Dual-Motor Door Operator with Planetary Gearing
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Solution Overview
Problem
Existing overhead door systems require longer times to open and close, and lack control over speed, which can lead to uneven motion and increased wear on the system, and often rely on mechanical springs for braking, which may not be efficient.
Innovation Solution
A door operator system utilizing two electric motors and a planetary gearing mechanism to control the gear ratio, allowing for adjustable speed and torque, reducing opening and closing times, and providing improved braking characteristics without additional mechanical components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single electric motor is used to control the door, then the device complexity is reduced, but the productivity is limited due to longer opening and closing times
Solution Approach 1:
The single motor is segmented into two separate electric motors (first and second electric motors) that can operate independently or in coordination. This segmentation allows the system to deliver higher power and faster acceleration during door opening/closing while maintaining manageable complexity through modular architecture
Solution Approach 2:
The system dynamically adjusts the gear ratio through the planetary gearing mechanism based on operational requirements. The control unit varies the gear ratio to optimize acceleration, speed, and torque at different stages of door movement, enabling fast operation without requiring a continuously high-power motor configuration
2Reliability
If mechanical springs are used for braking, then the braking force is sufficient, but the device complexity increases and reliability decreases
Solution Approach 1:
The mechanical spring-based braking system is replaced with an electric braking system. The electric motors, controlled by the control unit, provide braking torque through electrical control, eliminating the need for mechanical springs and associated components. This substitution improves reliability by removing mechanical wear points while maintaining sufficient braking force
Solution Approach 2:
The electric motors serve dual functions: they provide driving torque during door opening/closing and provide braking torque during door stopping. The planetary gearing mechanism also contributes to braking through its mechanical characteristics. This multi-functionality eliminates the need for separate braking components, reducing overall system complexity
3Adaptability or versatility
If the gear ratio is fixed in the planetary gearing, then the manufacturing precision is improved, but the adaptability is reduced due to inability to control speed variations
Solution Approach 1:
The planetary gearing mechanism is configured to allow dynamic adjustment of the gear ratio through controlled movement of planetary gears. The control unit varies the engagement state of planetary gears to change the effective gear ratio, enabling smooth speed control and adaptation to different operational conditions while maintaining manufacturability through a standardized planetary gear design
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 decreases opening and closing times, reduces wear on the door and operator, and allows for safer and more robust operation, while enabling smaller motor usage and cost-effective design.
Implementation Method 1
A door operator based on an electric motor is often provided, which connects to the door via linkage or a wire, belt, chain or similar. The motor thereby controls the motion of the door in response to operator input or similar. Many systems combine the electric motor with a balancing spring, which alleviates some of the load from the electric motor during certain operating conditions.
Data Source
AI summary
Door operator (10) for an overhead door system (400), said door operator (10) being configured to move a door (401) of said door system (400), comprising: a first electric motor (100), a second electric motor (200), a planetary gearing (300), a control unit (11) configured to control the first (100) and second electric motor (200), and wherein the first electric motor (100) is connected to a first planetary gearing input shaft (301) and the second electric motor (200) is connected to a second planetary gearing input shaft (302), and wherein a planetary gearing output shaft (303) is associated with a shaft (402) for movement of the door (401).