Shaft-Mounted Garage Door Operator with Removable Sun Gear
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Solution Overview
Problem
Conventional movable barrier operators require cumbersome and time-consuming installation processes, especially in spaces with limited room, often necessitating the removal of existing barriers, which can be dangerous due to weight and space constraints.
Innovation Solution
A shaft-mounted operator with a sun gear configuration that allows for assembly onto a previously installed movable barrier without removing it, using a rotational drive unit with an annular sun gear and removable portions that can be slidably mounted, eliminating the need for central bearings and enabling installation in confined spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional operators are installed using traditional methods, then the operator can be properly mounted, but the installation process becomes cumbersome and time-consuming requiring barrier removal
Solution Approach 1:
The operator is divided into multiple components: a motor assembly, a sun gear assembly with removable portions, and a bracket assembly. These segmented components can be assembled in place on the mounted barrier, eliminating the need to remove the entire barrier for installation. The sun gear specifically has removable portions that allow assembly without barrier removal.
Solution Approach 2:
The operator components are designed to nest within the existing barrier structure. The motor assembly mounts to the bracket, the sun gear assembly integrates with the barrier shaft, and all components fit within the confined space of the mounted barrier, allowing complete assembly in the installed position.
2Ease of manufacture
If the barrier is removed from its mount for operator installation, then the operator can be properly mated to the barrier, but the process becomes dangerous due to weight and requires specialized equipment
Solution Approach 1:
The operator components are prepared and configured before being installed on the mounted barrier. The motor assembly, sun gear, and bracket are readied in advance, then assembled in place on the securely mounted barrier, eliminating the need to handle and remove the heavy barrier during installation.
Solution Approach 2:
A bracket assembly serves as an intermediary component that mounts to the stationary barrier shaft and provides mounting points for the motor and sun gear. This intermediary structure allows the operator components to be assembled without directly handling the heavy barrier, reducing safety hazards.
3Adaptability or versatility
If space restrictions are present in the garage, then installation space is limited, but conventional operators require additional room for rail and trolley configuration
Solution Approach 1:
The operator is segmented into compact components that can be arranged in tight spaces. The motor assembly, sun gear, and bracket are designed as separate units that fit within the limited garage space, eliminating the need for extended rail and trolley configurations required by conventional operators.
Solution Approach 2:
The operator uses a vertical mounting configuration on the barrier shaft, utilizing the vertical dimension rather than requiring horizontal space for rail and trolley. The sun gear rotates around the vertical shaft, and the motor mounts vertically, allowing installation in garages with limited horizontal space.
4Area of stationary object
If a jackshaft operator is used for low ceiling garages, then space is saved, but L-shaped tracks and rollers are still required which are difficult to accommodate in very small spaces
Solution Approach 1:
The L-shaped tracks and rollers are extracted from the operator design. Instead, the operator uses a simplified configuration where the sun gear directly engages the barrier shaft and the motor mounts to a bracket, eliminating the need for complex track and roller assemblies while maintaining compact space occupation.
Data Source
AI summary
The movable barrier operator 10 is a shaft-mounted movable barrier operator that operates a garage door 20. Such an operator includes a motor 22 operably connected to shaft 26 such that motor 22 may move door 20 between the open and closed position. Shaft 26 may include axle 36 and wheels 38. The movable barrier 10 further includes a rotational drive unit 46 with a sun gear 52 having an open center 49 into which the axle 36 extends. Further, the rotational drive unit may have an annularly shaped portion 47 and a removable portion 48 such that the operator 10 may be installed onto a previously mounted garage door. The movable barrier operator may also include protection plates or a finger guard 90.