Modular Encoder for Automated Door Position Detection
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Solution Overview
Problem
Existing automated door systems require complete motor replacement when the integrated encoder malfunctions, leading to time-consuming and costly processes, as encoders are inseparable from the motor unit.
Innovation Solution
A modular device with a connector, encoder, and communication means that can be independently coupled to a door drive shaft, allowing for easy installation and replacement without needing to replace the entire motor, featuring a multiconnector for various shaft diameters and wireless communication options.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the encoder device is integrated in the motor, then the motor structure is compact and simple, but the entire motor must be replaced when the encoder malfunctions
Solution Approach 1:
The encoder device is separated from the motor into an independent replaceable unit that can be coupled to the door drive shaft independently. This segmentation allows the encoder to be replaced without replacing the entire motor, resolving the contradiction between compact structure and ease of repair.
Solution Approach 2:
The encoder function is extracted from the integrated motor-encoder assembly and implemented as a separate device that couples to the door drive shaft. This extraction enables independent replacement of the encoder while preserving the motor, directly addressing the repair difficulty issue.
2Reliability
If the complete motor is replaced when the encoder malfunctions, then the system reliability is restored, but the time and cost of replacement increases
Solution Approach 1:
By segmenting the encoder from the motor, the replacement process only requires removing and installing the small encoder unit rather than the entire motor assembly. This dramatically reduces replacement time while restoring system reliability.
Solution Approach 2:
The encoder is designed as a relatively cheap, easily replaceable component compared to the expensive motor. When the encoder fails, replacing this inexpensive component restores reliability without the time and cost of motor replacement.
3Reliability
If the complete motor is replaced when the encoder malfunctions, then the system reliability is restored, but the manufacturing cost increases
Solution Approach 1:
Segmenting the encoder from the motor allows the encoder to be manufactured and sold as a separate, lower-cost component. This reduces the manufacturing cost impact while maintaining the ability to restore system reliability through encoder replacement.
Solution Approach 2:
The encoder is designed as a inexpensive replaceable component compared to the motor. This pricing strategy allows cost-effective restoration of system reliability without requiring expensive motor replacement.
4Adaptability or versatility
If a multiconnector is used for various door drive shaft types, then the device adaptability increases, but the connector complexity increases
Solution Approach 1:
The connector is designed with multiple receptacles that can accommodate different door drive shaft types and diameters. This universal design provides adaptability across various shaft configurations while managing complexity through a standardized multi-receptacle structure.
Data Source
AI summary
The invention relates to a device (1) for detecting the position of an automated door, and a method of installation thereof, wherein the device comprises a connector (4, 20) adapted to couple the device to a door drive shaft (28, 32) moving an automated door such as a sectional overhead door, an encoder means (5) coupled to the connector (4, 20) and generating a position signal based on the movement of the door drive shaft (28, 32), which position signal is indicative of the door position, communication means connected to the encoder means (5) for transferring the position signal to a controlling device (34), and mounting means (2, 3) for mounting the device.