External motor drive system that adjusts creep of window covering systems using continuous cord loops

Abstract

A drive system for raising and lowering a window covering includes a motor, a driven wheel configured to engage a continuous cord loop, a controller for the motor, a sensor, and a housing. The continuous cord loop includes an endless loop of flexible material and one or more sensor targets disposed on the endless loop of flexible material. The housing supports a guide rail adjacent to the driven wheel. The sensor is mounted to the guide rail and configured to generate a signal indicative of the presence of each sensor target when the target is located in proximity to or in contact with the sensor. The controller is calibrated to store an initial position of each sensor target along the continuous cord loop and is configured to receive a signal indicative of the presence of the sensor target and to identify deviations from the initial position during continuous operation of the drive system.

Description

[Technical Field]

[0001] Cross-reference to related patent applications This application claims priority to U.S. Provisional Application No. 17 / 318,791, filed May 12, 2021, entitled "External Motor Drive System for Adjusting Creep in Window Covering System with Continuous Cord Loop," which is incorporated herein by reference in its entirety.

[0002] The present disclosure relates to a window covering extension and retraction system that uses a continuous cord loop, and more particularly to an external motor drive for a window covering extension and retraction system. [Background technology]

[0003] Window covering systems that unfold and retract coverings for architectural openings such as windows, arches, and the like are ubiquitous. These window covering unfold and retract systems may operate, for example, by raising and lowering the covering or by laterally opening and closing the covering. As used herein, the terms unfold and retract, open and close, and raise and lower the window covering are all used according to context. These window covering systems typically include a head rail or cassette in which the operating components for the covering are primarily housed. In some variations, the window covering system includes a bottom rail extending parallel to the head rail and some form of shade material, which may be a fabric material, shade material, or blind material, interconnecting the head rail and bottom rail. The shade material or blind material is movable with the bottom rail between an unfolded position and a retracted position relative to the head rail. For example, as the bottom rail lowers or raises relative to the head rail, the fabric or other material may unfold away from the head rail or retract toward the head rail, allowing the fabric or other material to accumulate adjacent to or within the head rail. Such mechanisms may include various controls, such as a pull cord that hangs from one or both ends of the headrail. The pull cord may hang linearly, or in window covering systems of the type addressed by this invention, the pull cord may take the form of a closed loop of flexible material such as a rope, cord, or beaded chain, referred to herein as a continuous cord loop, or alternatively, a chain / cord.

[0004] In some embodiments, window covering systems incorporate a motor and control electronics that operate mechanisms for extending and retracting the blind or shade material. Most commonly, the motor and control electronics are mounted within the headrail or tube (sometimes referred to as a tubular motor) of the window blind, avoiding the need for a pull cord, such as a continuous cord loop. Using such motor-operated systems or devices, the shade or blind material can be extended or retracted by user activation or by automated operation triggered, for example, by a switch or photocell. Such window covering systems with motors and control electronics mounted within the headrail may be referred to herein as "internal motors," "internal motor devices," or "internal motor systems."

[0005] The drive systems of the present invention incorporate a motor and control electronics mounted externally to the mechanism that unfolds and retracts the blind or shade material. Such drive systems are sometimes referred to herein as "external motors," "external motor devices," or "external motor systems," or "external actuators." External motor systems are typically mounted externally on the window frame or wall and engage the cord or chain (continuous cord loop) of the window covering to automate the opening and closing of the blinds.

[0006] In both internal and external motor systems (sometimes collectively referred to herein as motorized systems), the automated drive system incorporates control electronics for controlling operation. Motorized systems are typically controlled through a user control mechanism incorporating a radio frequency ("RF") controller or other remote controller that wirelessly communicates with the motor's associated drive system. These remote user control systems take many forms, including handheld remote controls, wall-mounted controllers / switches, smart home hubs, building automation systems, and smartphones, among others. The use of such remote controls is particularly meaningful for internal motor systems, where it is difficult or impossible to integrate user controls within the internally mounted drive system.

[0007] The external motor drive system of the present disclosure separates the external actuator from the headrail or other window covering mechanism, opening up new possibilities for integrating user controls within the external actuator itself. These integrated control functions are sometimes referred to herein as "on-device controls." On-device controls for external motor systems offer various advantages, such as ease of operation and convenience in accessing the controls and performing control functions. These on-device controls for external motor systems can be integrated with automated control systems through appropriate sensors, distributed intelligence, and network communications.

[0008] Automated control of window covering systems can provide a variety of useful control functions. Examples of such automated window control functions include calibrating the opening and closing of blinds to suit user preferences, and cooperative or centralized control of multiple blinds. There is a practical need to integrate various automated window control functions in an on-device control for an external actuator.

[0009] In a corded continuous cord-loop motor-drive system, the window covering drive mechanism is a cord that engages with a pulley drive of the motor-drive system. Cords, such as those made from synthetic and natural fibers, can experience various physical influences relative to the pulley drive during continuous operation. It is necessary to compensate for all physical influences of the continuous cord-loop cord / pulley motor-drive system while maintaining accurate automated control of the window covering function. Summary of the Invention [Means for solving the problem]

[0010] The embodiments described herein include a motor drive system that operates a mechanism for extending and retracting a window covering. The motor drive system includes an electrically operated motor and a drive assembly. The motor drive system advances a continuous cord loop in response to position-related commands from a controller. The continuous cord loop / motor drive system must maintain accurate automated positioning control of the window covering while compensating for physical effects during continuous operation. The embodiments described herein incorporate a continuous cord loop sensor system that maintains accurate automated positioning control of the window covering, for example, in the event of material fatigue or creep of the continuous cord loop or if the continuous cord loop stretches.

[0011] In various embodiments, the continuous cord loop includes a corded continuous cord loop, also referred to herein as a continuous cord loop cord, and the motor drive system includes a pulley motor drive system. In conventional implementations, a major concern is the tendency of the cord / pulley motor drive system to slip during continuous operation. However, because the frictional engagement of the cord with the pulley drive can withstand the forces applied during normal operation without slippage, the primary source of positioning error is material fatigue or “creep” of the continuous cord loop cord. The embodiments described herein incorporate a continuous cord loop sensor system that maintains the accuracy of the automated positioning control of the window covering in the event of material fatigue or creep of the continuous cord loop cord.

[0012] In various embodiments, the continuous cord loop comprises a chain-type continuous cord loop, also referred to herein as a continuous cord loop chain, and the motor drive system comprises a sprocket wheel motor drive system. Embodiments described herein incorporate a continuous cord loop sensor system that maintains accuracy of the automated positioning control of the window covering when the continuous cord loop chain stretches.

[0013] In various embodiments, a drive system is configured for use with a window covering system including a mechanism for unfolding and retracting the window covering and a continuous cord loop extending below the mechanism. The drive system includes a motor configured to operate with electrical power to rotate an output shaft of the drive system, and a driven wheel coupled to the output shaft of the motor and configured to engage the continuous cord loop. Rotation of the driven wheel in a first direction advances the continuous cord loop, causing the mechanism to unfold the window covering, and rotation of the driven wheel in a second direction advances the continuous cord loop, causing the roller blind mechanism to retract the window covering. The continuous cord loop includes an endless loop of flexible material and one or more sensor targets disposed on the endless loop of flexible material. The sensor targets are also referred to herein as markers or targets.

[0014] Additional components of the drive system include a controller for the motor, a sensor operably connected to the controller, and a housing for the motor, driven wheel, and controller. The housing includes a guide rail adjacent to the driven wheel, and the sensor is attached to the guide rail and configured to generate a signal indicating the presence of the sensor target (or one of the multiple sensor targets) when the sensor target is located in proximity to or in contact with the sensor. In one embodiment, the controller is calibrated to store an initial position of the sensor target (single marker) along the continuous code loop. In one embodiment, the controller is calibrated to store an initial top position of a first marker at a top position along the continuous code loop and an initial position of a second marker at a bottom position along the continuous code loop. The controller is configured to receive the signal indicating the presence of the sensor target and to identify deviations (e.g., fluctuations or changes in value) from the initial position (or each initial position) during continuous operation of the drive system.

[0015] In one embodiment, the drive system is configured for use with a window covering system, the window covering system including a mechanism for expanding and retracting the window covering and a continuous cord loop extending below the mechanism. The drive system includes a motor configured to operate with electrical power to rotate an output shaft of the drive system, a driven wheel coupled to the output shaft of the motor and configured to engage the continuous cord loop, and a controller for the motor. The drive system includes a housing that houses the motor, the driven wheel, and the controller. The drive system further includes a rechargeable battery electrically coupled to the motor and the controller. The motor and controller are battery-powered, and the rechargeable battery is housed within or coupled to the housing.

[0016] In one embodiment, an input / output ("I / O") device for a controller includes an input interface that receives user input along an input axis and a visual display aligned with the input axis of the input interface. In one embodiment, the I / O device includes a capacitive touch strip that receives user input along the input axis and an LED strip aligned with the input axis. In one embodiment, the I / O device extends longitudinally outside of a housing for the motor drive system, the housing supporting input buttons. In one embodiment, the buttons on the housing include a group mode module and a setting control module. In another embodiment, the housing supports an RF communication button.

[0017] In one embodiment, the group mode module communicates position-related commands to other motor drive systems in the identified group to operate each of the other mechanisms of those other motor drive systems. In one embodiment, the group mode module causes the RF communication module to communicate position-related commands to the other motor drive systems. In one embodiment, the other motor drive systems in the identified group operate each of the other mechanisms in accordance with the calibration results of each of the other motor drive systems' respective top positions and respective bottom positions.

[0018] In one embodiment, the setting control module allows user calibration of the top and bottom positions of the window covering travel, in one embodiment, during calibration, the user moves the window covering to the top and bottom positions, respectively, using the input interface and presses the setting button to set these positions.

[0019] In one embodiment, the drive assembly includes a driven wheel configured to engage and advance a continuous cord loop coupled to a mechanism for raising and lowering the window covering, and a motorized coupling mechanism configured to couple the driven wheel to an output shaft of the motor and rotate the driven wheel in first and second senses. Rotation of the driven wheel in the first sense advances the continuous cord loop in the first direction, and rotation of the driven wheel in the second sense advances the continuous cord loop in the second direction. A controller provides position-related commands to the motor and the motorized coupling mechanism to control the rotation of the driven wheel in the first and second senses.

[0020] In one embodiment, in addition to providing position-related and other control commands to the motor and drive assembly via an external motor device-on-device controller, such commands may be provided by an I / O device separate from the external motor device-on-device controller, such as a mobile user device. In one embodiment, the control system includes a web application capable of emulating various single-axis input and display functions of the external motor device-on-device controller.

[0021] In one embodiment, the external motor device is configured to raise or lower window coverings, such as roller shades and Roman shades, via vertical position control. In one embodiment, the external motor device is configured to open or close window coverings laterally (e.g., across the window frame) via horizontal position control, as in vertical blinds or curtains. In one embodiment, the control system includes a graphical user interface configured to display input controls that extend either vertically or horizontally, depending on the type of window covering system driven by the external motor.

[0022] In one embodiment, the motor drive system includes a motor external to the mechanism for raising and lowering the window covering, the motor configured to operate with electrical power to rotate an output shaft of the motor, and a drive assembly configured to engage and advance a continuous cord loop coupled to the mechanism for raising and lowering the window covering. Advancing the continuous cord loop in a first direction raises the window covering, and advancing the continuous cord loop in a second direction lowers the window covering. The motor drive system includes a controller that provides position-related commands to the motor and drive assembly to control the advancement of the continuous cord loop in the first direction and the advancement of the continuous cord loop in the second direction. The I / O device for the controller includes an input interface that receives user input along an input axis and causes the controller to provide position-related commands to the motor and drive assembly, and a visual display aligned with the input axis of the input interface.

[0023] In one embodiment, a drive system for use with a window covering system including a head rail, a mechanism associated with the head rail for expanding and retracting a window covering, and a continuous cord loop extending below the head rail for actuating the expanding and retracting mechanism includes a motor configured to rotate an output shaft thereof; a drive assembly configured to engage and advance the continuous cord loop coupled to the window covering expanding and retracting mechanism, the drive assembly advancing the continuous cord loop in a first direction to expand the window covering and advancing the continuous cord loop in a second direction to retract the window covering; a controller that provides position-related commands to the motor and drive assembly to control the advancement of the continuous cord loop in the first direction and the advancement of the continuous cord loop in the second direction; and a controller that receives user input along an input shaft to control the motor and drive assembly. and an I / O device for the controller, including an input interface that causes the controller to provide position-related commands to the drive assembly, and further including a visual display device aligned with the input axis of the input interface, wherein the drive assembly and controller operate in either a vertical mode or a horizontal mode, wherein in the vertical mode the drive assembly is configured to advance the continuous cord loop in a first direction to lower the window covering and to advance the continuous cord loop in a second direction to raise the window covering, and the visual display device and the input axis of the input interface are aligned vertically, and in the horizontal mode the drive assembly is configured to advance the continuous cord loop in the first direction to close the window covering laterally and to advance the continuous cord loop in the second direction to open the window covering laterally, and the visual display device and the input axis of the input interface are aligned horizontally.

