Spring Array Gear Counterbalance for Heavy Door Shafts
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Solution Overview
Problem
Existing counterbalance systems for upward acting doors require various sizes and spring constants, leading to bulkiness and space constraints, especially for heavy doors, as they need to accommodate large and ungainly springs to achieve adequate counterbalancing.
Innovation Solution
A counterbalance system utilizing an array of spring assemblies arranged around a shaft, with each assembly comprising a spring and a companion member in compression or tension, connected through a gear train to transmit torque efficiently, allowing for compact design and standardization of spring sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If large springs with high spring constants are used to counterbalance heavy doors, then the counterbalancing force is sufficient, but the system becomes bulky and requires more space
Solution Approach 1:
The patent divides a single large spring into multiple smaller springs arranged in an array around the shaft. Each spring in the array contributes a portion of the total counterbalancing force, achieving the required force output without needing a single large bulky spring. The segmented spring array is connected to the shaft through a gear train that aggregates the torque from all springs.
Solution Approach 2:
The patent uses an array of springs to create a distributed counterweight system that opposes the weight of the door. By arranging multiple springs around the shaft and connecting them through gears, the system achieves balanced counterforce without requiring individual springs to be oversized, thus reducing overall space requirements while maintaining sufficient counterbalancing capability.
2Adaptability or versatility
If multiple spring sizes and constants are used to accommodate various door weights, then the system can be adapted to different doors, but the installer must manage cumbersome inventory of various spring types
Solution Approach 1:
The patent employs springs of uniform size and spring constant in the array configuration. By varying the number of springs in the array rather than changing spring specifications, the system can accommodate different door weights using the same spring type. This universal approach eliminates the need for installers to manage multiple spring sizes and constants, improving ease of operation while maintaining adaptability.
3Force
If a single large spring is used for heavy doors, then adequate counterbalancing is achieved, but the spring becomes ungainly in size and shape
Solution Approach 1:
The patent segments a single large spring into multiple smaller, geometrically similar springs arranged around the shaft. Each spring in the array has a manageable, gainly shape rather than requiring one oversized spring. The segmented configuration maintains the necessary counterbalancing force through the combined effect of multiple springs while preserving aesthetically pleasing and practical geometry.
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 system effectively mitigates the weight of the door, enabling easier opening and closing while reducing the need for multiple spring sizes and constants, thus providing a compact and efficient counterbalancing solution for various door sizes.
Implementation Method 1
a spring assembly having a spring
Implementation Method 2
a gear train for connecting the connecting structure to the shaft and configured to apply the force associated with the spring to the shaft in the form of torque on the shaft
Data Source
AI summary
A system for exerting torque on a shaft includes: a spring assembly having; a spring; a companion member to the spring, wherein at least one of the spring and the companion member is in compression and the other of the spring and companion member is in tension; connecting structure for transmitting a force associated with the spring outside of the gear assembly; and a gear train for connecting the connecting structure to the shaft to apply torque to the shaft. A method of exerting torque on a shaft includes: arranging a plurality of spring assemblies arranged in an array around the shaft, each spring assembly having; a spring; connecting structure for transmitting a force associated with the spring; attaching a gear train to the connecting structure; and configuring the gear train to apply the force associated with the spring to the shaft in the form of torque on the shaft.