Roller Door Obstruction Detection and Lath Wear Reduction
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Solution Overview
Problem
Roller garage door assemblies face issues with unreliable anti-drop devices, wear on laths due to rubbing, and the need for improved obstruction detection and reaction, as well as inadequate insulation and sealing.
Innovation Solution
A roller door assembly featuring vertically-stacked laths, torsion springs for torque opposition, a driver motor system with a controller for obstruction detection, and a seal system using memory materials for enhanced safety and insulation, along with connectors to minimize lath separation and reduce wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional anti-drop devices are installed to prevent door failure, then door safety is improved, but the device complexity increases and reliability decreases due to installation removal and grey area responsibility
Solution Approach 1:
The patent removes the separate anti-drop device from the system and integrates its function directly into the torsion spring mechanism. The torsion spring inherently provides the anti-drop function by maintaining tension on the door, eliminating the need for additional components and reducing installation complexity while maintaining reliability.
Solution Approach 2:
The patent combines the anti-drop function with the torsion spring mechanism into a single integrated system. The torsion spring serves dual purposes: balancing the door weight during operation and preventing door free-fall when the motor fails, thereby reducing device complexity while maintaining safety.
2Reliability
If laths are forced against the support structure to provide sealing, then sealing performance is improved, but wear on the laths increases
Solution Approach 1:
The patent introduces a seal member positioned between the lath and the support structure that absorbs the contact force. This cushioning element prevents direct metal-to-metal contact, reducing wear on the lath while maintaining effective sealing at the top of the door.
3Strength
If laths are kept tightly connected to minimize separation, then structural integrity is improved, but wear due to rubbing increases
Solution Approach 1:
The patent applies different properties to different parts of the lath connection system. The laths maintain tight connection through connectors for structural integrity, while the seal member provides a localized cushioning effect at the contact point with the support structure, allowing slight movement without direct rubbing wear.
4Loss of energy
If the door is made insulated to improve thermal performance, then energy efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent uses composite construction with laths that have insulating material integrated into their structure. This approach provides thermal insulation while maintaining a relatively simple overall door assembly design, avoiding the need for complex multi-layer insulation systems.
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 provides reliable obstruction detection and reaction, prevents door free-fall, reduces wear on laths, and enhances insulation and sealing, improving the overall performance and safety of roller door assemblies.
Implementation Method 1
an elongate collapsible seal comprising a memory material capable of regaining shape after collapsing under compression
Implementation Method 2
a first torsion spring mounted around a portion of the shaft which provides a torque opposing moving of the door and a second torsion spring mounted around a portion of the shaft which provides a torque opposing moving of the door
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A roller door assembly (1)comprising a door (3) comprising a plurality of vertically-stacked and connected laths (5), a shaft (7) adapted for connection to a support for the roller door assembly, a first drum wheel (9) having a rim and a hub, the hub positioned on the shaft towards a first end thereof, a second drum wheel (11) having a rim and a hub, the hub positioned on the shaft towards a second end thereof, a first torsion spring (15) mounted around a portion of the shaft which provides a torque opposing moving of the door and a second torsion spring (17) mounted around a portion of the shaft which provides a torque opposing moving of the door, an open-ended barrel (19) positioned around and connected to the rims of the first and second drum wheels for wrapping of the laths of the door therearound, a door connector provided on the barrel and connected to a lath provided at a top end of the door, a driver (21) connected to the first drum wheel comprising a driver motor which provides a torque to rotate the first drum wheel about the shaft to move the door, and a driver controller connected to the driver and comprising a processor configured to send signals to the driver to move the door from an open position to a closed position and to move the door from a closed position to an open position, receive a plurality of driver motor torque signals used to move the door and compare the received driver motor torque signals with expected driver motor torque signals, wherein when an obstruction to closing of the door is encountered, the torque of the torsion springs opposing moving of the door increases, causing the driver motor torque to increase and the received driver motor torque signals to exceed the expected driver motor signals, and the driver controller sends a signal to the driver motor to cease rotation of the first drum wheel and moving of the door.