[0024] In another embodiment, a drive system for use with a window covering system including a mechanism for expanding and retracting a window covering and a continuous cord loop extending below the mechanism for expanding and retracting the window covering includes a motor configured to rotate an output shaft thereof; a drive assembly configured to engage and advance the continuous cord loop coupled to the mechanism for expanding and retracting the window covering, wherein advancing the continuous cord loop in a first direction expands the window covering and advancing the continuous cord loop in a second direction retracts the window covering; and a temperature sensor communicatively coupled to a controller that provides position-related commands to the motor and drive assembly, the temperature sensor configured to provide a temperature output representative of a temperature proximate the drive system; and a temperature sensor communicatively coupled to the controller that provides position-related commands to the motor and drive assembly. a light sensor operably coupled to the drive system, the light sensor configured to provide a light output representative of ambient light intensity in the vicinity of the drive system; and a controller providing position-related commands to the motor and drive assembly to control the advancement of the continuous cord loop in a first direction and the advancement of the continuous cord loop in a second direction, wherein the controller receives a plurality of sunlight incidence conditions including a temperature output and a light output, and if the plurality of sunlight incidence conditions received by the controller correspond to one or more window covering criteria, the controller causes the drive assembly to advance the continuous cord loop in the first direction to expand the window covering, and if the plurality of sunlight incidence conditions received by the controller correspond to one or more window covering removal criteria, the controller causes the drive assembly to advance the continuous cord loop in the second direction to retract the window covering.

[0025] In another embodiment, a method of controlling a motor follower includes receiving, by a processor via a graphical user interface of a computing device, a request to select a window covering mechanism from at least one vertical window covering mechanism configured to raise and lower the window covering via the motor follower and at least one horizontal window covering mechanism configured to open and close the window covering laterally via the motor follower; displaying, by the processor via the graphical user interface of the computing device, graphical representations of the at least one vertical window covering mechanism and the at least one horizontal window covering mechanism; receiving a selection of one of the at least one vertical window covering mechanism and the at least one horizontal window covering mechanism; and in response to receiving a selection of one of the vertical window covering mechanism and the at least one horizontal window covering mechanism, displaying via the graphical user interface a position control visual display having a vertically aligned input axis if the selected window covering mechanism is one of the at least one vertical covering mechanism, and displaying via the graphical user interface a position control visual display having a horizontally aligned input axis if the selected window covering mechanism is one of the at least one horizontal window covering mechanism, and in response to receiving a position control input via the position control visual display having an input axis, outputting, by the processor, a position control command to the motor follower based on the position control input.

[0026] In a further embodiment, a motor drive system comprises: a motor configured to operate with electrical power to rotate its output shaft, the motor being external to a mechanism for raising and lowering a window covering; a drive assembly configured to engage and advance a continuous cord loop coupled to the mechanism for raising and lowering the window covering, wherein advancing the continuous cord loop in a first direction raises the window covering and advancing the continuous cord loop in a second direction lowers the window covering; and a controller that provides position-related commands to the motor and drive assembly to control the advancement of the continuous cord loop in the first direction and the advancement of the continuous cord loop in the second direction, the drive assembly comprising: a motor controller powering the motorized coupling mechanism that couples the drive assembly to the output shaft of the motor and is configured to rotate the driven wheel in the first and second directions; and the controller and motor controller are configured to implement motor acceleration / deceleration trajectory speed control that limits the acceleration of the motor from an idle state to full operating speed and limits the deceleration of the motor from full operating speed back to the idle state.

[0027] In one embodiment, a drive system for use with a window covering system including a head rail, a mechanism associated with the head rail for expanding and retracting the window covering, and a continuous cord loop extending below the head rail for actuating the mechanism for expanding and retracting the window covering includes a motor configured to rotate an output shaft thereof, a drive assembly configured to engage and advance the continuous cord loop coupled to the mechanism for expanding and retracting the window covering, the drive assembly advancing the continuous cord loop in a first direction to expand the window covering and advancing the continuous cord loop in a second direction to retract the window covering, and a drive assembly providing position-related commands to the motor and drive assembly to control the advancement of the continuous cord loop in the first direction and the advancement of the continuous cord loop in the second direction. and an I / O device for the controller including a graphical user interface configured to receive user inputs that cause the controller to control position-related commands to the motor and drive assembly at a selected speed to advance the continuous cord loop in a selected one of a first direction and a second direction, wherein in a first speed control mode, the I / O device causes the controller to control the speed at which the continuous cord loop is advanced to a selected percentage within a speed range from a rest speed to a maximum speed, and in a second speed control mode, the I / O device causes the controller to control the speed at which the continuous cord loop is advanced to a selected one of a limited number of predetermined speed levels.

[0028] In one embodiment, the motor drive system includes a first motor configured to operate with electrical power to rotate an output shaft thereof, the first motor being external to a first mechanism for raising and lowering the window covering; a drive system configured to engage and advance a continuous cord loop coupled to the first mechanism for raising and lowering the window covering, wherein advancing the continuous cord loop in a first direction raises the window covering and advancing the continuous cord loop in a second direction lowers the window covering; and a drive system configured to provide position-related commands to the first motor and the first motorized drive system to control the movement of the continuous cord loop. The system includes a controller that controls advancement in a first direction and advancement in a second direction of the continuous cord loop; an RF communications module operatively coupled to the controller for controlling RF communications of position-related commands to a network of other motor-driven systems that operate other mechanisms to raise and lower other window coverings, respectively; and a group mode module for identifying one or more of the other motor-driven systems to be included in a group selected by a user and for causing the RF communications module to communicate position-related commands to one or more of the identified other motor-driven systems.

[0029] In one embodiment, the motor drive system includes: a motor configured to operate with electrical power to rotate an output shaft thereof, the motor being external to the mechanism for raising and lowering the window covering; a drive assembly configured to engage and advance a continuous cord loop coupled to the mechanism for raising and lowering the window covering, wherein advancing the continuous cord loop in a first direction raises the window covering and advancing the continuous cord loop in a second direction lowers the window covering; a controller providing position-related commands to the motor and drive assembly to control the advancement of the continuous cord loop in the first direction and the advancement of the continuous cord loop in the second direction to control the raising and lowering of the window covering; and a setting control module for user calibration of a top and bottom position of the window covering, wherein the controller limits the raising and lowering of the window covering between the top and bottom positions following user calibration.

[0030] In one embodiment, a drive system for use with a window covering system including a mechanism for raising and lowering a window covering and a continuous cord loop extending below the mechanism comprises: a motor configured to operate on electrical power to rotate an output shaft of the motor; a driven wheel coupled to the output shaft of the motor and configured to engage the continuous cord loop, such that rotation of the driven wheel in a first direction advances the continuous cord loop, causing the mechanism to raise the window covering, and rotation of the driven wheel in a second direction advances the continuous cord loop, causing the mechanism to lower the window covering; one or more sensor targets disposed on the continuous cord loop; a controller for the motor; and a sensor operably connected to the controller, the sensor configured to generate a signal indicative of the presence of each of the one or more sensor targets disposed on the continuous cord loop when the sensor target is located in proximity to or in contact with the sensor.

[0031] In another embodiment, the drive system may be used in conjunction with a window covering system including a roller blind mechanism for raising and lowering a window covering fabric and a continuous cord loop extending below the mechanism, the drive system including a motor configured to be powered to rotate an output shaft of the drive system, a driven wheel coupled to the output shaft of the motor and configured to engage the continuous cord loop, one or more sensor targets disposed on the continuous cord loop, a controller for the motor, and a sensor operably connected to the controller, the sensor configured to generate a signal indicative of the presence of the sensor target on the continuous cord loop when the sensor target is located in proximity to or in contact with the sensor, the controller being calibrated to store the position of each of the one or more sensor targets along the continuous cord loop and configured to receive the signal indicative of the presence of each sensor target and to identify deviations from their respective positions during continuous operation of the drive system.

[0032] Additional features and advantages of certain embodiments will be set forth in, and in part will be apparent from, the description which follows. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the accompanying drawings as well as the illustrative embodiments written in the specification and claims hereof.

[0033] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.

[0034] Non-limiting embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, which are schematic and are not intended to be drawn to scale, and which, unless indicated as representative of the background art, represent aspects of the disclosure. [Brief explanation of the drawings]

[0035] [Figure 1] FIG. 1 is a perspective view of a window covering system with an external motor system installed on a flat wall, according to one embodiment. [Figure 2] FIG. 2 is a perspective view of an installed external motor system for a window covering system according to the embodiment of FIG. 1. [Figure 3] FIG. 1 is an isometric view of an external motor device. [Figure 4] 4 is an exploded view of the disassembled components of the external motor device according to the embodiment of FIG. 3. [Figure 5] FIG. 1 illustrates an isometric view of an external motor device with a sprocket cover in an open position, according to one embodiment. [Figure 6] FIG. 1 is an elevation view of an external motor arrangement from the rear, in section through a sprocket driven wheel, according to one embodiment. [Figure 7] FIG. 1 is a block diagram of a control system architecture for an external motor device for a window covering system, according to one embodiment. [Figure 8] FIG. 1 is an elevation view of a battery pack for an external motor device, according to one embodiment. [Figure 9] 9 is an exploded view of the disassembled components of the battery pack of the external motor device according to the embodiment of FIG. 8. [Figure 10] FIG. 1 is a schematic diagram of monitored and controlled variables of an external motor control system for a window covering system, according to one embodiment. [Figure 11] FIG. 1 is an elevation view of exploded motor drive components of an external motor system, according to one embodiment. [Figure 12] FIG. 10 is a flowchart diagram of a group mode routine, according to one embodiment. [Figure 13] FIG. 10 is a flowchart diagram of a grouping mesh routine, according to one embodiment. [Figure 14] FIG. 10 is a flowchart diagram of a calibration routine for an external motor control system, according to one embodiment. [Figure 15] FIG. 10 is a flowchart diagram of a shade control routine, according to one embodiment. [Figure 16] FIG. 10 is an isometric view of an external motor device according to a further embodiment. [Figure 17] FIG. 1 is a front view of a graphical user interface displayed on an electronic device presenting a position control screen of an external motor control application, according to one embodiment. [Figure 18] FIG. 1 is a front view of a graphical user interface displayed on an electronic device presenting a window covering style setup screen for an external motor control application, according to one embodiment. [Figure 19] FIG. 10 is a front view of a graphical user interface displayed on an electronic device presenting a window covering selection screen of an external motor control application, according to one embodiment. [Figure 20] FIG. 1 is a front view of a graphical user interface displayed on an electronic device presenting a position control screen of an external motor control application, according to one embodiment. [Figure 21] FIG. 10 is an isometric view of an external motor device according to a further embodiment. [Figure 22] FIG. 1 is a front view of a graphical user interface displayed on an electronic device presenting a speed control screen of an external motor control application, according to one embodiment. [Figure 23] FIG. 12 is an elevation view of the top of a three external motor device from the rear with the cover removed, according to one embodiment. [Figure 24] FIG. 12 is an elevation view of the top of a three external motor device from the rear with the cover removed, according to one embodiment. [Figure 25] FIG. 1 illustrates an isometric view of a curved guide rail with a mounting surface for an infrared sensor, according to one embodiment. [Figure 26] FIG. 1 illustrates an isometric view of an infrared sensor on a printed circuit board, according to one embodiment. [Figure 27] FIG. 1 illustrates an isometric view of a curved guide rail with leaf spring contact sensors, according to one embodiment. [Figure 28] FIG. 1 is a perspective view of a curved guide rail with a flat contact sensor, according to one embodiment. [Figure 29] FIG. 1 illustrates an isometric view of a flat guide rail with a flat contact sensor, according to one embodiment. [Figure 30] FIG. 1 is a perspective view of a flat guide rail with wire contact sensors, according to one embodiment. [Figure 31] FIG. 1 is a block diagram of a power management system for an external motor device, according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0036] The present disclosure is described in detail herein with reference to the embodiments illustrated in the drawings, which form a part hereof. Other embodiments may be used, and / or other changes may be made, without departing from the spirit or scope of the present disclosure. The exemplary embodiments described in the Detailed Description are not meant to limit the subject matter presented herein. Furthermore, various components and embodiments described herein may be combined to form additional embodiments not expressly described without departing from the spirit or scope of the invention.

