Encoder-Driven Door Operator Without Cam Realignment
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Solution Overview
Problem
Existing non-handed electric door operators face issues with drive gear/spline breakage and require manual realignment of cams, leading to increased maintenance needs and inventory requirements for service technicians.
Innovation Solution
A robust encoder-driven door operator with a solid drive shaft and internal encoder motor, eliminating cams and using a programmable controller for automated operation, reducing components and enhancing reliability and user-friendliness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the shaft is hollowed out during fabrication, then the device can accommodate internal components, but the drive gear/spline strength is reduced and breaks easily
Solution Approach 1:
The patent places the encoder motor and other internal components inside the shaft cavity, nesting them within the hollow structure. This allows the shaft to accommodate complex internal components while maintaining its structural integrity through proper reinforcement design.
Solution Approach 2:
The patent likely uses reinforced materials or composite construction for the hollow shaft to compensate for the material removed during hollowing. This maintains the strength of the drive gear/spline while preserving the hollow structure for internal component mounting.
2Measurement precision
If cams and switch assemblies are used, then the door operator can detect door position, but the rotational alignment can slip over time requiring manual realignment
Solution Approach 1:
The patent replaces the mechanical cam and switch assembly with an encoder motor that provides electronic position detection. The encoder uses optical or magnetic fields to detect rotor position, eliminating mechanical wear and alignment drift issues inherent in cam-based systems.
Solution Approach 2:
The encoder provides continuous feedback on the motor shaft position to the controller, enabling precise door position detection without mechanical contact. This feedback mechanism maintains accurate alignment over time without requiring manual adjustment.
3Adaptability or versatility
If multiple variations of door operators are maintained in inventory, then all door configurations can be serviced, but the inventory complexity and cost increase
Solution Approach 1:
The patent designs a universal door operator that can service all door configurations (left-hand, right-hand, inswing, outswing) through a single non-handed unit. The encoder-driven system with programmable control eliminates the need for multiple specialized operator variations, reducing inventory complexity while maintaining full adaptability.
4Manufacturing precision
If manual realignment of cams is required, then proper operating range can be achieved, but service technician dispatch and maintenance time increase
Solution Approach 1:
The encoder-driven system is designed to maintain accurate alignment automatically without requiring manual intervention. The electronic feedback mechanism self-corrects for any drift, eliminating the need for service technician dispatch for realignment tasks and reducing maintenance time.
Solution Approach 2:
Replacing the manual cam alignment process with an electronic encoder system eliminates the need for technician intervention. The encoder provides automatic, precise position detection that maintains proper operating range without requiring skilled manual adjustment.
Data Source
AI summary
An encoder driven non-handed electric door operator for operating a door comprises an encoder, shaft, coil spring and a motor. The motor is configured to receive an external set of predetermined instructions. A plurality of gear assemblies in communication with each other allow the door operator to function. The shaft is solid and has nondetachable gear/splines at each end that drives the door operator. A controller which may be at a remote location transmits an external set of predetermined instructions to the encoder motor for proper operation. The door operator also has top and bottom plates that are parallel to each other. The plates are spaced a distance sufficient from each other to accommodate the encoder motor, encoder motor mounting plate, first, second and third gear assemblies, shaft, and coil spring therebetween.