Movable Barrier Operator Travel Limit Adjustment
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Solution Overview
Problem
Current movable barrier operators face challenges in making fine-tune adjustments to travel limits, often resulting in undesirable gaps between the barrier and its stopping position, requiring complex manual adjustments and expensive electronic devices.
Innovation Solution
A movable barrier operator system that includes an electrical component generating a quantized signal, an analog-to-digital converter, and a controller to derive an output signal for a motor, allowing for precise adjustments of travel limits without disassembly or expensive electronics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cam and limit switch combination is used to determine travel limits, then the device complexity is low and ease of manufacture is high, but the manufacturing precision and measurement precision are insufficient resulting in undesirable gaps
Solution Approach 1:
The patent replaces the traditional mechanical cam and limit switch system with an optical sensor system that uses light beams to detect the position of the movable barrier. This substitution enables precise measurement of travel limits without the mechanical wear and imprecision inherent in cam-based systems, while the microprocessor automatically processes the optical sensor signals to determine exact travel limits.
Solution Approach 2:
The patent uses optical sensors to create a virtual copy or representation of the physical barrier position through light detection. Instead of relying on physical contact between cams and limit switches, the system creates an optical replica of the barrier's position state, allowing for more precise and wear-free measurement of travel limits.
2Measurement precision
If cam locations are adjusted to achieve fine-tune travel limit adjustment, then the measurement precision improves, but the ease of operation deteriorates requiring disassembly and multiple technicians
Solution Approach 1:
The patent implements a self-adjusting system where the microprocessor automatically calculates and adjusts the travel limits based on signals from the optical sensors. The system performs the measurement and adjustment functions autonomously without requiring manual intervention, disassembly of components, or coordination between multiple technicians, thereby maintaining high precision while dramatically improving ease of operation.
Solution Approach 2:
The patent replaces manual mechanical adjustment of cam positions with an automated electronic system. The microprocessor receives electrical signals from optical sensors and automatically determines the correct travel limit positions, eliminating the need for technicians to physically disassemble and reposition mechanical components.
3Manufacturing precision
If expensive electronic devices such as encoders and hall-effect devices are used to achieve fine-tune adjustment, then the manufacturing precision improves, but the ease of manufacture and cost-effectiveness deteriorate
Solution Approach 1:
The patent employs relatively simple and inexpensive optical sensors instead of expensive encoders or hall-effect devices. These optical sensors provide sufficient precision for travel limit measurement at a fraction of the cost of alternative electronic components, making the system more cost-effective and easier to manufacture while maintaining the required measurement accuracy.
Solution Approach 2:
The patent substitutes complex expensive electronic measurement devices with simpler optical sensing technology. The optical sensors, combined with microprocessor-based signal processing, achieve the necessary measurement precision without requiring costly encoders or hall-effect sensors, thereby improving ease of manufacture and reducing system cost.
Data Source
AI summary
A method and a device capable of making fine-tune adjustments in the traveling limits of a movable barrier operator are disclosed. More particularly, an apparatus in accordance with the present invention comprises of a movable barrier operator for controlling a travel limit of a movable barrier comprises of an electrical component sending an input signal to a controller, a controller to derive an output signal from the input signal, and a motor to receive the output signal and modify the travel limit of the movable barrier. More specifically, said method and device can be used to make such fine-tune adjustments to modify an undesirable gap of a movable barrier in its fully closed or fully open positions.