[0037] Reference will now be made to the exemplary embodiments illustrated in the drawings, and specific language will be used to describe the same, it being understood, however, that no limitation of the scope of the invention is thereby intended. Alterations and further modifications of the features of the invention herein illustrated, and further applications of the principles of the invention herein illustrated, which would occur to one of ordinary skill in the art and in possession of this disclosure, are to be considered within the scope of the invention.

[0038] This disclosure describes various embodiments of an external motor device for controlling the operation of a window covering system. In various embodiments, the external motor device employs an on-device control, a separate control device (e.g., a mobile computing device), or both. As used in this disclosure, a "window covering system" is a system for extending and retracting, or raising and lowering, a window covering. In the embodiment shown at 200 in FIG. 1 , the window covering system includes a headrail 202 and a mechanism (not shown) associated with the headrail (i.e., a mechanism within or adjacent to the headrail) for extending and retracting the window covering. In this embodiment, the window covering system 200 includes a continuous cord loop 220 extending below the headrail that activates the mechanism associated with the headrail to extend and retract the window covering. As used in this disclosure, "headrail" is a broad term for the structure of the window covering system, including the mechanism for extending and retracting the window covering. The window covering system further includes an external motor 210. A continuous cord loop 220 operably couples a window covering mechanism associated with the headrail 202 to an external motor 210 to raise and lower a window shade (fabric, or blind) 204. As seen in FIG. 2, the external motor 210 is mounted to a wall 206 adjacent to a window, which in this illustration is covered by a shade 204. For example, the external actuator may be attached to the wall 206 using hardware such as bolts 214 or using a mount such as bracket 194 in FIG. 4.

[0039] In this disclosure, "window covering" includes any covering material that can be deployed and retracted using a continuous cord loop system (i.e., a system having a mechanism for deploying and retracting the window covering using a continuous cord loop) to cover a window or other architectural opening. Such window coverings include most shades and blinds, as well as other covering materials such as roller shades; honeycomb shades; horizontal sheer shades; pleated shades; woven wood shades; Roman shades; Venetian blinds; Pirouette® shades (Pirouette is a trademark of Hunter Douglas NV, Rotterdam, Germany); and certain systems for opening and closing curtains and drapes. While the window covering embodiments described herein refer to blind(s), it is understood that these embodiments are exemplary of other forms of window coverings.

[0040] As used in this disclosure, a "continuous cord loop" is an open-ended loop of flexible material, such as a textile cord, a bead chain, or a ball chain. As used in this disclosure, a continuous cord loop of a textile cord may also be referred to as a cord-style continuous cord loop, a continuous cord loop cord, or simply a cord. A chain-style continuous cord loop may also be referred to herein as a continuous cord loop chain. Various types of metal and plastic bead chains and ball chains are commonly used as continuous cord loops for window covering systems. A typical ball chain has a diameter of 5 mm (0.2 inches) and may include metal and plastic bead chains or ball chains. A cord-style continuous cord loop includes a length of natural or synthetic fiber. Continuous cord loops, which take the form of fiber loops, are available in a variety of styles and diameter ranges, such as D-30 (1 1 / 8" to 1 1 / 4"), C-30 (1 3 / 16" to 1 7 / 16"), D-40 (1 3 / 16" to 1 7 / 16"), and K-35 (1 1 / 4" to 1 1 / 2"), among others. In various embodiments, the cord is made from multiple lengths of fiber braided, twisted, or woven together to form a rolled composite structure. Synthetic fiber cords may be formed from, for example, nylon, polypropylene, or polyester. Natural fiber cords may be formed from, for example, manila hemp or sisal.

[0041] A continuous cord loop includes two substantially parallel cords or chains having an overall length (e.g., 1 meter) and a loop length or "drop" (e.g., 0.5 meters). A continuous cord loop may be available in different cord loop lengths, i.e., lengths between a first loop end and a second loop end, rounded to the nearest foot. In a typical window covering system design, the continuous cord loop includes a first loop end at the headrail that engages a mechanism associated with the headrail that unfolds and retracts the window covering, and a second loop end that is distal to the headrail. In one embodiment, e.g., a roller blind system, the continuous cord loop extends between the headrail and the second loop end, but does not extend across the headrail. In this embodiment, the first loop end may be wrapped around a clutch that is part of the mechanism that unfolds and retracts the blind. In another embodiment, e.g., a vertical blind system, a section of the continuous cord loop extends across the headrail. In one embodiment, the continuous cord loop extends substantially vertically below the headrail. When an external motor device of the present invention is retrofitted to control a previously installed window covering mechanism, the continuous cord loop can be part of the previously installed window covering mechanism. Alternatively, a user can retrofit the cord or chain of the continuous cord loop to a previously installed window covering mechanism.

[0042] The continuous cord loop system may cause the window covering to unfold and retract by raising and lowering, by opening and closing laterally, or by other movements that expand the window covering to cover an architectural opening and retract the window covering to uncover an architectural opening. It should be understood that the embodiments described herein generally refer to raising and lowering the blinds under the control of an external motor system or manually, and that these embodiments are illustrative of other movements that expand and retract the window covering. The external actuator 210 incorporates a motor drive system and control electronics that automate the movement of the continuous cord loop 220 in one of two directions to raise or lower the blinds 204. In one embodiment of the window covering system 200, the continuous cord loop 220 includes a rear cord / chain 224 and a front cord / chain 222. In this embodiment, pulling down the front cord raises (retracts) the blinds, and pulling down the rear cord lowers (unfolds) the blinds. As used in this disclosure, "advancing" a continuous cord loop means moving the continuous cord loop in either direction (e.g., pulling down the front cord of the continuous cord loop or pulling down the back cord of the continuous cord loop). In one embodiment, when the continuous cord loop is released, the blind automatically stops and locks into place. In one embodiment, the back cord of the continuous cord loop, at the bottom of the blind, can be used to open any of the vanes on the blind, while the front cord can be used to close those vanes.

[0043] As seen in the isometric view of FIG. 3 , the external motor 100, which generally corresponds to the external motor 210 of FIGS. 1 and 2 , may include a housing 102 that houses the motor, associated drive mechanism, and control electronics. The external actuator 100 includes various on-device controls for user input and output. For example, the external actuator 100 may include a touch strip 104 (also called a slider or LED strip). In the illustrated embodiment, the touch strip 104 includes a single-axis input device and a single-axis visual display device. The external actuator 100 further includes various button inputs, including a power button 106 on the front of the housing and a set of control buttons 110 on the top of the housing. In one embodiment, the control buttons 110 include an RF button 112, a set button 114, and a group button 116.

[0044] In one embodiment, buttons 106, 110 are physical (movable) buttons. The buttons may be recessed within housing 102 or may protrude above the surface of housing 102. Instead of, or in addition to, the touch strip and physical buttons seen in FIG. 1 , the input controls may include any suitable input mechanism capable of closing electrical contacts in an electrical circuit, breaking an electrical circuit, changing the resistance or capacitance of an electrical circuit, or causing some other state change in an electrical circuit or electronic routine.

[0045] In various embodiments, alternative or additional input devices may be employed, such as various types of sensors (e.g., gesture or other biometric sensors, accelerometers, light sensors, temperature sensors, contact sensors, pressure sensors, motion sensors, proximity sensors, presence sensors, capacitive sensors, and infrared ("IR") sensors). Other user input mechanisms include touchscreen buttons, holographic buttons, voice activation devices, audio triggers, relay input triggers, or electronic communication triggers, among other possibilities, including combinations of these input mechanisms. FIG. 16 shows an alternative external motor 1000 that includes input devices 1004, 1006, 1012, 1014, and 1016 that generally correspond to the input devices of motor 100. Additionally, external motor 1000 includes a two-dimensional screen 1008 located on the front of external motor 1000 above LED strip 1004 and below power button 1006. The two-dimensional screen 1008 may be a touch screen and may provide various input / output functions such as a virtual keypad, an alphanumeric display, and a graphical user interface, among others.

[0046] 4 is an exploded view of the components of the external actuator 100. Starting with the components at the front of the device at the bottom left, a front bezel 130 includes a power button glass plate that covers the power button 106. A front cover glass plate 134 defines an opening for the power button. 132 The front cover 136 houses the power button 106 and serves as a transparent cover plate for the touch strip 104. The visual display components of the single-axis strip 104 include an LED strip (also called an LED) 140 and a diffuser 138. The input sensor for the single-axis strip 104 is a capacitive touch sensor strip 142. These components serve as the I / O devices for the external motor 100 and include an input interface that receives user input along an input axis and a visual display aligned with the input axis. The I / O devices extend vertically outside the housing 102 when fully assembled.

[0047] Other input / output components include connectors for communication and / or power transfer, such as a USB port 146, and a speaker (audio output device) 144. The LEDs and audio output of the external motor 100 can be used by the external motor's 100 state machine to provide visual and / or audio cues to signal an action to be taken or to signal a state change. Parameters for the LEDs 140 visual cues include, for example, (a) different positions of the LED indicator (block of LEDs) along the slider 104, (b) different RGB color values ​​of the LED light, and (c) a steady or flashing LED indicator (including different flash rates).

[0048] In an example of a visual cue involving the group mode feature, a user can press the group mode button 116 once to cause the external motor devices in the network to light up their LED indicators to let the user know which devices will be controlled. When a user presses the group mode 116 button and successfully programs the external motor 100 to control multiple external motors in the network, the color of the LED strips 140 of all external motors being controlled will change from a steady blue to a steady green.

[0049] In an example of a visual cue involving the set function, when the user initiates the calibration procedure by pressing and holding the set button, the LED strip 140 will change red and blue to inform the user that the external motor 100 is in calibration mode. Once the user successfully completes the calibration procedure, the LED strip 140 will flash green to indicate that the shade is calibrated.

[0050] In an example of a visual cue involving a position setting, when a user taps their finger at a particular location along the capacitive touch strip 104, the LED strip 140 lights up a block of LEDs at this last known location. This indicator tells the user how far the shades are open or closed.

[0051] In an example of an audio cue, an audio alarm sounds to signal a safety hazard. In a further example, the speaker 144 broadcasts instructions to the user for the shade control function.

[0052] The motor drive components are housed between the main body 150 and the back cover 170 of the housing 102. The motor components include a motor 152 (e.g., a 6V DC motor) and various components of a drive assembly. The drive assembly components include a worm gear 154 driven by the rotation of the motor and coupled to a multi-stage gear assembly 160, and a clutch (not shown in FIG. 2 ). The gear assembly 160 includes a helical gear 162 (first stage gear), a first spur gear 164 (second stage gear) rotatably mounted in a sleeve bearing 156, and a second spur gear 166 (third stage gear). A printed circuit board (“PCB”) 148 houses the control electronics for the external motor device 100.

[0053] The spur gear 166 is coupled via a clutch (not shown) to a sprocket 184, also referred to as a driven wheel, mounted on the rear side of the back cover 170. The continuous cord loop (chain) 120 is attached to the sprocket 184 so that the movement of a drive component, when coupled to the driven wheel 184 by the clutch, advances the continuous cord loop 120.

[0054] The drive assembly is configured to engage and advance a continuous cord loop coupled to a mechanism that raises and lowers the window covering. The drive assembly includes a driven wheel 184 and a coupling mechanism (152, 160, clutch) that couples the driven wheel 184 to the output shaft of the motor. The coupling mechanism is configured to rotate the driven wheel 184 in first and second senses. Rotation of the driven wheel in the first sense advances the continuous cord loop in the first direction, and rotation of the driven wheel in the second sense advances the continuous cord loop in the second direction.

[0055] The structural components of the rear of the external motor 100 include a rear cover 178, a driven wheel cover 190, a rear cover glass 180, and a sprocket cover glass 188. These components are covered by a rear bezel 192, which is coupled to a bracket 194 that serves as a mounting for the external motor 100. FIG. 5 is an isometric view of the external motor device with the driven wheel cover 190 in the open position, according to one embodiment. The external motor 100 includes a removable panel 108 on the side of the housing 102 to provide access to the internal components of the external motor 100. FIG. 6 is a rear elevation view of the external motor device 100 with the driven wheel cover 190 removed. When the sprocket cover 190 is closed, the housing 102 and the driven wheel cover 190 define an opening 182 at the top of the external motor 100. A continuous cord loop 120 is routed through these openings during installation.

