Roll Door Interlock for Residual Motion Safety Locking
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Solution Overview
Problem
Existing high-speed roll doors lack adequate safety measures to prevent unauthorized access and accidental opening during machine or robot operations, particularly when kinetic energy in tools or workpieces persists after the machine has stopped.
Innovation Solution
A roll door system with a control system and electro-mechanical lock mechanism that ensures the door remains locked until all motion within the cell has ceased, combining electronic and mechanical safety features to prevent unauthorized access and ensure safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the roll door is equipped with high-speed opening and closing capability, then productivity is improved, but safety is worsened due to risk of accidental opening during machine operations with residual kinetic energy
Solution Approach 1:
The system performs preliminary action by detecting machine stop status and initiating a controlled door opening sequence only after confirming the machine has stopped. The control system activates the door motor in reverse direction gradually, allowing the door to open slowly and safely without sudden movements that could cause accidents during machine operations with residual kinetic energy.
Solution Approach 2:
The system implements feedback by continuously monitoring machine operational status through sensors and communicating with the machine control system. The door control system receives real-time status signals from the machine and adjusts door operation accordingly - preventing opening while the machine is running and enabling controlled opening only after the machine has stopped, thus maintaining safety while allowing high-speed operation when safe.
2Reliability
If the roll door includes motion detection and time-delay locking mechanisms, then safety is improved, but device complexity increases
Solution Approach 1:
The control system serves multiple functions: it detects door position, monitors machine operational status, controls motor operation speed and direction, manages locking mechanisms, and coordinates with machine control systems. By making the control system universal and multi-functional, the patent reduces the need for separate dedicated components for each function, thereby improving safety without proportionally increasing overall system complexity.
Solution Approach 2:
The patent combines the door control system with the machine control system into an integrated safety network. Sensors, motors, locks, and control logic are merged into a coordinated system where the door controller communicates directly with the machine controller. This merging allows shared resources and centralized control, improving safety through coordinated operation while avoiding the complexity of entirely separate systems.
3Reliability
If the roll door uses electro-mechanical locks and safety switches, then safety is improved, but ease of operation is worsened due to additional locking and unlocking steps
Solution Approach 1:
The system implements self-service by automatically managing the locking and unlocking sequences without requiring manual intervention. When the machine stops, the control system automatically unlocks the electro-mechanical lock and initiates the door opening sequence. When the door reaches the fully open position, the system automatically re-locks it. This automation eliminates the need for operators to manually manipulate locks or switches, maintaining high safety standards while preserving ease of operation.
Data Source
Figure 1a~2
Figure 3a~3c
Figure 4~5
AI summary
Disclosed is a roll door (1) comprising a roll operator (2) extending between two frame profiles (3), a flexible door leaf (5) secured to the roll operator (2) and to a beam (6) and rollable on the roll operator (2). The roll door further comprises a locking pin (8), and an electro-mechanical lock (9) arranged to receive the locking pin (8) and further arranged to lock the locking pin (8) in an end position. The electro-mechanical lock (9) is arranged to send a status signal to a control system with information that the roll door (1) is closed, wherein a machine connected to the control system may be started, and the electro-mechanical lock (9) is arranged to receive a status signal from a control system with information if a machine is started. If the machine is started, the electro-mechanical lock (9) is arranged to lock the locking pin (8) in the end position.