Door Operator System with Cable-Driven Drive Unit
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Solution Overview
Problem
Conventional overhead door operator systems are complex and cumbersome, requiring balancing springs that increase installation difficulties and costs due to the need for high accuracy in manufacturing and alignment of fixed racks.
Innovation Solution
An overhead door operator system with a drive unit mounted on the door, featuring an elongated transmission member that wraps around a driven transmission member, eliminating the need for balancing springs and allowing for relative movement, thus reducing complexity and installation costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed rack is used to drive the door, then the door can be moved along the door frame, but high accuracy in manufacturing and alignment is required which increases cost and complexity
Solution Approach 1:
The patent transitions from a fixed rigid rack system to a dynamic cable-driven system where the cable can flex and adapt to door movement. The cable is wound around a drum that rotates as the door moves, allowing the transmission member to dynamically adjust its position and length, eliminating the need for precise fixed rack alignment while maintaining reliable door movement.
Solution Approach 2:
The patent changes the physical state and configuration of the transmission member from a rigid fixed rack to a flexible cable that can be wound and unwound. This parameter change allows the system to accommodate door movement without requiring high manufacturing and alignment accuracy, as the cable can flex and adjust its configuration dynamically during operation.
2Force
If balancing springs are implemented to reduce opening force, then the force required to open the door is reduced, but the complexity of the door system increases and installation becomes cumbersome
Solution Approach 1:
The patent extracts and removes the balancing spring component from the door system entirely. Instead of adding complexity with springs, the invention uses a cable-windum mechanism where the cable is wound around a rotating drum during door opening, providing mechanical advantage and reducing the force required without introducing additional balancing components.
Solution Approach 2:
The patent replaces the mechanical balancing spring system with a cable-driven windum mechanism. The cable is wound around a drum that rotates as the door opens, using the winding action to provide mechanical advantage and reduce opening force, substituting the spring-based balancing system with a more compact and less complex cable-based system.
3Productivity
If an electric motor mounted above the door pulls the door up using wires, then the door can be opened, but the system becomes complex and cumbersome to install
Solution Approach 1:
The patent merges the motor, cable winding mechanism, and door operation into a single integrated unit mounted on the door itself. The motor drives a drum that winds the cable, combining multiple functions (motor drive, cable management, door operation) into one compact assembly that is easier to manufacture and install as a complete unit rather than separate components.
Solution Approach 2:
Instead of mounting the motor above the door and pulling it up with wires, the patent inverts the approach by mounting the motor on the door itself and using a cable-windum mechanism where the cable is wound around a drum on the door. This inversion simplifies the system by eliminating the need for overhead mounting infrastructure and complex wire management.
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
The system provides a cost-efficient, safer, and more reliable door operation with reduced torque requirements, improved alignment, and resistance to wear and external interference, while simplifying installation and manufacturing processes.
Implementation Method 1
the driven transmission member being movably connected to the elongated transmission member and arranged to interplay with said elongated transmission member for driving the driven transmission member along said elongated transmission member by means of the elongated transmission member at least partially wrapping around the driven transmission member
Data Source
AI summary
An overhead door operator system (1) for opening and closing an opening (2), comprising a door frame (3) comprising a first frame section (4) at a first side (5) of the opening (2) and a second frame section (6) at a second side (7) of the opening (2). The operator system further comprises a door (8) arranged to be moved between an open and closed (C) position, the door (8) being movably connected to the door frame (3) and a drive unit (10) mounted on the door (8), the drive unit (10) comprising at least one motor (11) arranged to move the door (8) from the closed position (C) to the open position (O). An elongated transmission member (19) extends along the first side (5) of the opening (2) and the first frame section (4). The drive unit (10) further comprises a driven transmission member (18) in driving connection with the motor (11).