[0056] Referring again to FIG. 3 , the input interface of the external motor 100 can recognize various user input gestures in generating commands to open or close the window coverings and other system functions. These gestures include typing-style gestures such as touch, press, push, tap, double tap, and two-finger tap; pattern tracing gestures such as swipe, wave, and hand motion control; and multi-touch gestures such as pinching a specific spot on the capacitive touch strip 104. In the case of a two-dimensional user interface, such as the touchscreen 1008 of FIG. 16 , additional user gestures such as multi-touch rotation and tracing two-dimensional patterns may be employed. In one embodiment, the two-dimensional input interface 1008 can include a single-axis control that receives user input along an input axis.

[0057] The on-device control of the external motor of the present invention incorporates a shade position control I / O device, such as slider 104. Slider 104 extends vertically on housing 102 along the input axis of the I / O device. The vertical orientation of slider 104 naturally corresponds to the physical attributes of shade positioning when mapping a given input to a shade control function in the command generation device, providing intuitive, user-friendly control functionality. Examples of shade control I / O positioning functionality via slider 104 include, among others:

[0058] (a) A gesture at a given slider position between the bottom and top of the slider 104 corresponds to a given absolute position (height) of the blinds as measured by an encoder or other sensor.

[0059] (b) A gesture at a given position between the bottom and top of the slider 104 corresponds to a given relative position of the blind with respect to the calibrated distance between the set bottom position and the set top position (e.g., a gesture at a position 25% from the bottom of the slider 104 corresponds to a blind position of 25% of the calibrated distance from the set bottom position to the set top position).

[0060] (c) Gestures at the top and bottom of the slider 104 can perform different shade control functions depending on the gesture. Pressing and holding the top of the slider 104 commands the blinds to move continuously upward, while pressing and holding the bottom of the slider 104 commands the blinds to move continuously downward. Tapping the top of the slider 104 commands the blinds to move to their top position, while tapping the bottom of the slider 104 commands the blinds to move to their bottom position.

[0061] (d) Dynamic gestures (eg, swipes) up and down on the slider 104 can be assigned different functions, such as "up" and "down," or "start" and "stop."

[0062] The slider 104 provides a versatile I / O device suitable for various control functions of the window covering motor drive system. The various shade control functions can be based on a single-axis, quantitative scheme associated with the touch strip 104, such as a percentage scale with 0% at the bottom of the touch strip 104 and 100% at the top of the touch strip 104. For example, the slider 104 can be used to set blind positions at various opening levels via pre-set control options, such as 0% open (i.e., closed), 25% open, 50% open, 75% open, or 100% (fully) open. A user can command these opening levels via the slider 104 by swiping, tapping, or pressing various points on the slider. Additionally, the slider command scheme can incorporate boundary positions for state changes. For example, a slider input below the quarter-way position can command the window covering to close from 25% open to 0% open.

[0063] Various functions of the slider 104 may employ a combination of the slider's single-axis input sensing and single-axis display functions. For example, the LED strip 140 may illuminate specific locations along the touch strip 104, with these illuminated locations corresponding to boundaries along the slider for state changes in the shade command structure.

[0064] In the external motor device 2100 of Figure 21, the vertical touch strip input device has been replaced with capacitive touch buttons 2110, 2120, 2130 for various movement states. Touch button 2110 activates an up movement, touch button 2120 activates a down movement, and touch button 2130 activates an idle (stationary) movement state. For example, pressing the up or down button may cause continuous up or down movement, tapping the button may move the window covering position up or down to the next set position, and double-tapping the button may move the window covering position to the top or bottom calibrated position.

[0065] 7 is a diagram of a motor-driven control system 300 for a continuous cord loop driven window covering system. The control system 300 includes a DC motor 302, a gear assembly 304, and a clutch 306. Both the DC motor 302 and the clutch 306 are powered by a motor controller 308. The power source includes a battery pack 312. A user can recharge the battery pack 312 via a power supply circuit 314 using a charging port 316 or a solar array 318.

[0066] The central control element of control system 300 is microcontroller 310, which monitors and controls power supply circuitry 314 and motor controller 308. In one embodiment, microcontroller 310 and motor controller 308 are battery powered. Inputs to microcontroller 310 include motor encoder 322 and sensors 324. In one embodiment, sensors 324 include one or more temperature sensors, light sensors, and motion sensors. In one embodiment, control system 300 regulates daylighting, controls room temperature, limits glare, and controls other window covering functions such as privacy.

[0067] In one embodiment, the microcontroller 310 monitors the current draw from the motor controller 308 and uses this data to monitor various system conditions. For example, the control system 300 can use current flow sensing to lift heavier blinds at a slower speed during calibration and lighter blinds at a faster speed. In another embodiment, the microprocessor 310 monitors the motor current draw and determines deviations from a constant current draw as an indication of the window covering's position and its opening level. For example, if the current draw averages 1 ampere while raising the window covering, assuming the blinds are fully closed (0% open), the current draw may spike to 3 amperes to indicate that the fabric is retracted and the window blinds are in the fully open position (100% open).

[0068] In another embodiment, the monitored current flow measurements are analyzed to determine the direction of the driven wheel, and thereby the opening or closing direction of the window blinds. In one example, an external motor drive rotates the driven wheel in one direction and then the opposite direction while monitoring the current flow. The direction producing a greater current flow indicates the direction the blinds are opening. This method assumes that a greater torque (and greater current flow) is required to open the window, and a lesser torque (and lesser current flow) is required to close the window.

[0069] Additionally, the microcontroller 310 may have wireless network communication with various RF modules via a radio frequency integrated circuit ("RFIC") 330. The RFIC 330 controls two-way wireless network communication with the control system 300. Wireless networks and communication devices can include local area networks ("LANs"), which may include user remote controls, wide area networks ("WANs"), wireless mesh networks ("WMNs"), "smart home" systems and devices such as hub thermostats and smart thermostats, among many other types of communication devices or systems. The control system 300 may employ standard wireless communication protocols such as Bluetooth, WiFi, Z-Wave, ZigBee, Thread, etc.

[0070] The output interface 340 controls system output from the microprocessor 310 to output devices such as an LED 342 and a speaker 344. The output interface 340 controls the display of visual and audio cues that identify the state of the external motor control system and communicate messages. The input interface 350 controls system input from input devices such as a capacitive touch device 352 and buttons 354. The input interface 350 recognizes given user inputs that can be mapped by the microprocessor 310 to shade control functions within the instruction generation device. For example, the input interface 350 may recognize given user finger gestures on a touch strip or other capacitive touch device 352.

[0071] In one embodiment, the encoder 322 is an optical encoder that outputs a given number of pulses per revolution of the motor 302. The microcontroller 310 advantageously counts these pulses and analyzes the pulse count to determine operational and positional characteristics of the window covering installation. Other types of encoders, such as magnetic encoders, mechanical encoders, etc., may also be used. The number of pulses output by the encoder may be related to the linear displacement of the blind fabric 204 by a distance-to-pulse or pulse-to-distance conversion factor. For example, referring to FIG. 5 , when the window blinds 204 are in a fully closed position (0% open), the button on the external motor 210 can be pressed and held to raise the window blinds to the top of the window frame, at which point the button can be released. The external motor 210 can measure this travel as the total length (height) of the fabric 204 and thus determine its fully open, fully closed, and intermediate positions.

[0072] In one embodiment, control system 300 monitors various modes of system operation and engages or disengages clutch 306 depending on the operating state of system 300. In one embodiment, when DC motor 302 is rotating its output shaft under user (operator) control or automatic control by microcontroller 310, clutch 306 is engaged, thereby advancing continuous cord loop 320. When microcontroller 310 is not processing an operator command or automated function to advance the continuous cord loop, clutch 306 is disengaged, allowing a user to manually advance the continuous cord loop and operate the window covering system. In the event of a power outage, clutch 306 is disengaged, allowing manual operation of the window covering system.

[0073] The battery pack 312 may be an internal component of the external motor device 100 housed within the housing 102, or it may be an external device removably coupled to the housing 102. As shown in the embodiment of FIG. 8, the battery pack 380 provides a removable, rechargeable battery for powering the device 100. The battery pack 380 is shown as an external device that can be coupled to the motor device 100 by plugging a power connector 390 into a socket (not shown) in the housing 102. In this example, the battery pack 380 can be inserted face-up to plug the power connector 390 into a socket that receives it from the bottom side. However, it is contemplated that other battery pack configurations can be used, allowing the battery pack to be inserted into the housing from any angle or orientation. Additionally, the battery pack can be configured with a power connector or other connection mechanism on any side of the battery pack to mate with a socket or coupling within the housing.

[0074] As shown in FIG. 9 , the battery pack components include a power connector 390, a housing 392, a lid 394, a protection circuit board 396, and a battery holder 398 (e.g., a lithium-ion battery). As shown in FIGS. 8 and 9 , the housing 392 of the battery pack 380 has straight sides (e.g., square) and may include curved edges. The form factor is not limited to this particular configuration and may be any configuration that can be accommodated by the window control system housing 102. For example, in FIGS. 8 and 9 , the battery pack 380 is an external device detachably coupled to the housing 102, the housing having substantially square sides and capable of storing a lithium-ion battery in the battery holder 398. In another example, as shown in FIG. 11 , the battery pack 526 is an internal component of the external motor device 100, the external motor device further having rectangular sides and capable of storing six AAA rechargeable batteries 528.

[0075] In the assembly of the battery pack 380, battery cells (not shown), such as lithium-ion batteries, are disposed and / or secured within a battery holder 398. The battery cells may be inserted onto or between electrical contacts within the battery holder 398, e.g., in a vertically aligned stack of battery cells, with electrical contacts coupled to positive and negative battery terminals (not shown). Electrical lines 397 within the battery holder 398 are connected to a PCB 396, which may be mounted within the battery pack 380 separate from the battery holder 398. An electrical connector 390 is attached to the PCB 396, extending vertically from the PCB. The battery pack 380 is closed by attaching a lid 394 so that the electrical connector 390 extends above the battery pack 380 through a slot 395.

[0076] Figure 31 is a block diagram of a power management system 3100 for an external motor device. The power management system includes a battery pack control PCB 3120 operably coupled to a motor control main board 3110. The motor control main board 3110 provides positioning and other motor control commands to the motor via the battery pack control PCB 3120 and monitors the operation of the battery pack control PCB 3120. The battery pack control PCB 3120 supplies DC power to the motor 3140 (e.g., 12V at 2A power) and to the main board 2110 (e.g., in the range of 3-4.2V).

[0077] The battery pack control PCB 3120 interfaces with various DC power sources 3150, 3124, 3126, and the battery and protection components 3150 includes a rechargeable battery 3170 and a charging protection board 3160. The PCB 3120 also outputs DC power to the battery and protection components 3150 to recharge the rechargeable battery 3170 as needed.

[0078] The second DC power input of the battery pack control PCB 3120 is a solar charger interface 3122, which receives DC power from a photovoltaic (PV) array 3124. The photovoltaic cells of the PV array 3124 use sunlight as an energy source to generate DC current. In one embodiment, the solar charger interface 3122 is a high-energy device that incorporates energy harvesting technology. In one example, the solar charger specifications include: current <1 uA, peak charging current >20 mA, 4.2 V charging capability, very low charging voltage (e.g., 100 mV), and battery leakage current <1 uA.

[0079] The third DC power input on the battery pack control PCB 3120 is a USB charger interface 3128, which receives 5V DC power from a USB cable 3126 plugged into a charger such as an AC power adapter. In one example, the USB charger specifications include very low battery leakage current, overvoltage protection, overcurrent protection, and support for 4.2V charging.

[0080] The battery pack control PCB 3120 includes a gauge 3130 (also referred to as a fuel gauge) that measures the remaining battery capacity level under various operating conditions. The fuel gauge 3130 interfaces with various system components, such as the battery and protection component 3150 and the battery indicator 3136. In one embodiment, the fuel gauge 3130 incorporates a low-power microcontroller that incorporates environmental data and calculates the remaining energy. In one embodiment, the fuel gauge microcontroller does not require initial calibration. In one example, the fuel gauge specifications include a sleep current of approximately 10 uA, a 4.2 V charge capability, and a capacity of >12,000 mA. In one embodiment, the fuel gauge 3130 includes a display that displays the remaining energy level of the battery. In an alternative embodiment, the gauge 3130 can be an indicator light that displays a light or a specific color (e.g., red, orange, or green) that represents the remaining battery capacity.

[0081] The battery pack control PCB 3120 includes a boost converter 3134 as a motor drive. The boost converter 3134 is a DC-DC power converter that boosts voltage while reducing current from its input (DC power supply) to its output or load (DC motor 3140). By increasing the supply voltage, the boost converter 3134 can reduce the number of cells required in the battery 3170. In one example, the boost converter specifications include an input voltage of 3V to 4.5V, an adjustable output of 9V to 12V, 2A, a shutdown current (at Vin) of <5uA, and an efficiency of >90%.

