Door Operator Position Detection Using Gear Encoder
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Solution Overview
Problem
Conventional door operator systems cannot detect the current-time position of a movable barrier, limiting their ability to stop or hold the barrier at midway positions and making it difficult to use variable frequency motors due to the absence of position detection capabilities.
Innovation Solution
A door operator system equipped with an electric motor, a current-time position detecting device comprising a first gear, an angular position sensing unit, a revolution counting unit, and an arithmetic unit, which calculates the total circumferential intervals and displacement of the movable barrier based on detected angular positions and revolutions, enabling precise position detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional door operator with limit switches is used, then the door can be stopped at upper or lower stop points, but the current-time position of the movable barrier cannot be detected and midway stopping is impossible
Solution Approach 1:
The patent replaces the conventional mechanical limit switch system with an electronic position detection system using a gear encoder and microcontroller. The gear encoder generates pulse signals that are counted by the microcontroller to determine the exact position of the movable barrier, enabling continuous position monitoring rather than just endpoint detection.
Solution Approach 2:
The position detection system serves multiple functions: it detects the current-time position of the barrier, determines whether upper or lower stop points are reached, enables midway stopping, and provides feedback for variable frequency motor control. This multi-functional approach eliminates the need for separate limit switches while enhancing overall system capability.
2Adaptability or versatility
If variable frequency motor is used for advanced door operation, then speed control and midway stopping are enabled, but position detection capability is required which conventional systems lack
Solution Approach 1:
The patent implements a feedback mechanism where the gear encoder continuously provides position information to the microcontroller, which then adjusts the variable frequency motor's speed and direction accordingly. This closed-loop control ensures reliable motor operation by preventing over-energization and ensuring accurate positioning, even with the enhanced operational flexibility provided by variable frequency control.
3Reliability
If limit switches are used for stop point detection, then upper and lower stop points can be identified, but the system cannot detect position failures or prevent motor over-energization
Solution Approach 1:
The continuous feedback from the gear encoder to the microcontroller provides real-time position information, enabling the system to detect when the barrier reaches stop points, identify position failures, and prevent motor over-energization. The microcontroller monitors the pulse count continuously, allowing it to recognize abnormal conditions and take corrective action.
Solution Approach 2:
The patent uses LED indicators to provide visual feedback about the system's operational state and detected positions. Different LED patterns or colors can indicate normal operation, approach to stop points, failure conditions, or motor status, making the system's state information visible and improving reliability monitoring.
Data Source
AI summary
A door operator system capable of detecting a current-time position of a movable barrier comprises a current-time position detecting device comprising a first gear, a first angular position sensing unit, a revolution counting unit and an arithmetic unit. The first gear is coupled to an output shaft of a motor or a winding shaft. The first angular position sensing unit is provided for detecting a first angular position of the first gear. The revolution counting unit counts the number of revolutions of the first gear. The arithmetic unit calculates a number of total circumferential intervals of the output shaft of the motor or the winding shaft based on D=(La*X)+A/(360/X), where D is the number of the total circumferential intervals, La is the number of revolutions of the first gear, A is the first angular position, X is a number of circumferential intervals per revolution of the first gear.