Movable Barrier Operator Head Unit with Segmented Circuit Boards
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Solution Overview
Problem
Existing movable barrier operators, such as garage door operators, face challenges including complex maintenance due to high voltage components, limited accessibility of circuitry components, and inadequate packaging for transportation, which complicates installation and maintenance, and may result in unnecessary component replacement and damage during transport.
Innovation Solution
A head unit design with a fire-resistant container for high voltage components and a separate circuit board for lower voltage components, allowing tool-free housing removal and improved wireless communication range, along with a battery cover for easy access and replacement, and a guide for secure belt or chain operation, enhancing usability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high voltage components are enclosed in a UL-certified housing, then safety is improved, but maintenance complexity increases due to requiring tools to open the enclosure
Solution Approach 1:
The circuit board is divided into two separate sections: a high voltage section enclosed in a UL-certified housing for safety, and a low voltage section accessible without tools for easy maintenance. This segmentation allows different parts of the system to have different access requirements based on their voltage levels and safety needs.
2Device complexity
If all circuitry is integrated on one large circuit board, then device complexity is reduced, but repairability worsens when a single component fails
Solution Approach 1:
The circuit board is segmented into high voltage and low voltage sections, allowing the low voltage section to be accessed and replaced independently without affecting the high voltage components. This enables selective repair of failed components without requiring replacement of the entire circuit board.
3Reliability
If foam and cardboard inserts are used for packaging, then product protection is improved, but environmental impact worsens due to landfill waste
Solution Approach 1:
The packaging material is changed from foam and cardboard to a recyclable plastic alternative that provides equivalent or superior protection during transport. This parameter change maintains product protection while improving environmental sustainability through recyclability.
Data Source
AI summary
In accordance with one aspect of the present disclosure, a head unit of a movable barrier operator is provided including a motor for moving a movable barrier and a first circuit board operable to provide power to the motor. The head unit includes a fire-resistant container that contains the first circuit board. This permits the electrical components of the head unit that utilize higher voltage, such as 120 volts, to be provided on the first circuit board and contained in the fire-resistant container. The head unit further includes a second circuit board outside of the fire-resistant container and operably coupled to the first circuit board. Because the second circuit board is outside of the fire-resistant container, the second circuit board may contain electrical components of the head unit that operate at lower voltages, such as at or below 24 volts.