[0082] In one embodiment, the battery pack control PCB 3120 incorporates an integrated circuit that includes multiple power rails and power management functions in a single chip. The IO expander 3132 provides additional inputs and outputs (I / O) on a microprocessor (MPU) or microcontroller (MCU) system. In one embodiment, the IO expander 3132 is a GPIO expander and includes an efficient data bus interface that reduces the I / O requirements of the MPU or MCU of the motor drive motherboard 3110 as an input to the boost converter 3134.

[0083] 10 is an input / output (black box) diagram of an external motor control system 400. Monitored variables (inputs) 410 of the external motor control system 400 include user input commands for blind control (e.g., a string packet containing commands) 412, distance from the top of the blinds to the current position (e.g., in meters) 414, blind roll-up speed (e.g., in meters per second) 416, current battery charge level (e.g., in mV) 418, temperature sensor output (e.g., in mV) 420, light sensor output (e.g., in mV) 422, motion sensor output (e.g., in mV) 424, smart home hub commands (e.g., a string packet containing commands) 426, smart home data (e.g., a thermostat temperature value in degrees Celsius) 428, and motor 302 current draw (e.g., in amps) 430.

[0084] Controlled variable (output) of the external motor control system 400 430 is the intended winding speed of the blind at a given time (e.g., in meters per second) 432 , the intended displacement from the current position at a given time (e.g., in meters) 434 , feedback instructions from the device to the user (e.g., a string packet containing instructions); 436 , clutch engagement / disengagement command at a given time 438 , and output data to the smart home hub (e.g., the temperature value in degrees Celsius corresponding to the temperature sensor output 420) 440 Examples include:

[0085] In one embodiment, the external motor control system 400 receives data (sensor outputs) 420 , 422 , and 424 (e.g., smart thermostats) to a third-party home automation control system or device. The third-party system or device can act on this data to control other home automation functions. Third-party home automation devices include "smart thermostats," such as the Honeywell Smart Thermostat (Honeywell International Inc., Morristown, New Jersey), Nest Learning Thermostat (Nest Labs, Palo Alto, California), Venstar programmable thermostat (Venstar, Inc., Chatsworth, California), and Lux ​​programmable thermostat (Lux Products, Philadelphia, Pennsylvania). Other home automation devices include HVAC (heating, ventilation, and air conditioning) systems and smart ventilation systems.

[0086] In another embodiment, the external motor control system 400 accepts data as well as instructions from third party systems and devices and acts upon these instructions and data to control the window covering system.

[0087] In one embodiment, the external motor control system 400 schedules the operation of the window covering system via a schedule programmed by the user.

[0088] In one embodiment, the sensor output of the motion sensor 424 is incorporated into a power saving process. The sensor 424 may be a presence / motion sensor in the form of a passive infrared ("PIR") sensor, or may be a capacitive touch sensor associated with a capacitive touch input interface of the external motor, for example. In this process, the external motor system 400 sleeps / sleeps until the presence / motion sensor detects user motion or presence. In one embodiment, an LED indicator on the external motor device illuminates to indicate that the device is ready for use. In one embodiment, after a period of inactivity, the device goes into a low power state to conserve energy.

[0089] In further embodiments, the external motor control system 400 may control multiple window covering systems and group the window covering systems to control them together, as described above with respect to group mode control. Examples of groups include external motors associated with windows facing a particular direction, external motors associated with windows located on a given floor of a building, etc.

[0090] In another embodiment, the external motor control system 400 controls a window covering system based on monitored sensor outputs. For example, based on the light sensor output 422, the window covering system may automatically open or close based on specific lighting conditions, such as opening the blinds at sunrise. In another example, based on the motion sensor output 424, the system may automatically open the blinds upon detecting a user entering the room. In yet another example, based on the temperature sensor output 420, the system may automatically open the blinds during the day to warm a cold room. Additionally, the system may store temperature sensor data for transmission to other devices.

[0091] FIG. 11 is an elevational view of the structural and operating components assembled from motor drive subassembly 500, viewed from one side. Front housing 514 and rear housing 516 enclose the drive train and other operating components of drive system 500, but are shown here separated from these components. DC motor 520 operates under power and control from PCB 532 and battery pack 526. Battery pack 526, shown in phantom in FIG. 11, is a rectangular-sided battery holder capable of storing six AAA rechargeable batteries 528, although the use of six batteries is for illustrative purposes only. Batteries 528 may be nickel-metal hydride ("NiMH") or lithium-ion polymer ("LiPo") batteries arranged in a vertically stacked configuration within battery pack 526. Battery pack 526 may be located within front housing 514 and rear housing 516, as shown, or may be external to these housings. The drive system 500 may incorporate other forms of battery pack 526 and other arrangements of batteries 528 within the battery pack 526. The battery pack 526 may be a removable component that can be inserted and removed at the bottom or side of the external motor device, for example, by removing the access panel 108 on the side of the external motor device 100 (FIG. 5). The battery 528 may be recharged while the battery pack 526 is stored within the external motor device 100 or after removing the battery pack 526 from the external motor device 100. The PCB 532 may include power management components that control power to the motor 520, control recharging of the battery 528, and may include other functions such as monitoring and displaying the charge status of the battery 528. An example of a power management system is shown in FIG. 31.

[0092] DC motor 520 has a rotating output shaft that rotates driven wheel 508 via multi-stage gear assembly 522. Multi-stage gear assembly 522 includes gear 523 aligned with the motor output shaft and face gear 524. Face gear 524 is coupled to driven wheel 508 by clutch system 512. Clutch 512 is a coupling mechanism that includes an engaged configuration, in which rotation of the motor 520 output shaft (transmitted by the multi-stage gear assembly) causes rotation of driven wheel 508, and a disengaged configuration, in which driven wheel 508 is not rotated by the motor output shaft. In one embodiment, clutch 512 is an electrically operated device that mechanically transfers torque, such as an electromagnetic clutch or solenoid. In another embodiment, clutch 512 is a purely mechanical, bidirectional clutch that is not electrically operated.

[0093] Successive presses of the power button 504 alternately switch the drive assembly between an engaged and disengaged configuration of the clutch system 512. The power button 504 corresponds to the power button 106 in the external actuator embodiment 100 of Figures 1 and 2. In one embodiment, the power button 106 switches the driven wheel or sprocket 508 on and off by, respectively, engaging and disengaging the clutch system 512. In another embodiment, pressing the power button 106 triggers the external actuator 100 to power on and off.

[0094] In one embodiment utilizing a purely mechanical bidirectional clutch, when the power button 106 is pressed in the “on” position, the mechanical clutch engages the driven wheel with the motor output shaft and gear assembly. This is a tensioned position in which the mechanical clutch does not allow movement of the driven wheel by manually pulling or towing the front chain / cord 122 or the back chain / cord 124. In this engaged configuration, when the external motor 100 receives a shade control command from an on-device control or other device, it energizes the motor, causing the output shaft and gear to rotate, which in turn rotates the driven wheel. When the power button 106 is pressed in the “off” position, the mechanical clutch disengages the driven wheel from the output shaft and gear, allowing manual operation of the front chain / cord 122 or the back chain / cord 124. In the disengaged configuration, if a shade control command is sent when the clutch is disengaged, the driven wheel will not rotate.

[0095] In another embodiment, the clutch system is an electromagnetic clutch in which the driven wheel is constantly engaged with the output shaft and gear assembly, allowing manual operation of the front chain cord 222 or the rear chain cord 224. This clutch does not lock the driven wheel to the output shaft and gear, but rather engages the driven wheel with the output shaft and gear when energized.

[0096] In a further embodiment, when the external motor 100 is turned "on" via the power button 106, i.e., engaged with the driven wheel, the system will recognize when the user pulls on the front or back chain / cord. In one embodiment, if the user pulls on the front chain / cord 122 while the external motor is under tension, the LED associated with the touch strip 104 will flash, informing the user that they can instead use the capacitive touch strip to control the device.

[0097] In another embodiment, if the user pulls on the chain / cord while the external motor is turned "on" via the power button 106, i.e., engaged with the driven wheel, and tension is applied to the drive assembly, the external actuator 100 will recognize the user's action using sensors and / or encoders and automatically lower or raise the blinds or take other action based on the command associated with the particular pulling action. The action stated can include pulling on the front chain / cord 122 or the back chain / cord 124.

[0098] In one embodiment, a sensor and / or encoder on the external motor 100 measures manual cord movement via a user "pulling" or pulling the cord. The mechanical coupling of the sprocket 184 to the gear assembly 160 includes a specific amount of slack, such that a user's pulling of the continuous cord loop 120 causes a specific amount of movement of the sprocket, which is recognized by a sensor or encoder (e.g., encoder 322, FIG. 7). Based on the output of the sensor or encoder, the shade control command structure can include various shade control actions and engage the motor to perform a given action. Pulling the cord while the external motor 100 is engaged to open or close the blinds can send various commands, such as stopping the blinds from opening or closing.

[0099] 10 is an example of a towing operation that engages the motor to execute a shade control command.

[0100] (a) Senses a downward pull and engages the DC motor in the same direction. For example, if a user pulls down on the front chain / cord 122, the motor will operate to lower the window shade.

[0101] (b) A downward pull is sensed and the DC motor is disengaged. For example, if the user pulls down on the rear chain / cord 124 while the motor is raising or lowering the window shade, the motor will disengage, stopping the shade in that position.

[0102] (c) A downward pull is sensed, engaging the DC motor in the opposite direction. For example, if a user pulls down on the rear chain / cord 124, the motor will activate and raise the window shade.

[0103] Referring again to FIG. 3, the RF button 112 is used to pair or synchronize the external motor with a cell phone via an RF chip, including, but not limited to, BLE ("Bluetooth Low Energy"), WiFi, or other RF chips. The RF button 112 can also be used to pair or synchronize with third-party devices, such as smart thermostats, HVAC systems, or other smart home devices, by forming a mesh network utilizing RF chips with various protocols, including, but not limited to, BLE (Bluetooth Low Energy) mesh, ZigBee (e.g., ZigBee HA 1.2), Z-Wave, WiFi, and Thread.

[0104] The group button 116 groups multiple external motors 100 in the network to control these external motors simultaneously. In one embodiment, group mode allows a user to control all external motors in a group from one external motor 100. In one embodiment, to add additional external motors to a group, a user presses and holds the group button 116 to enter pairing mode. The LED light on the touch strip 104 will flash orange to indicate that the device is in pairing mode. In one embodiment, a user presses and holds the group button of every external motor in the network they want to add to the group within a specified time frame. The LED color will change from orange to green for every external motor added to the group to indicate successful pairing. In another embodiment, a user can remove a device currently in the group by pressing the group button 116 once, so the group button performs a toggle function to add or remove external motors from the group. In one embodiment, a user presses the set button 114 to complete the pairing and linking of the external motors in the group.

[0105] To control a group of external motors that are linked or synchronized together, a user can activate group control by pressing the group button 116. In one embodiment, this causes the LED on the capacitive touch slider 104 to change color. All external motors in the group will illuminate or flash the same LED color to indicate that the external motors have entered group control mode. The user can then use the capacitive touch slider control 104 to position the blinds and control all linked devices.

[0106] FIG. 12 is a flow chart diagram of the group mode routine executed by the external motor 100. Once a user establishes a group, the group mode routine triggers shade control actions by other external motors in the group in response to a shade control command at a given external motor. At 602, the routine begins upon pressing the group button. Alternatively, the group mode routine may begin upon receiving a group mode command from another device recognized by the external motor, such as a smartphone, smart hub, or third-party device. At 604, the system determines whether the external motor is calibrated. If the external motor is not calibrated, the external motor's LED strip displays a flashing red error code. This notifies the user that the external motor must be calibrated before shade control commands (position-related commands) can be shared with other external motors in the group. If the external motor is calibrated, the system allows all shade control commands to be broadcast to other external motors in the group over a network (e.g., BLE mesh). The system then returns the error code. 608 After flashing or broadcasting a location-related command, the group mode routine is exited.

[0107] FIG. 13 is a flow chart diagram of a grouping mesh routine executed by the external motor in response to a grouping call received at 702. For example, the grouping call may be triggered at 606 in the group mode routine of FIG. 12. Upon receiving the grouping call, the external motor enters BLE mesh mode. 704, thereby communicating a message to other external motors in the group (BLE mesh) using the BLE protocol. In the case of an external motor network that uses another protocol 330 (FIG. 7) for RF communication, e.g., ZigBee, Z-Wave, WiFi, or Thread, the grouping call routine may be modified at 704 to initiate communication with other external motors in the group based on the applicable protocol. Similarly, the grouping call routine may be modified to accommodate different mesh topologies of the external motor network, e.g., hub-and-spoke (star topology).

