Shaft-Mounted Overhead Door Operator with Magnetic Clutch

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Solution Overview

Problem

Conventional overhead door operators occupy valuable space, are cumbersome to install and maintain, and have unreliable locking mechanisms.

Innovation Solution

A shaft-mounted overhead door operator with a clutch system that includes a passive biasing member and a selectively releasable magnetic actuator, allowing for efficient power transfer and disengagement, along with a compact design and remote control functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If conventional overhead door operators are mounted to the ceiling above the door, then the door can be opened and closed, but they occupy valuable storage space and are cumbersome to install and maintain

Engineering Contradiction:

Improveease of installation and maintenanceVSAvoidspace occupied by operator

Core Design Contradiction:

Ease of operationVSArea of stationary object

Solution Approach 1:

The patent transitions from ceiling-mounted operation to shaft-mounted operation, changing the spatial dimension of installation. The operator is mounted on the vertical shaft itself rather than on the ceiling above the door, utilizing the shaft's structure to reduce the space required in the overhead storage area while maintaining operational functionality.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The operator is divided into separate functional modules: a motor assembly, a clutch assembly, and a gear train, which are distributed along the shaft. This segmentation allows each component to be optimized independently and simplifies installation and maintenance by enabling modular replacement without removing the entire operator from the shaft.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conventional overhead door operators are designed with traditional locking mechanisms, then the door can be secured, but the locking mechanisms are indirect and unreliable

Engineering Contradiction:

Improvereliability of locking mechanismVSAvoidcomplexity of locking mechanism

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical locking mechanisms with a magnetic locking system. Electromagnets positioned on the shaft interact with magnetic latches on the clutch assembly to engage and disengage the clutch, providing a more reliable and direct locking mechanism that eliminates the need for complex mechanical linkages and improves response time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The magnetic field acts as an intermediary between the control system and the locking mechanism. Instead of direct mechanical connection, the electromagnets create magnetic fields that indirectly control the engagement state of the clutch, allowing for smoother operation and more reliable locking without complex mechanical intermediaries.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If a clutch system with magnetic actuator is used for shaft-mounted operation, then space efficiency and reliability improve, but the device complexity increases

Engineering Contradiction:

Improvereliability of torque transferVSAvoidcomplexity of clutch system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The clutch assembly incorporates a passive spring mechanism that automatically returns the clutch to its disengaged state after magnetic actuation. This self-service feature eliminates the need for additional active control mechanisms to reset the clutch, reducing overall system complexity while maintaining reliable torque transfer during operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The clutch system utilizes changes in magnetic field strength to control engagement. By varying the electrical current to the electromagnets, the system can precisely control the magnetic force to engage or disengage the clutch, providing reliable torque transfer control without requiring complex mechanical adjustment mechanisms.

Inventive Principle:

Principle #35Parameter changes

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 a space-efficient, reliable, and easy-to-install overhead door operator that can be remotely controlled, ensuring safe and efficient operation of overhead doors while allowing for manual operation during power outages.

Implementation Method 1

a selectively releasable magnetic actuator configured to urge the first component toward the second component

Methodology Applied

Scientific EffectMagnetic field: Magnetic Field

Implementation Method 2

a passive biasing member configured to urge the first component away from the second component in an axial direction generally parallel to the shaft

Methodology Applied

Scientific EffectMechanical force: Mechanical Force

Data Source

PatentUS11686145B2Shaft mounted overhead door operator, clutch and kit therefor

Publication Date: 2023.06.27 HALL LABS LLC

AI summary

A shaft-mounted overhead door operator is disclosed having a motor, a torque transfer component such as a gear train, and a clutch that is axially movable to engage or disengage the clutch. While the door operator has power, the clutch is engaged to ensure door operator can raise, lower, and stop the overhead door as directed from a remote control. The clutch can be released in the event of a loss of power or by direction from the remote control in which case the clutch releases the shaft of the overhead door. The shaft-mounted overhead door is small, having a width no greater than three times the diameter of the shaft to which it is mounted.