceed the specified number of times ith, it determines that the motor 8 is not in an overload state and shifts to the process of step S107.

[0066] When, in step S114, the second processing unit 162 determines that the determination count i has exceeded the specified count ith, it sets the lower limit position Pl based on the count value n (hereinafter referred to as "count value nx") at that time (step S114). This count value nx is the count value n when the position of the shutter curtain 4 is the pushed-in position.

[0067] For example, the second processing unit 162 obtains a count value nd from the count value nx using the following formula (2), and sets the count value nd as the lower limit position Pl. nd = nx - n2 …(2) Note that the count number n2 may be a fixed value obtained from experiments or the like, or may be the sum of variables calculated from a fixed value obtained from experiments or the like and a threshold value S. When the count number n2 is the sum of variables calculated from a fixed value obtained from experiments or the like and a threshold value S, the lower limit position Pl without the above-mentioned deflection can be obtained more accurately without variation due to size.

[0068] For example, the second processing unit 162 may obtain a count value nd from the count value nx using the following formula (3), and set the count value nd as the lower limit position Pl. nd = nx - P2 - S / P3 …(3)

[0069] Here, P2 and P3 may be fixed values obtained from experiments or the like. The calculation formula (3) is a formula that can obtain the lower limit position Pl without the above-mentioned deflection more accurately without variation due to the size of the shutter curtain 4. The inventors of the present application have found that regardless of the size of the shutter curtain 4, the load increases after a certain time (corresponding to the fixed value P2) from when the shutter curtain 4 reaches the lower limit position Pl, and the rising angle of the load is constant (that is, the slope is constant). And the inventors of the present application have found that the larger the threshold value S, the longer the time required for overload detection and the greater the deflection. Therefore, in the calculation formula (3), by subtracting the fixed value P2 and S / P3 linked to the threshold value S from the count value nx, the lower limit position Pl without the above-mentioned deflection and without variation due to size can be calculated more accurately.

[0070] Note that when the shutter curtain 4 reaches the pushed-in position, the shutter curtain 4 may be bent. Therefore, when the count value nd is obtained (step S114) or when the overload state of the motor 8 is detected (step S113: YES), the drive control unit 14 stops the closing operation of the motor 8 and performs a "bending elimination operation" to open the shutter curtain 4 from the pushed-in position (count value nx) to the lower limit position Pl (count value nd) in order to eliminate the above-mentioned bending (step S115). In the bending elimination operation, the motor is operated in the opening direction, but actually, there may be a deviation of several pulses (hereinafter referred to as "Δxpls") between the stop command position and the stop position. Therefore, the drive control unit 14 may stop and adjust at the position of the lower limit position Pl + Δxpls in the "bending elimination operation". This Δxpls is a value smaller than the count number n2. Note that the state where the above-mentioned bending is eliminated, that is, the state of the shutter curtain 4 after the bending elimination operation is completed, may be a state where the bending of the shutter curtain 4 when the overload state of the motor 8 is detected by the second overload detection is alleviated. That is, the state of the shutter curtain 4 after the bending elimination operation is completed is a state where the shutter curtain 4 is in the fully closed state and the bending of the shutter curtain 4 when the overload state of the motor 8 is detected by the second overload detection is alleviated. The state where the bending of the shutter curtain 4 is alleviated includes a state where there is no such bending and a state where such bending is within an acceptable range in the shutter device 2.

[0071] When the bending elimination operation ends, the second processing unit 162 stores the set lower limit position Pl (count value nd) in the storage unit 17 (step S116) and ends the setting mode. Note that the second processing unit 162 may set the current position (count value nd) of the shutter curtain 4 at the time when the bending elimination operation ends as the lower limit position Pl.

[0072] As described above, the embodiments of the present invention have been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and designs and the like within the scope not departing from the gist of the present invention are also included.