[0108] The set button 114 is used to calibrate or pre-set the maximum open and closed positions of the blinds. After a user installs / mounts the external motor 100, the user can calibrate the device and manually set the positions at which the blinds will be fully open or fully closed. The user then presses the top of the capacitive touch slider 104 to raise the blinds to their highest position. Once the blinds reach their highest position, the user presses the set button 114 again to save the highest position. The user then presses the bottom of the capacitive touch slider control 104 to lower the blinds. Once the blinds reach their lowest position, the user presses the set button again to save the lowest position. The top and bottom positions set by the user can reflect user preferences, which may vary from external motor to external motor.

[0109] FIG. 14 is a flow chart diagram of a calibration routine executed by the external motor 100. The calibration routine begins with a calibration command 802, which can be executed by pressing and holding the set button 114 on the external motor or by some other method, such as input at a mobile device. At 804, the system passes control to the shade control state machine and the calibration state machine. The shade control state machine is discussed below with reference to FIG. 15. The calibration state machine controls the command structure for the LED indicators, calculates the top and bottom positions selected by the user based on the encoder pulse data, saves these top and bottom positions if confirmed by the user, calculates the distance between the top and bottom positions, and scales the shade control command to match the calibrated position. These routines allow the user to execute various motor control commands to move the blinds to the desired top position. At 806, the system detects whether the user has selected and confirmed the top position by pressing the set button. If so, the routine saves (calibrates) the top position at 808. At 810, the system again passes control to the shade control state machine and the calibration state machine. 812 Now the system detects whether the user has selected and confirmed the bottom position by pressing the set button, and if so, saves (calibrates) the bottom position at 814. Once the user has finally confirmed the calibration at 814, the system exits the calibration routine.

[0110] In the illustrated embodiment, the calibration procedure sets the top position and then the bottom position. In an alternative embodiment, the calibration procedure sets the bottom position and then the top position, instead of setting the top position and then calibrating the bottom position.

[0111] In another calibration embodiment, the user reverses the direction of movement by pressing and holding the set button 114 for a limited period of time. In this embodiment, if the user presses the top of the capacitive touch slider control 104 with the intention of raising the blinds, but the external motor 100 lowers the blinds instead, the user can reverse this direction by pressing and holding set 114 for a specified time frame. The user then presses the top of the capacitive touch slider control 104 to fully raise the blinds and then presses the set button 114 to set the top position. The user then presses the bottom of the capacitive touch slider control 104 to lower the blinds and then presses the set button 114 to set the bottom position.

[0112] In a further calibration embodiment, the user can press set for auto-calibration, during which the external motor determines the top and bottom positions via predetermined sensor measurements.

[0113] FIG. 15 is a flowchart of a shade control routine executed by the external motor 100. At 902, the system receives a command to transfer control to the shade control state machine. At 904, the system transfers control to the motor control routine. The motor control routine starts and stops the motor, moves the motor in a selected direction (up / down), moves the motor to a selected position, and adjusts the motor speed. The motor control routine is typically triggered by a user command, but can also be automated, for example, upon sensing a safety-affecting condition. At 906, the system detects whether group mode is active for the external motor. If yes, the external motor's control system broadcasts 908 a shade control message to the other motors in the group to execute. The shade control command executed in response to message 908 can differ between different external motors in the group. For example, calibrated position-based shade control commands will differ depending on the calibrated top and bottom positions for each external motor. If group mode is not active, the external motor exits the shade control routine at 906, otherwise it broadcasts the shade control message and then exits the routine at 908.

[0114] The I / O principles described above for the external motor device on-device control can be applied to various types of shade position control I / O devices separate from the external motor device on-device control, such as mobile user devices. In various embodiments, a web application emulates the single-axis input sensing and single-axis display capabilities of the external motor device on-device control described above. In various embodiments, the web application utilizes mobile device input technologies, such as touchscreen input, gesture-based input, and GPS location sensing. For example, the web application control may accept inputs such as dragging, tapping, double-tapping, and multi-touch input, as well as gestures such as tracing patterns, swiping, and waving, and hand movement control. In various embodiments, a two-dimensional I / O device, such as a 2D touchscreen, can be configured to operate when a user provides input along a single axis, e.g., the vertical or horizontal axis of the touchscreen.

[0115] 17-20 and 22 are front views of graphical user interfaces displayed on an electronic device 1705 (e.g., a mobile electronic device) presenting various screens of an external motor control application. The window covering application position control screen 1700 of FIG. 17 includes a vertical slider control 1730 having a bar 1740 that can be set at a desired vertical position via touchscreen input. In addition, the graphical user interface 1700 includes up-button 1710 and down-button 1720 controls, which can receive various types of touchscreen input. For example, pressing the button may cause continuous up or down movement, tapping the button may move the window covering position up or down to the next set position (e.g., a 75% set position), and double-tapping may move the window covering position to the top or bottom calibrated position.

[0116] The window covering application configuration screen 1800 of FIG. 18 is used to configure the external motor control application depending on what type(s) of window covering device(s) will be installed with the external motor control. The window covering device type options include roller shades 1810, vertical blinds 1820, curtains or drapes 1830, and Roman shades 1840. The roller shades 1810 and Roman shades 1840 are characterized by vertical position control, i.e., the external motor device raises or lowers the roller shade or Roman shade. The vertical blinds 1820 and curtains or drapes 1830 are characterized by horizontal position control, i.e., the external motor device opens or closes the vertical blind or curtain horizontally, e.g., across the window frame.

[0117] As seen in window covering application selection screen 1900 of FIG. 19 , the external motor control application can be configured to control two or more external motor controllers, for example, in different rooms or multiple devices within a given room. Following configuration, the user can select one of these devices for control via device selection screen 1900. In an exemplary embodiment, the user has configured two external motor window controllers: a roller shade device 1930 in Bedroom 1 and a curtain or drape device 1940 in Bedroom 2. The user selects device 1930 via radio button 1910 for control using the window covering application. Alternatively, the user can select device 1940 via radio button 1920. In various embodiments, if the external motor controller selected in selection screen 1900 is associated with a roller shade 1810 or a Roman shade 1840, the window covering application will display a position control application screen configured for vertical position control. In various embodiments, if the external motor control device selected in the selection screen 1900 is associated with vertical blinds 1820 or curtains or drapes 1830, the window covering application will display a position control application screen configured for horizontal position control.

[0118] In the window covering application position control screen 1700 use case of Figure 17, the control application displays the position control screen 1700 followed by a user selection 1910 of the device position in the selection screen 1900, the user selection being as shown in "Bedroom 1" in the window covering device header 1760. To control the raising and lowering of the roller blinds 1930, the position control screen 1700 displays a vertical slider control 1730.

[0119] The window covering application position control screen 2000 of FIG. 20 includes a horizontal slider control 2030 having a bar 2040 that is settable to a desired horizontal position via touchscreen input. The horizontal slider control 2030 is divided into ten segments of horizontal positions represented by a vertical bar 2050, and a user can move the window covering device precisely to one of these preset positions (e.g., an 80% position, with 100% being the right-most position) via touchscreen input. The position control screen 2000 also includes a left button 2010 and a right button 2020 that can be used to cause leftward or rightward movement of the window covering device, respectively. In an example use of the window covering application position control screen 2000 of FIG. 20, the control application displays the position control screen 2000 following a user selection 1920 of a device position in the selection screen 1900, with the user selection being as shown in "Bedroom 2" in the window covering device header 2060. To control the horizontal opening and closing of the curtain or drapes 1940 , the position control screen 2000 includes a horizontal slider control 2030 .

[0120] In addition to window covering application position control screens, such as portrait position screen 1700 of Figure 17 and horizontal position screen 2000 of Figure 20, the window covering application may include one or more speed control screens. The speed control screens may include controls that set the absolute value of the motor's speed as well as the direction of the window covering speed (e.g., up / down or left / right). Additionally, the speed control screens may include controls, such as a radio button control that selects one of several pre-set speed settings, or selects one of the following settings: idle, low, medium, and high.

[0121] Mapping a given user gesture to a given shade control command, also referred to herein as a "position-related command," allows commands applicable only to the local external motor 100 to be distinguished from commands applicable to multiple external motors. In one example, a double tap on the top of the capacitive touch slider design commands the system to provide 100% opening to all window coverings in a pre-defined group of window blinds, not just the local blinds. In another example, a two-finger tap commands the system to open all window coverings connected within the network.

[0122] In one embodiment, the window covering application can control the direction and speed of the window covering's forward and backward movements. Speed ​​control screen 2200 of FIG. 22 is used to set the direction (open / close) and speed of the window covering's movement. In the illustrated embodiment, the user selects a roller blind in the window covering device selection screen of FIG. 17, and speed control screen 2200 controls the roller blind's longitudinal direction and roll speed (e.g., in meters per second). Open / close control 2210 displays a lower-arrow 2214 and a raise-arrow 2218 icon, which respectively lower (open) and raise (close) the roller blind on the window blind controller. The speed control screen includes two different modes 2220, 2230 for the user to select the blind's roll speed; typically, only one of these modes is used at a time. Set speed level mode 2200 includes a control 2224 that selects a percentage value between 0% (roller blind stationary, i.e., idle) and 100% (full speed), inclusive. In various embodiments, the percentage control 2224 may select a percentage value within a continuous range or may select a percentage value from a series of discrete values. For example, as shown, the percentage control selects a percentage value with one decimal point, i.e., 58.5% of maximum speed. The preset speed mode 2230 includes several radio buttons, one of which may be selected to select one of a limited number of predetermined roller blind winding speeds. Here, the predetermined speeds include low speed 2232, medium speed 2234, and high speed 2236. In one embodiment, the maximum speed in mode 2220 and the preset speeds in mode 2230 are default speeds. In one embodiment, the maximum speed in mode 2220 and the preset speeds in mode 2230 are set by the user during device setup.

[0123] In one embodiment, the external motor device may include a variety of interchangeable driven wheels to accommodate different styles of continuous cord loop chains or cords. A user may attach a suitable driven wheel to the rotatable shaft of the motor drive assembly during installation or configuration of the external motor device. FIG. 23 shows at 2310 a drive wheel assembly including a cord-style continuous cord loop 2314 attached to a pulley-style driven wheel 2318. In one embodiment, the pulley wheel 2318 accommodates a range of cord thicknesses, and during normal operation, the cord 2314 engages the pulley wheel 2318 via frictional engagement. The drive wheel assembly includes a guide rail 2320 for the continuous cord loop 2314. The guide rail 2320 is a curved rail supported by support legs 2324 in close proximity to or contact with a section of the continuous cord 2314. In the disclosed embodiment, the drive wheel assembly 2310 includes a continuous cord loop sensor 2328 attached to the guide rail 2320. Figure 23 shows at 2330 a metal bead continuous cord loop chain 2334 attached to a sprocket-wheel driven wheel 2338 having cogs that interlock with the metal beads of the continuous cord loop chain 2334. Figure 23 shows at 2350 a plastic bead continuous cord loop chain 2354 attached to a sprocket-wheel driven wheel 2358 having cogs that interlock with the plastic beads of the continuous cord loop chain 2354.

[0124] In conventional implementations, a major concern is the tendency of the cord / pulley-motor drive system to slip during continuous operation. However, because the frictional engagement of the cord with the pulley drive can withstand the forces applied during normal operation without slippage, the primary cause of positioning error is material fatigue. One form of material fatigue in synthetic or natural fiber cords is wear over time that can be characterized as "creep." Creep describes the tendency of elastic materials to move slowly or permanently deform during long-term exposure to continuous or continually applied mechanical loads.

[0125] In conventional pulley drive systems, the most pressing concern in most practical uses of pulley drive systems typically focuses on speed differentials in the pulley drive. However, in motor drive systems for window coverings, another concern is relative motion resulting from speed differentials between the window covering drive mechanism (e.g., a continuous cord loop cord) and the pulley wheel. This relative motion, due to creep, causes the cord to move relative to the sprocket wheel during continuous operation, which can cause the final position of the window covering to move or vary over time and introduce errors into the position control. For example, position control systems measure the relative position of the window covering by measuring encoder counts at the motor, and any movement or variation of the continuous cord loop cord relative to the pulley driven wheel can impair the accuracy of the position control system. The disclosed embodiments attempt to address the creep issue in pulley wheel motor drive systems for corded continuous cord loops. The embodiments disclosed herein incorporate a continuous cord loop sensor system to address this issue.

