Overhead Door Operator Motorized Drive and Brake Control
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Solution Overview
Problem
Conventional overhead sectional door systems are complex and cumbersome to install, requiring balancing springs that increase complexity and risk of damage, such as broken wires, leading to potential extensive damages during operation, maintenance, and installation.
Innovation Solution
A method at a control device for controlling an overhead door operator system that includes a drive unit mounted on the door with a motor and a transmission member system, which utilizes detection signals from movement sensors to determine unexpected door movements and activates a brake function to prevent further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If balancing springs are used to reduce the force required to open the door, then the door operator system becomes more complex and cumbersome to install, but the force required to open the door is reduced
Solution Approach 1:
The patent removes the balancing spring mechanism from the door operator system entirely. Instead of using springs to counterbalance the door weight, the system uses a motorized drive unit with transmission members (chains or belts) that directly lift and lower the door sections. This extraction of the spring mechanism eliminates the associated complexity and installation difficulties while maintaining the ability to reduce opening force through motor control.
Solution Approach 2:
The patent replaces the mechanical spring-based balancing system with an electromechanical system. The motorized drive unit with controlled transmission members substitutes the passive spring mechanism, allowing for more precise control of door movement and force application while reducing overall system complexity and eliminating spring-related installation issues.
2Force
If balancing springs with wires are used to reduce opening force, then the door operator system becomes more complex, but the risk of extensive damages from broken wires increases
Solution Approach 1:
The patent eliminates the wire-based spring mechanism entirely, removing the source of potential wire breakage and associated damages. The transmission members are attached to the door sections themselves rather than using separate wires, significantly reducing the risk of catastrophic failure from wire breakage.
Solution Approach 2:
The patent incorporates detection means (sensors) that detect unexpected door movements or failures before they can cause extensive damage. The control unit receives signals from these sensors and activates the brake function to prevent further damage, providing a protective mechanism that acts beforehand to mitigate potential harm from transmission member failures.
3Reliability
If detection means and control mechanisms are added to prevent unexpected door movement, then extensive damages are mitigated, but the device complexity increases
Solution Approach 1:
The patent uses detection means (sensors) that continuously monitor door position and movement, providing feedback to the control unit. When unexpected movement is detected, the control unit processes this feedback and activates the brake function. This feedback loop provides reliable protection against extensive damages while maintaining relatively simple system architecture through straightforward sensor-controller-actuator configuration.
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 solution effectively mitigates extensive damages associated with overhead door operator systems by efficiently detecting unexpected door movements and activating a brake function, thereby preventing uncontrolled movement and reducing the risk of further damage.
Implementation Method 1
a brake member (132) arranged to provide a brake force... The brake function may be understood to comprise transforming kinetic energy to thermal energy through friction so as to stop the door movement
Data Source
AI summary
The disclosure relates to an overhead door operator system and to a method for controlling such a system. The overhead door operator system opens and closes an opening. The system includes 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). A door (8) is movably connected to the door frame (3). A drive unit (10) is mounted on the door (8). 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) includes a driven transmission member (18) in driving connection with the motor (11) and the elongated transmission member. The method comprises the steps of: detecting door movement; determining if detected door movement relates to unexpected door movement; and, if so, taking action so as to prevent more extensive damages.