[0073] (Modification 1) In the above embodiment, the shutter curtain 4 may be configured with any member or structure. For example, the shutter curtain 4 may be formed of a plurality of slats 4a, may be formed of a sheet, or only a part thereof may be configured of a plurality of slats 4a.

[0074] (Modification 2) In the above embodiment, the load detection unit 15 uses the pulse width of the position pulse as the motor load. However, the present invention is not limited to this. If the motor load can be detected, it is not necessary to use the pulse width of the position pulse. For example, the load detection unit 15 may detect the motor load by detecting the torque of the motor 8 using a known technique.

[0075] (Modification 3) In the above embodiment, the control unit 13 executes the deflection elimination operation. However, if the deflection of the shutter curtain 4 does not occur or is acceptable at the pushed-in position, the deflection elimination operation does not have to be executed.

[0076] (Modification 4) In the above embodiment, the control unit 13 shifts to the setting mode when a setting signal is received. However, the present invention is not limited to this. When the lower limit position Pl is not stored in the storage unit 17, the control unit 13 may shift to the setting mode when an operation signal is received from the operation device 3.

[0077] (Modification 5) In the above embodiment, the operation device 3 outputs a setting signal to the shutter device 2 when a predetermined operation is performed. However, the present invention is not limited to this. For example, the operation device 3 may be provided with a dedicated switch for setting the upper limit position Pu and the lower limit position Pl. Then, the operation device 3 may output a setting signal to the shutter device 2 when the switch is operated.

[0078] (Modification Example 6) In the above-described embodiment, when the measured value Bn exceeds the threshold value S (ith + 1) times continuously, the second processing unit 162 determines that the motor 8 is in an overload state. However, the present invention is not limited to this. The second processing unit 162 may determine that the motor 8 is in an overload state when the measured value Bn exceeds the threshold value S one or more times.

[0079] (Modification Example 7) In the above-described embodiment, the second processing unit 162 may estimate the lower limit position Pl without deflection from the count value nx using deep learning or IoT (Internet of Things) technology.

[0080] As described above, when a predetermined operation is performed on the operation device 3, the shutter device 2 according to the above-described embodiment starts the opening operation of the shutter curtain 4 and executes the first overload detection. When the overload state of the motor 8 is detected by the first overload detection, the shutter device 2 sets the upper limit position Pu based on the current position of the shutter curtain 4. Further, when the overload state of the motor 8 is detected by the first overload detection, the shutter device 2 starts the closing operation of the shutter curtain 4, and during the closing operation, when the position of the shutter curtain 4 passes the threshold value nth, the second overload detection is started. When the overload state of the motor 8 is detected by the second overload detection, the shutter device 2 sets the lower limit position Pl at a position separated by a first distance in the opening direction from the current position of the shutter curtain when the overload state is detected by the second overload detection.

[0081] According to such a configuration, a constructor or a user can set the upper limit position Pu and the lower limit position Pl of the shutter curtain 4 only by performing a predetermined operation on the operation device 3. Therefore, the constructor or the user can set the upper limit position Pu and the lower limit position Pl with a one-touch operation, and can easily set the upper limit position Pu and the lower limit position Pl. Further, the lower limit position Pl where the deflection is eliminated can be set.

[0082] Note that all or part of the above-described control unit 13 may be implemented by a computer. In this case, the computer may include a processor such as a CPU or GPU and a computer-readable recording medium. Then, a program for implementing all or part of the functions of the control unit 13 may be recorded on the computer-readable recording medium, and the program recorded on this recording medium may be read by the processor and executed to be realized. Here, the "computer-readable recording medium" refers to a portable medium such as a flexible disk, a magneto-optical disk, a ROM, a CD-ROM, etc., and a storage device such as a hard disk built in a computer system. Furthermore, the "computer-readable recording medium" refers to something that dynamically holds a program for a short time, like a communication line when transmitting a program via a network such as the Internet or a communication line such as a telephone line, and may also include something that holds a program for a certain period of time, like a volatile memory inside a computer system serving as a server or a client in that case. Also, the above program may be for realizing a part of the aforementioned functions, and may further be realized in combination with a program already recorded in the computer system for the aforementioned functions, or may be realized using a programmable logic device such as an FPGA.

