Overhead Door Operator With End-Cap Drive Mounting
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Solution Overview
Problem
Conventional overhead door operator systems are complex to install and require balancing springs, which increase complexity and installation time, and mounting components to the door is cumbersome, especially when using sandwich panel materials.
Innovation Solution
A door operator system with a drive unit mounted to an end cap, utilizing an elongated transmission member and driven transmission member that interplay along the door's movement trajectory, eliminating the need for balancing springs and simplifying installation by using a more modular and cost-effective design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If balancing springs are implemented to reduce the force required to open the door, then the force requirement is reduced, but the device complexity increases
Solution Approach 1:
The patent removes the balancing spring mechanism entirely from the door operator system. Instead of using springs to counterbalance the door weight, the system uses a motorized drive unit with transmission members that directly control door movement, eliminating the need for mechanical balancing components and thereby reducing device complexity while maintaining force management through controlled motor operation.
Solution Approach 2:
The patent replaces the mechanical balancing spring system with an electromechanical drive unit. The motorized system uses electrical control and structured transmission members (rack and pinion or chain) to manage door movement forces, substituting passive mechanical balancing with active electromechanical control that reduces overall system complexity.
2Ease of manufacture
If conventional mounting methods are used to attach components to the door, then component attachment is achieved, but the installation time increases
Solution Approach 1:
The patent divides the door operator system into modular components: a drive unit, transmission members, and end cap arrangements. These segmented modules can be independently manufactured and then quickly assembled on-site, reducing installation time while maintaining ease of attachment through standardized connection interfaces designed for rapid assembly.
Solution Approach 2:
The patent incorporates mounting features and attachment mechanisms into the end cap arrangements and drive unit components during manufacturing. These preliminary integrated features enable quick connection to the door without requiring complex on-site fabrication or adjustment, thereby reducing installation time while maintaining ease of attachment.
3Ease of operation
If drive units are mounted directly to the door using conventional methods, then the door can be driven, but the mounting process becomes cumbersome and time consuming
Solution Approach 1:
The patent merges the drive unit mounting function with the end cap arrangement into a single integrated component. The end cap serves both as a structural element of the door and as the mounting interface for the drive unit, eliminating separate mounting steps and reducing mounting time while maintaining ease of door driving operation through unified design.
Solution Approach 2:
The end cap arrangement acts as an intermediary component between the door and the drive unit. This mediator element provides a standardized interface that simplifies the connection process, allowing the drive unit to be quickly attached to the door through the end cap without requiring direct complex mounting to the door structure itself.
Data Source
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AI summary
An overhead door operator system (1) for opening and closing an opening (2), comprising a door frame (3) comprising a first frame section (4) at a first side (7) of the opening (2) and a second frame section (6) at a second side (5) of the opening (2). The operator system further comprises a door (8) arranged to be moved between an open and closed (C) position, the door (8) being movably connected to the door frame (3) and a drive unit (10), the drive unit (10) comprising at least one motor (11) arranged to move the door (8) from the closed position (C) to the open position (O). An elongated transmission member (19) extends along the first side (7) of the opening (2) and the first frame section (4). The drive unit (10) further comprises a driven transmission member (18) in driving connection with the motor (11). The overhead door operator system (1) further comprises an end cap arrangement (100) attached to the door (8), the drive unit (10) being mounted to an end cap (101) of the end cap arrangement (100).