[0126] In a continuous cord loop chain driven by a sprocket wheel, stresses on the continuous cord loop chain during continuous operation can cause the continuous cord loop chain to stretch or lengthen. For example, metal bead and ball chains can stretch due to stresses on the continuous cord loop chain when a motor accelerates from an idle state to full operating speed. The embodiments described herein incorporate a continuous cord loop sensor system that maintains accuracy in automated positioning control of window coverings when the continuous cord loop chain is stretched.

[0127] FIG. 24 shows a pulley-driven wheel drive assembly 2400 including a continuous cord loop sensor system that addresses creep issues in cord-based continuous cord loop drives. The pulley-driven wheel drive assembly includes a pulley-type driven wheel 2430 that engages a continuous cord loop cord 2410. A curved guide rail 2440, supported by support legs 2450, is positioned proximate to the cord 2410 across a segment at the lower loop end of the cord. The cord 2410 carries one or more sensor targets (also referred to herein as targets or markers) on an area of ​​the cord surface facing the guide rail. A continuous cord loop sensor 2460 (also referred to herein simply as the sensor) is attached to the guide rail adjacent to the bottom of the continuous cord loop. In this example, the sensor 2460 is a proximity sensor spaced a short distance 2470 from the target 2420 within the sensor's operating range. In other embodiments, the sensor may be a contact sensor attached to the guide rail in contact with the cord 2410.

[0128] The sensor target or marker can be formed of any material suitable for marking a code for proximity or contact sensing by sensor technology. For example, the marker can be formed from a metal, metal alloy, other conductive material, or a reflective or retroreflective material suitable for receiving electromagnetic energy emitted by the sensor and reflecting that energy back to the sensor. The sensor target or marker can be a piece of tape, foil, coating, or printed pattern of material on the surface area of ​​the continuous cord loop cord. The marker can have a variety of shapes or patterns, such as rectangular, polygonal, or circular, among other possibilities. The marker can be a durable material that is firmly adhered or applied to the surface of the continuous cord loop cord so that it remains intact on the cord surface during continuous operation, especially in the case of contact sensing.

[0129] The marker, or each of the plurality of markers, is located on a portion of the cord that faces the sensor when a target approaches or contacts the sensor during movement of the continuous cord loop cord. In one configuration, the marker is located at a single location on the cord that serves as a reference point along the length of the cord. The control system records the initial location of the reference point during system calibration. In another configuration, multiple markers are located at different initial locations. The controller is calibrated to store the initial position of each of the multiple markers along the continuous cord loop and is configured to receive a signal indicative of the presence of each sensor marker and to identify deviations from their respective initial positions during continuous operation of the drive system.

[0130] In one embodiment, the sensor target includes a first marker and a second marker located at two positions on the code, e.g., an uppermost reference point and a lowermost reference point. The controller may be calibrated to store a first initial position of the first marker corresponding to the uppermost position of the window covering and a second initial position of the second marker corresponding to the lowermost position of the window covering. In one embodiment, the uppermost and lowermost reference points correspond to calibrated upper and lower limits imposed on the range of movement of the window covering. The uppermost reference point (initial position of the first marker) may correspond to the uppermost position set in 808, and the lowermost reference point (initial position of the second marker) may correspond to the lowermost position set in 814, in the set calibration routine of FIG. 8 .

[0131] As the continuous cord loop cord continues to move, when a target or one of the targets passes the sensor assembly, the controller receives a signal from the sensor indicating the presence of the target. In one embodiment, the controller compares the target's current location to its calibration standard and generates an indication or other response if the controller identifies a deviation from the initial position. In one embodiment, the controller recalibrates the drive system to correct (adjust) the window covering positioning signal for any detected deviation. In embodiments including first and second indicators, the controller can recalibrate one or both of the calibrated top position and the calibrated bottom position, thereby adjusting the range of movement of the window covering. This procedure allows the controller to compensate for creep of the continuous cord loop cord.

[0132] The sensor may be a device mounted on the guide rail that is configured to output a signal indicating the presence of a sensor target when the sensor target is located in proximity to or in contact with the sensor. A controller may receive the signal and generate an indication or other response to the signal. In various embodiments, the sensor is a proximity sensor, e.g., a sensor that can detect the presence of a proximity target without any physical contact and emits an output signal when the target is located within the sensor's operating range. In one embodiment, the proximity sensor emits a beam of electromagnetic radiation, such as an electromagnetic field or infrared (IR), and looks for a change in the electromagnetic field or a return signal. In one embodiment, the sensor target or each of the multiple sensor targets includes a piece of reflective material that is configured to reflect the beam of electromagnetic energy emitted by the sensor back to the sensor when the sensor target is located in proximity to the sensor. Proximity sensors can have high reliability and a long functional life because there are no mechanical parts and no physical contact between the sensor and the target.

[0133] In various embodiments, the sensor is a contact sensor, e.g., a sensor that senses the presence of a target through physical contact with the target and outputs a signal indicative of the presence of the sensor target upon such physical contact. In one embodiment, the contact sensor includes a plurality of contacts connected to an electrical circuit. The sensor target includes a piece of conductive material that creates a short in the electrical circuit when the conductive material comes into contact with the plurality of contacts.

[0134] In various embodiments, an IR sensor is mounted on or within the guide rail as a proximity sensor. The guide rail mount and IR sensor can have a surface mount configuration and a through-hole mount configuration. Figures 25 and 26 show a curved guide rail with a mounting surface for the IR sensor and an infrared sensor on a PCB. In the guide rail mounting portion 2500 of FIG. A curved guide rail 2510 with support legs 2520 includes a sensor mounting portion 2530. The sensor mounting portion 2530 receives an IR sensor module 2600, such as sensor 2610 on a PCB 2620. The sensor 2600 has a through-hole mounting configuration that seats the mounting portion 2630 within an opening 2540 in the PCB.

[0135] In one embodiment, the IR sensor module 2610 includes a side-by-side IR emitter and IR sensor. The 940 nm emitters (LEDs) are encapsulated side-by-side, facing the same direction, with corresponding silicon phototransistors. In another example, the IR sensor is a phototransistor-output, reflective photointerrupter with an optimal optical sensing distance of 0.5 mm. In yet another example, the IR sensor is a miniature, SMD-type reflective microsensor with a detectable sensing distance of 1.0 mm. The sensor's working distance is well-matched to the constraints imposed by the mechanical layout of the external motor drive.

[0136] In one example, the target was a piece of metal tape on the cord. When the target was within the sensor's operating range, the reflection from the metal tape caused the sensor's output to drop to ground. This signal was used as a reliable reference point to correct for any deviations in the window covering's positioning control. A drawback of IR sensors was the increased computational load placed on the microcomputer 310 to sample and effectively analyze the analog output signal. In testing, the physical configuration of the code and markings dramatically changed signal quality, as these characteristics affected the effective distance from the sensor to the target. Signal quality could be improved by perforating the metal tape before adhering it to the cord.

[0137] FIG. 27 shows an embodiment of a continuous cord loop sensor system 2700 with a contact sensor, including a curved guide rail 2710 with leaf spring contacts 2720 that protrude above the guide rail without making contact with the continuous cord loop. One goal of the leaf spring sensor 2700 was to mitigate signal quality concerns by using well-established principles of contact sensors. The sensor 2700 has an electrical circuit including two or more contacts, in this case, leaf spring contacts 2720. Physical contact between a passing metal tape or other conductive marking and the leaf spring contacts 2720 creates an alternative circuit path with very low electrical impedance, e.g., a short circuit. The resulting signal is a short between the two leaf spring contacts, which is detectable by the microcomputer 310, resulting in a robust sensor requiring only a light computational load. The actuation height of the leaf spring contacts allows the springs to extend into the pulley to accommodate variations in cord thickness. However, leaf spring contacts can be fragile and tend to deform during installation or use.

[0138] FIG. 28 shows a curved guide rail 2810 Electrical leads 2840, 2850 Flat Contact 2820 、283028 shows an embodiment of a continuous cord loop sensor system 2800 with a contact sensor including a pulley wheel redesigned from the traditional V-groove design to account for the lack of conformance of the contact points within its operating height. The redesigned pulley wheel has a flatter profile, allowing the cord to pass around the side of the pulley and make consistent contact with the flat contact points.

[0139] FIG. 29 shows an embodiment of a continuous cord loop sensor system 2900 with a contact sensor, including a flat contact 2920 on a flat guide rail 2910. The flat contact 2920 extends from an electrical printed circuit board (PCB) 2940 through a recess 2930. This design addressed an issue with the flat contact design 2800, in which the bend radius of the curved guide rail 2810 could prevent a metallic tape sign from achieving full contact with the flat contact. In performance testing, the flat guide rail significantly improved the reliability of the flat contact design. Testing included two configurations for the flat contact sensor: (a) a horizontal configuration, in which the flat contact was collinear with the continuous cord loop cord, and (b) a vertical configuration, in which the flat contact was perpendicular to the continuous cord loop cord. Both configurations present two problems. The proximity of connector 2920 to recess edge 2930 can cause the metal tape to catch on the contacts and pull them away from the PCB after extended use. If the metal tape is relatively smooth (e.g., new tape), the flat guide rails may not exert enough force to press the flat contacts against the metal tape, resulting in a false negative.

[0140] 30 shows an embodiment of a continuous cord loop sensor system 3000 with a contact sensor that includes a flat guide rail 3010 with wire contacts 3020 that protrude above the guide rail. In this design, the sensor PCB is hidden below the guide rail, which solves the problem in sensor system 2900 where the metal tape could catch on the contacts and pull the connector off the PCB. Additionally, the higher profile of the wire contacts 3020 ensures that the contacts protrude into the pulley and make solid contact with the metal tape indicators.

[0141] Applicant tested three configurations of the fourth contact sensor embodiment 3000: (a) a 1 mm diameter wire in a horizontal configuration, collinear with the continuous cord loop cord; (b) a 1 mm diameter wire in a vertical configuration, perpendicular to the continuous cord loop cord; and (c) a 0.5 mm diameter wire in a horizontal configuration, collinear with the continuous cord loop cord. In performance testing, the wire contact 3020 made good contact with the metal tape sign. It was observed that the smooth, rounded configuration of the 90° curve of the wire contact 3020 prevented the metal tape from getting caught on the contact. The horizontal configuration performed better than the vertical configuration. The 1 mm diameter horizontal wire contact performed better than the 0.5 mm diameter horizontal wire contact, in that the larger diameter contact provided stronger contact with the metal tape.

[0142] While various aspects and embodiments have been disclosed, other aspects and embodiments are contemplated. The various disclosed aspects and embodiments are for purposes of illustration and are not intended to be limiting, with the true scope and spirit being indicated by the following claims.

[0143] The foregoing method descriptions and interface configurations are provided merely as examples and are not intended to require or imply that the steps of the various embodiments must be performed in the order presented. As will be understood by one of ordinary skill in the art, the steps of the foregoing embodiments may be performed in any order. Words such as "then," "next," and the like are not intended to limit the order of the steps; these words are merely used to guide the reader through the method descriptions. Although a process flow diagram may describe operations as a sequential process, many of the operations may be performed in parallel or concurrently. Additionally, the order of operations may be re-arranged. A process may correspond to a method, a function, a procedure, a subroutine, a subprogram, etc. When a process corresponds to a function, its termination may correspond to a return of the function to the calling function or the main function.

[0144] The various illustrative logic blocks, modules, circuits, and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, computer software, or a combination of both. To clearly illustrate this interchangeability of hardware and software, the various illustrative components, blocks, modules, circuits, and steps have been described above generally in terms of their functionality. Whether such functionality is implemented as hardware or software depends on the particular application and design constraints imposed on the overall system. Those skilled in the art may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present invention.

[0145] Embodiments implemented in computer software may be implemented in software, firmware, middleware, microcode, hardware description languages, or any combination thereof. A code segment or machine-executable instruction may represent a procedure, a function, a subprogram, a program, a routine, a subroutine, a module, a software package, a class, or any combination of instructions, data structures, or program statements. A code segment may be coupled to another code segment or a hardware circuit by passing information, data, arguments, parameters, or memory contents. Information, arguments, parameters, data, etc. may be passed, forwarded, or transmitted via any suitable means including memory sharing, message passing, token passing, or network transmission.

[0146] The actual software code or specialized control hardware used to implement these systems and methods is not a limitation of the present invention. Thus, the operation and behavior of the systems and methods will be described without reference to specific software code, with the understanding that software and control hardware can be designed to implement the systems and methods based on the description herein.

