Motor Lock Control Unit with Graduated Switching Plate for Automatic Calibration
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Solution Overview
Problem
Existing motor locks require manual calibration due to mechanical tolerances, leading to increased costs and resource wastage, as they cannot be adjusted by end-users or fitters without trial and error, limiting their usability as spare parts.
Innovation Solution
Incorporating a switching plate with periodic graduation marks and sensors that detect these marks, allowing for incremental detection of movement, enabling automatic calibration of the lock's bolt positions and eliminating the need for manual adjustment by setting 'start' and 'end' values based on detected stops, with optional dual sensors for accurate direction detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual calibration is required to adjust the switching plate position, then the lock can be adjusted to fit mechanical tolerances, but the complexity of installation and repair increases, and the lock cannot be used as a spare part without specialized adjustment
Solution Approach 1:
The system performs self-calibration by automatically detecting the bolt's retracted and extended positions using the sensor and scale, eliminating the need for manual adjustment. The control unit stores the detected positions and uses them for automatic control, allowing the lock to be installed and used without specialized adjustment procedures.
Solution Approach 2:
The calibration process is performed automatically during the first operation or installation phase. The system proactively detects and stores the mechanical stop positions before normal operation begins, so that subsequent operations benefit from pre-established accurate positioning without requiring manual intervention.
2Manufacturing precision
If the switching plate is manually adjusted by loosening screws and repositioning, then the bolt stroke can be corrected, but time is wasted during installation and maintenance
Solution Approach 1:
The system automatically determines the correct switching plate position by detecting the bolt's mechanical stops through the sensor and scale, eliminating the need for time-consuming manual trial and error adjustment. The calibration is performed automatically during initial operation.
Solution Approach 2:
The manual mechanical adjustment process (loosening screws, repositioning, tightening) is replaced by an automated optical/electronic detection system using the sensor, scale, and control unit, which rapidly determines the correct position without physical manipulation of the switching plate.
3Manufacturing precision
If the lock requires specialized adjustment procedures, then manufacturing precision can be achieved, but the lock cannot be sold as a replaceable spare part
Solution Approach 1:
The lock performs automatic self-calibration upon installation, detecting its own mechanical boundaries and adjusting its control parameters accordingly. This eliminates the need for specialized adjustment knowledge, allowing anyone to install a spare part by simply mounting it and initiating the automatic calibration sequence.
Solution Approach 2:
The system proactively performs calibration during the first use or installation phase, storing the detected positions for future operations. This preliminary automatic adjustment ensures that spare parts can be universally applied without requiring the installer to have specialized adjustment skills or tools.
4Reliability
If the motor is allowed to run until mechanical blockage occurs, then the bolt is ensured to be fully retracted, but the motor experiences unnecessary strain and potential damage
Solution Approach 1:
The sensor detects the periodic scale markings on the switching plate to determine the bolt's position in real-time. When the detected position indicates the bolt has reached the retracted state, the control unit immediately stops the motor, providing feedback-based control that prevents mechanical blockage and motor strain while ensuring complete retraction.
Solution Approach 2:
The system proactively stops the motor before mechanical blockage can occur by detecting the bolt's position through the sensor and scale. The control unit uses the pre-stored retracted position information to halt motor operation at the optimal moment, preventing harmful mechanical contact while ensuring full retraction is achieved.
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
Enables the lock to operate without mechanical adjustments, reducing strain on the motor and ensuring the bolt is fully retracted or extended, while allowing the control unit to be used as a spare part, thus reducing costs and resource wastage through automated calibration.
Implementation Method 1
the switching plate has a scale with periodic graduations and the sensor detects these graduations and thus incrementally records the movement of the switching plate
Implementation Method 2
a motor lock in which a sensor device is provided for contactless detection of the movement of the drive rod. The sensor device consists of at least one coil whose magnetic field changes when the position of the drive rod changes. Upon detection of such a change as a result of manual operation, the motor is activated
Data Source
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AI summary
A control unit for a motorized lock with a push rod (15) for actuating a bolt comprises a switching plate (11) and a sensor (13, 14), wherein the switching plate (11) is connectable to the push rod (15) of the lock. According to the invention, the switching plate (11) has a scale with periodic graduations (12), wherein the sensor (13, 14) detects these graduations (12) so that the movement of the switching plate can be incrementally detected by the sensor (13, 14). Preferably, two sensors (13, 14) are provided for detecting the movement and the direction of movement of the switching plate. For calibration, the bolt is retracted to its stop and then extended until at least one graduation (12) is detected. A starting value is assigned to this graduation.When using the lock, when extending the bolt from this starting value, a count is taken for each passing division (12) upwards or downwards and the motor is stopped when a certain end value is reached, and when retracting, a count is taken for each passing division (12) downwards or upwards and the motor is stopped when the starting value is reached.