Hybrid Door Motion Encoder With Adjustable Absolute Positioning

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Solution Overview

Problem

Existing devices for monitoring the motion of powered doors, such as roller doors and sectional doors, are complex and costly due to their numerous components and require frequent maintenance, especially when they need to relearn door positions after power loss or manual operation.

Innovation Solution

A hybrid encoder system with an absolute position encoder and a relative position encoder, where the absolute position encoder is manually adjustable without moving the drive means, allowing for simpler and more robust monitoring of door motion parameters using fewer components and optical sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a sophisticated position encoder with multiple optical sensors is used, then measurement precision is improved, but device complexity increases and manufacturing cost rises

Engineering Contradiction:

Improvedoor position identification accuracyVSAvoidnumber of optical sensors and components

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The encoder system is segmented into two functional parts: a absolute position encoder using a single optical sensor with a coded wheel for sector identification, and a relative position encoder using another single optical sensor for velocity measurement. This segmentation reduces the total number of optical sensors from multiple to just two, while maintaining measurement precision through the specialized function of each sensor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A coded wheel with radial transparent and opaque segments is introduced as an intermediary element between the light source and optical sensor. This coded wheel encodes absolute position information through its pattern, allowing a single optical sensor to determine sector position without requiring multiple sensors simultaneously observing different features.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If physical limit switches are used, then ease of manufacture is improved, but reliability deteriorates due to vulnerability to damage from repeated contact

Engineering Contradiction:

Improvesimplicity of installationVSAvoidresistance to damage from contact

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The mechanical contact-based limit switch system is replaced with an optical encoding system. The absolute position encoder uses a light source and optical sensor to detect the position of a coded wheel without any physical contact between the sensing elements and the moving door, thereby eliminating wear and damage from repeated contact while maintaining ease of manufacture through integrated circuitry.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If a learning controller is used, then adaptability is improved, but loss of information occurs when power is unavailable or manually operated

Engineering Contradiction:

Improveself-learning capabilityVSAvoidstored door position knowledge

Core Design Contradiction:

Adaptability or versatilityVSLoss of information

Solution Approach 1:

The absolute position encoder continuously provides preliminary information about the door's sector position through the coded wheel pattern, independent of power state or manual operation. This preliminary position data is immediately available upon power restoration or after manual operation, allowing the controller to rapidly re-establish full position knowledge without requiring extensive relearning procedures.

Inventive Principle:

Principle #10Preliminary action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution provides accurate and efficient monitoring of door positions and velocities with fewer moving parts and components, reducing manufacturing and maintenance costs while maintaining comparable accuracy to more complex systems.

Implementation Method 1

Real time readings of the values of continuously varying parameters, in particular displacement and velocity, can be measured by optoelectronic elements

Methodology Applied

Scientific EffectOptical detection: Photoelectric Effect

Data Source

PatentUS8037922B2Device for monitoring motion of a movable closure

Publication Date: 2011.10.18 AUTOMATIC TECH AUSTRALIA

AI summary

A device for monitoring motion of a movable closure arranged for travel between limit positions, comprising an absolute position encoder for identifying whether the closure is in one of a plurality of sectors of travel, a relative position encoder for monitoring the speed and relative position of the closure, and a drive means for operatively coupling the relative position encoder and the absolute position encoder to the closure, such that there is a fixed relationship between motion of the closure and movement of both encoders, wherein the absolute position encoder features an adjustment assembly comprising a first element and a second element, the first element being selectively adjustable in position relative to the second element to adjust the absolute position encoder without movement of the drive means or the relative position encoder.