[0147] If implemented in software, the functions may be stored as one or more instructions or code on a non-transitory computer-readable or processor-readable storage medium. The steps of a method or algorithm disclosed herein may be embodied in a processor-executable software module, which may reside on a computer-readable or processor-readable storage medium. Non-transitory computer-readable or processor-readable media include both computer storage media and tangible storage media that facilitate transfer of a computer program from one place to another. Non-transitory processor-readable storage media may be any available medium that can be accessed by a computer. By way of example, and not limitation, such non-transitory processor-readable media may include RAM, ROM, EEPROM, CD-ROM, or other optical disk storage, magnetic disk storage, or other magnetic storage devices, or any other tangible storage medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer or processor. As used herein, disk and disc include compact disc ("CD"), laser disc, optical disc, digital versatile disc ("DVD"), floppy disk, and Blu-ray disc, where disks typically reproduce data magnetically while discs reproduce data optically using a laser. Combinations of the above are also intended to be included within the scope of computer-readable media. Additionally, the operations of a method or algorithm may reside as one or any combination or set of codes and / or instructions on a non-transitory processor-readable medium and / or computer-readable medium, which may be incorporated into a computer program product. As a preferred embodiment, the present invention can also be configured as follows. 1. A drive system for use with a window covering system including a mechanism for raising and lowering a window covering and a continuous cord loop extending below said mechanism, a motor configured to operate on electrical power to rotate an output shaft thereof; a driven wheel coupled to the output shaft of the motor and configured to engage the continuous cord loop, wherein rotation of the driven wheel in a first direction advances the continuous cord loop and causes the mechanism to raise the window covering, and rotation of the driven wheel in a second direction advances the continuous cord loop and causes the mechanism to lower the window covering; one or more sensor targets disposed on said continuous cord loop; a controller for the motor; a sensor operably connected to the controller and configured to generate a signal indicative of the presence of each of the one or more sensor targets disposed on the continuous cord loop when the sensor target is located in proximity to or in contact with the sensor; 2. The drive system described in claim 1, wherein the sensor is a proximity sensor and each of the one or more sensor targets comprises a piece of reflective material configured to reflect a beam of electromagnetic energy emitted by the sensor back to the sensor when the target is located in proximity to the sensor. 3. The drive system of claim 2, wherein the proximity sensor includes an infrared sensor. 4. The motor drive system described in claim 1, wherein the sensor is a contact sensor having a plurality of contacts connected to an electrical circuit, and each of the one or more sensor targets includes a piece of conductive material configured to create a short circuit in the electrical circuit when the piece of conductive material comes into contact with the plurality of contacts. 5. The drive system of claim 4, wherein the contact sensor comprises a plurality of leaf spring contacts. 6. The drive system of claim 4, wherein the contact sensor comprises a plurality of flat contacts recessed in the guide rail. 7. The drive system of claim 4, wherein the contact sensor comprises a plurality of wire contacts, the wire contacts protruding above the guide rail. 8. The drive system of claim 1, wherein each of the one or more sensor targets is a piece of metallic or reflective tape adhered to an endless loop of flexible material. 9. The drive system of claim 1, wherein the guide rail has a curved surface adjacent the driven wheel or a substantially flat surface adjacent the driven wheel. 10. A drive system as described in claim 1, wherein the controller is calibrated to store the position of each of the one or more sensor targets along the continuous cord loop, and is configured to receive signals indicating the presence of each of the sensor targets and to identify deviations from their respective positions during continuous operation of the drive system. 11. The drive system of claim 1, wherein the one or more sensor targets comprise a first marker and a second marker, the controller is calibrated to store a first position of the first marker corresponding to a top-most position of the window covering and a second position of the second marker corresponding to a bottom-most position of the window covering, and the controller is configured to receive signals indicative of the presence of each of the first marker and the second marker and to identify deviations from their respective positions during continuous operation of the drive system. 12. The drive system of claim 11, wherein the controller is configured to recalibrate the first position and the second position upon identifying the deviation. 13. A drive system for use with a window covering system including a roller blind mechanism for raising and lowering a window covering fabric and a continuous cord loop extending below said mechanism, comprising: a motor configured to be electrically powered to rotate an output shaft thereof; a driven wheel coupled to an output shaft of the motor and configured to engage the continuous cord loop; one or more sensor targets disposed on said continuous cord loop; a controller for the motor; a sensor operably connected to the controller, the sensor configured to generate a signal indicative of the presence of a sensor target on the continuous cord loop when the sensor target is located in proximity to or in contact with the sensor; A drive system wherein the controller is calibrated to store the respective positions of one or more sensor targets along the continuous cord loop and configured to receive the signal indicative of the presence of each sensor target and to identify deviations from the respective positions during continuous operation of the drive system. 14. The drive system of claim 13, wherein the one or more sensor targets comprise a first marker and a second marker, the controller is calibrated to store a first position of the first marker corresponding to a top position of the window covering and a second position of the second marker corresponding to a bottom position of the window covering, and the controller is configured to receive the signals indicative of the presence of each of the first marker and the second marker and to identify deviations from the respective first or second positions during continuous operation of the drive system. 15. The drive system of claim 14, wherein the controller is configured to, if it identifies a deviation from the respective first or second position during continuous operation of the drive system, recalibrate the respective first or second position to compensate for the identified deviation. 16. The drive system of claim 13, wherein rotation of the driven wheel in a first direction advances the continuous cord loop, causing the roller blind mechanism to raise the window covering, and rotation of the driven wheel in a second direction advances the continuous cord loop, causing the roller blind mechanism to lower the window covering. 17. The drive system of claim 13, wherein the controller is configured to perform a recalibration upon identifying the deviation. 18. The drive system of claim 13, wherein the sensor is a proximity sensor and each of the one or more sensor targets comprises a piece of reflective material configured to reflect a beam of electromagnetic energy emitted by the sensor back to the sensor when the target is located in proximity to the sensor. 19. The drive system of claim 18, wherein the proximity sensor includes an infrared sensor. 20. A drive system as described in claim 13, wherein the sensor is a contact sensor having a plurality of contacts connected to an electrical circuit, and each of the one or more sensor targets comprises a piece of conductive material configured to create a short in the electrical circuit when it comes into contact with the plurality of contacts. 21. A drive system for use with a window covering system including a mechanism for extending and retracting the window covering and a continuous cord loop extending below the mechanism, comprising: a motor configured to operate on electrical power to rotate an output shaft thereof; a driven wheel coupled to an output shaft of the motor and configured to engage the continuous cord loop; a controller for the motor; a housing that houses the motor, the driven wheel, and the controller; a rechargeable battery electrically coupled to the motor and the controller, wherein the motor and the controller are battery powered, and the rechargeable battery is housed within or coupled to the housing. Drive system. 22. The drive system of claim 21, wherein the rechargeable battery comprises a battery pack external to and removably coupled to the housing. 23. The drive system according to claim 21, wherein the rechargeable battery is housed in a housing. 24. The drive system of claim 23, wherein the rechargeable battery comprises a battery pack that is removable from the housing. 25. The drive system of claim 21, wherein the rechargeable battery comprises a battery pack and a battery pack control printed circuit board ("PCB") electrically coupled to the battery pack, the battery pack control PCB configured to supply DC power to the motor and the controller. 26. The drive system of claim 25, wherein the battery pack control PCB includes a gauge configured to measure and display the remaining energy level of the rechargeable battery. 27. A drive system as described in claim 26, wherein the gauge comprises a microcontroller configured to capture environmental data and to calculate the remaining energy level.

Claims

1. 1. A drive system for use with a window covering system including a mechanism for raising and lowering a window covering and a continuous cord loop extending below the mechanism, comprising: a motor configured to operate on electrical power to rotate an output shaft thereof; a driven wheel coupled to the output shaft of the motor and configured to engage the continuous cord loop, wherein rotation of the driven wheel in a first direction causes the continuous cord loop to cause the mechanism to raise the window covering, and rotation of the driven wheel in a second direction causes the continuous cord loop to advance and cause the mechanism to lower the window covering; one or more sensor targets configured to be disposed on the continuous cord loop; a controller for the motor; a sensor operably connected to the controller and configured to generate a signal indicative of the presence of each of the one or more sensor targets disposed on the continuous cord loop when the sensor target is located in proximity to or in contact with the sensor.

2. 2. The drive system of claim 1, wherein the sensor is a proximity sensor and the one or more sensor targets each comprise a piece of reflective material configured to reflect a beam of electromagnetic energy emitted by the sensor back to the sensor when the target is located in proximity to the sensor.

3. The drive system of claim 2 , wherein the proximity sensor comprises an infrared sensor.

4. 2. The motor drive system of claim 1, wherein the sensor is a contact sensor including a plurality of contacts connected to an electrical circuit, and wherein each of the one or more sensor targets includes a piece of conductive material configured to create a short in the electrical circuit when the piece of conductive material contacts the plurality of contacts.

5. The drive system of claim 4 , wherein the contact sensor comprises a plurality of leaf spring contacts.

6. The drive system of claim 4 , wherein the contact sensor comprises a plurality of flat contacts recessed in a guide rail.

7. The drive system of claim 4 , wherein the contact sensor comprises a plurality of wire contacts, the wire contacts projecting above the guide rail.

8. The drive system of claim 1 , wherein each of the one or more sensor targets is a piece of metallic or reflective tape configured to adhere to the continuous cord loop.

9. The drive system of claim 1 , wherein the sensor comprises a guide rail having either (i) a curved surface adjacent the driven wheel or (ii) a substantially flat surface adjacent the driven wheel.

10. 2. The drive system of claim 1, wherein the controller is calibrated to store the position of each of the one or more sensor targets along the continuous cord loop and configured to receive signals indicative of the presence of each of the one or more sensor targets and to identify deviations from their respective positions during continuous operation of the drive system.

11. 2. The drive system of claim 1, wherein the one or more sensor targets comprise a first marker and a second marker, the controller is calibrated to store a first position of the first marker configured to correspond to a top-most position of the window covering and a second position of the second marker configured to correspond to a bottom-most position of the window covering, and the controller is configured to receive signals indicative of the presence of each of the first marker and the second marker and to identify deviations from the respective positions during continuous operation of the drive system.

12. The drive system of claim 11 , wherein the controller is configured to recalibrate the first position and the second position upon identifying the deviation.

13. 1. A drive system for use with a window covering system including a roller blind mechanism for raising and lowering a window covering fabric and a continuous cord loop extending below the mechanism, comprising: a motor configured to be electrically powered to rotate an output shaft thereof; a driven wheel coupled to an output shaft of the motor and configured to engage the continuous cord loop; one or more sensor targets configured to be disposed on the continuous cord loop; a controller for the motor; a sensor operably connected to the controller, the sensor configured to generate a signal indicative of the presence of each of the one or more sensor targets when the sensor target is located in proximity to or in contact with the sensor; A drive system wherein the controller is calibrated to store the respective positions of one or more sensor targets and is configured to receive the signal indicative of the presence of each of the one or more sensor targets and to identify deviations from the respective positions during continuous operation of the drive system.

14. 14. The drive system of claim 13, wherein the one or more sensor targets comprise a first marker and a second marker, the controller is calibrated to store a first position of the first marker configured to correspond to a top-most position of the window covering and a second position of the second marker configured to correspond to a bottom-most position of the window covering, and the controller is configured to receive the signal indicative of the presence of each of the first marker and the second marker and to identify deviations from the respective first or second positions during continuous operation of the drive system.

15. 15. The drive system of claim 14, wherein the controller is configured to, if it identifies a deviation from the respective first or second position during continuous operation of the drive system, recalibrate the respective first or second position to compensate for the identified deviation.

16. 14. The drive system of claim 13, wherein rotation of the driven wheel in a first direction is configured to advance the continuous cord loop, causing the roller blind mechanism to raise the window covering, and rotation of the driven wheel in a second direction is configured to advance the continuous cord loop, causing the roller blind mechanism to lower the window covering.

17. The drive system of claim 13 , wherein the controller is configured to perform a recalibration upon identifying the deviation.

18. 14. The drive system of claim 13, wherein the sensor is a proximity sensor and the one or more sensor targets each comprise a piece of reflective material configured to reflect a beam of electromagnetic energy emitted by the sensor back to the sensor when the target is located in proximity to the sensor.

19. The drive system of claim 18 , wherein the proximity sensor includes an infrared sensor.

20. 14. The drive system of claim 13, wherein the sensor is a contact sensor comprising a plurality of contacts connected to an electrical circuit, and wherein each of the one or more sensor targets comprises a piece of conductive material configured to create a short in the electrical circuit when in contact with the plurality of contacts.

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