Self-Calibrating Door Closer with Encoder Feedback
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Solution Overview
Problem
Conventional door closers require complex and burdensome adjustments to achieve desired closing profiles, which are often neglected due to user unawareness or inability, leading to suboptimal performance across varying conditions like temperature changes and wear over time.
Innovation Solution
A self-powered door closer with a control unit that includes a calibration mode to match the mechanical assembly, using encoders to determine arm and valve positional values, allowing for precise control of the valve to adjust operating characteristics, thereby simplifying the adjustment process and ensuring consistent performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional door closers use mechanical valves and springs to control closing force, then the door closer can provide automatic closing function, but the adjustment complexity increases and users find it burdensome to achieve desired closing profiles
Solution Approach 1:
The patent replaces the traditional mechanical valve adjustment system with an electronic control system that uses a motor to actuate the valve. The control unit receives user input through simple interfaces (buttons, switches, or wireless communication) and automatically adjusts the valve position, eliminating the need for users to manually complex mechanical adjustments while maintaining precise control over closing profiles
Solution Approach 2:
The control unit includes memory that stores calibration data mapping valve positions to door angles. During installation, the system performs automatic calibration by moving the door through its range of motion and recording the corresponding valve positions. This self-calibration process eliminates the need for users to perform complex manual adjustments, making the system easy to install and adjust
2Reliability
If door closer valve settings are adjusted manually to compensate for temperature and wear variations, then closing performance can be maintained, but the time and effort required for adjustment increases
Solution Approach 1:
The patent implements a feedback mechanism where encoders monitor both the door angle and valve position. This feedback is fed to the control unit, which compares actual positions with desired positions and automatically makes corrections. The system continuously monitors operating conditions and adjusts valve positioning to maintain optimal closing performance despite temperature changes, wear, or installation variations, eliminating the need for repeated manual adjustments
Solution Approach 2:
The system performs automatic calibration during installation before normal operation begins. The calibration process pre-configures the valve positions for various door angles by moving the door through its full range of motion and recording the corresponding encoder values. This preliminary action establishes the baseline operating parameters, so the door closer is immediately ready for use without requiring time-consuming manual adjustments
3Adaptability or versatility
If door closers use fixed mechanical configurations, then manufacturing is simpler, but adaptability to different installation conditions and temperature variations decreases
Solution Approach 1:
The patent transforms the static mechanical valve system into a dynamic, electronically controlled system. The valve position is no longer fixed but can be dynamically adjusted by a motor based on real-time feedback from encoders and commands from the control unit. This dynamic capability allows the door closer to adapt to different installation conditions, temperature variations, and wear over time, providing versatility while maintaining a relatively simple overall device structure
Solution Approach 2:
The control unit stores and utilizes calibration data that maps valve positions to door angles for specific installation configurations. By changing the operational parameters (valve position) based on feedback from encoders and stored calibration data, the system adapts to different installation conditions and environmental factors without requiring physical modifications to the mechanical structure
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 enables reliable and precise control of door closing profiles, adapting to temperature changes and wear, ensuring optimal door operation without the need for frequent user adjustments, thus improving the consistency and reliability of door closer performance.
Implementation Method 1
a motor that is configured to move the valve
Implementation Method 2
The valve is configured to control movement of hydraulic fluid around the movable element to very the operating characteristics of the door closer
Data Source
AI summary
A door closer with an automated calibration mode is disclosed. The door closer that can be self powered and includes a control unit to intelligently control a valve within the door closer to vary the operating characteristics of the door closer as needed. The control unit includes a calibration mode that can be invoked to match the control unit to the mechanical door closer assembly. A plurality of positional values being output encoders coupled to an arm of the door closer and the motor for the valve can be determined. The positional values from the encoders and the positions that they indicate can then be stored in a memory within the controller for use during normal operation of the door closer.