Explanation of Signs

[0083] 2 Shutter device 3 Operating device 4 Shutter curtain 8 Motor 13 Control unit 14 Drive control unit 15 Load detection unit 16 Processing unit 17 Storage unit

Claims

1. A shutter device that sets an upper limit position and a lower limit position and performs an opening and closing operation of a shutter curtain, a motor that drives the shutter curtain to open and close, a shutter control device that performs the opening and closing operation by controlling the motor and executes overload detection for detecting an overload state of the motor during the opening and closing operation, a current position acquisition unit that obtains the current position of the shutter curtain, comprising: The shutter control device, when a predetermined process is performed, starts an opening operation or a closing operation of the shutter curtain, and when the overload state is detected during the opening operation or the closing operation, stops the opening operation or the closing operation; a drive control unit, a first processing unit that sets the upper limit position based on the current position of the shutter curtain when the overload state is detected by the overload detection during the opening operation, during the closing operation, when the position of the shutter curtain exceeds a threshold value, starts the overload detection, and sets, as the lower limit position, a position that is separated from the current position of the shutter curtain in the opening direction by a first distance when the overload state is detected by the overload detection; a second processing unit, A shutter device comprising:

2. The shutter device according to claim 1, wherein a threshold value for determining the overload state of the overload detection is a variable.

3. The shutter device according to claim 1, wherein when the overload state is detected by the overload detection during the closing operation and the lower limit position is set, the drive control unit stops the closing operation of the shutter curtain and moves the shutter curtain to the lower limit position set by the second processing unit.

4. The shutter device according to claim 1, wherein when there is a deviation between a stop command position and a stop position and the overload state is detected by the overload detection during the closing operation and the lower limit position is set, the drive control unit stops the closing operation of the shutter curtain and moves the shutter curtain in an opening operation by a second distance smaller than the first distance.

5. an output unit that outputs a pulse signal corresponding to the rotation of the motor, a load detection unit that counts the number of pulses of the pulse signal, comprising: The shutter device according to any one of claims 1 to 4, wherein the second processing unit sets the lower limit position to a value obtained by subtracting a predetermined number of pulses from the count value of the pulse signal when the overload state is detected by the overload detection during the closing operation.

6. The shutter device according to claim 5, wherein the second processing unit determines that the motor is in an overload state when a change amount between the pulse width of the pulse signal corresponding to the current count value and the pulse width of the pulse signal corresponding to the count value two or more counts before exceeds a predetermined value one or more times.

7. A setting method for a shutter device to set an upper limit position and a lower limit position of a shutter curtain, When a predetermined process is performed, an opening operation step of starting an opening operation of the shutter curtain, A first detection step of performing a first overload detection for detecting an overload state of a motor that drives the shutter curtain during the opening operation, A first current position acquisition step of obtaining a current position of the shutter curtain during the opening operation, A first stop step of stopping the opening operation when the overload state is detected in the first detection step, A first setting step of setting the current position of the shutter curtain stopped in the first stop step to the upper limit position, A closing operation step of starting a closing operation of the shutter curtain when the upper limit position is set, A second current position acquisition step of obtaining a current position of the shutter curtain during the closing operation, A second detection step of starting a second overload detection for detecting an overload state of the motor when the position of the shutter curtain exceeds a threshold value during the closing operation, A second stop step of stopping the closing operation when the overload state is detected by the second overload detection, A second setting step of setting, as the lower limit position, a position that is a predetermined distance away from the current position of the shutter curtain in the opening direction when the overload state is detected by the second overload detection, so that the shutter curtain is in a fully closed state and the deflection of the shutter curtain generated in the second stop step is eliminated, A setting method including the above steps.

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