Modular Door Counterbalance With Tool-Free Spring Tension Adjustment
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Solution Overview
Problem
Existing counterbalance systems for vertical acting doors, such as residential garage doors, fail to adequately match the torque requirements of doors, making door movement inefficient and requiring manual winding of torsion springs, which is difficult and often necessitates special tools for installation and customization.
Innovation Solution
A counterbalance system comprising a power spring within a casing, an anchoring mechanism for tool-free assembly, and a winding mechanism to adjust spring tension, allowing for customization and efficient matching of torque requirements, with multiple units that can be stacked for varying door weights.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional torsion springs are used in counterbalance systems, then the system structure is simple, but the torque requirements cannot be properly matched and manual winding is required
Solution Approach 1:
The patent changes the fundamental parameter of spring configuration from traditional torsion springs to a power spring system with cable drums and cables. This parameter change enables proper torque matching for door movement while accepting increased system complexity, as the new configuration includes multiple components (power spring, casing, cable drums, cables) that work together to provide the required torque characteristics.
Solution Approach 2:
The patent substitutes the traditional mechanical torsion spring system with a power spring mechanism that uses cable drums and cables to transmit force. This mechanical substitution allows for better torque matching and eliminates the need for manual winding, as the power spring automatically provides the required counterbalancing force throughout the door's range of motion.
2Ease of repair
If torsion springs are used, then installation is simple, but special tools are required and spring replacement is difficult
Solution Approach 1:
The patent segments the counterbalance system into modular components: power spring, casing, cable drums, and cables. This segmentation allows individual components to be replaced or serviced independently without requiring disassembly of the entire system. The power spring can be replaced by simply detaching cables from cable drums, eliminating the need for complex disassembly procedures required with traditional torsion springs.
Solution Approach 2:
The patent extracts the power spring from a protective casing, allowing it to be independently accessed and replaced. The casing serves as a separate structural component that houses the spring mechanism, enabling the spring to be removed and replaced without disturbing the casing or other system components. This extraction principle simplifies maintenance and repair operations.
3Adaptability or versatility
If traditional counterbalance systems are used, then the structure is straightforward, but customization for unique door installations is inefficient
Solution Approach 1:
The patent creates a universal counterbalance system where the power spring, casing, and cable drum assembly can be adapted to various door weights and configurations. The system's modular design allows it to serve multiple functions and accommodate different installation requirements without requiring completely different components, thereby reducing installation time while maintaining adaptability.
Solution Approach 2:
The patent introduces dynamic adjustability to the counterbalance system, allowing customization for unique door installations. The system can be adjusted to match specific door weight and torque requirements, providing versatility for different applications. This dynamic capability enables efficient customization without requiring complete system replacement or complex assembly procedures.
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 improved door movement by matching torque requirements, simplifies spring replacement and installation, eliminates the need for special tools, and allows for easy customization and adjustment of counterbalance loads.
Implementation Method 1
The spring element in one embodiment includes a power spring disposed within a casing member
Implementation Method 2
The power spring offers a means for efficiently and rapidly matching the effective spring rate and the resultant torque exerted by the power spring
Implementation Method 3
The winding mechanism provides for an efficient method adjusting and otherwise tensioning the spring element
Implementation Method 4
The anchoring mechanism allows for a mechanically uncomplicated and releasable coupling between the casing of the power spring and certain anchoring components
Data Source
AI summary
A counterbalance system for an upward acting door including a first casing and a second casing. Each casing includes a spring element disposed therein operable to store and release potential energy in response to movement of the upward acting door between open and closed positions. The first casing is interlockable with the second casing to accommodate and counterbalance upward acting doors of differing weights.