Wireless Communication System for Roll-Up Door Reliability
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Solution Overview
Problem
Current high-speed roll-up door systems rely on coiled cords for communication, which are prone to fatigue, tangling, and false safety device trips, and are expensive and time-consuming to install and service.
Innovation Solution
A wireless communication system using RF, optical, or IR devices replaces the coiled cord, enabling two-way communication between bottom-bar devices and a controller, reducing the need for additional cabling and improving reliability and maintenance efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coiled cord is used to provide communication between bottom-bar devices and a controller, then communication can be established, but the cord can fatigue, break, and tangle with door parts and supports
Solution Approach 1:
The patent replaces the mechanical coiled cord connection with a wireless communication system using RF transceivers. The bottom-bar device and controller each have wireless communication modules that transmit signals through the air, eliminating the physical cord that was prone to fatigue, breaking, and tangling. This substitution of mechanical connection with electromagnetic field-based communication resolves the durability issue while maintaining communication reliability.
2Reliability
If a coiled cord is used for communication, then connection is established, but the flapping cord can cause false photosensitive safety device trips
Solution Approach 1:
The wireless communication system replaces the mechanical cord that flapped and caused false safety trips with electromagnetic signal transmission. By eliminating the physical cord entirely, the source of the harmful flapping motion is removed, preventing false trips of photosensitive safety devices while maintaining the communication function.
3Reliability
If a coiled cord system is used, then communication is achieved, but the system is expensive to purchase and time consuming to install and service
Solution Approach 1:
The wireless communication system eliminates the need for physical cord installation, routing, and connection. The RF transceivers can be installed remotely without requiring access to the door mechanism, significantly reducing installation time. Similarly, servicing involves reprogramming or replacing electronic modules rather than manually handling and reconnecting cords, reducing service time and costs.
4Speed
If the remote module operates continuously in high current mode, then communication responsiveness is improved, but battery life is reduced
Solution Approach 1:
The remote module employs periodic action by operating in alternating high-current and low-current modes. It transmits status information at specific intervals rather than continuously, and uses sleep modes between transmissions. This periodic operation maintains communication responsiveness when needed while significantly extending battery life by minimizing power consumption during idle periods.
Solution Approach 2:
The remote module dynamically changes its operational parameters by switching between different current consumption modes. It adjusts its power state based on communication needs, transitioning between high-current active transmission modes and low-current sleep modes. This parameter change allows the system to optimize between responsiveness and battery life depending on the operational context.
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 wireless system enhances the reliability and reduces maintenance costs by eliminating cord-related issues, improving door operation and safety, and extending battery life through power-efficient modes.
Implementation Method 1
an RF module for supporting two-way communication and sending signals indicative of the status of the detection device and the battery
Data Source
AI summary
A door system includes a support connected to a structure, and a door mounted on the support and movable relative to the support between an opened position and a closed position. The door includes a detection device and a remote module coupled to the detection device. The remote module includes a battery and an RF module for supporting two-way communication and sending signals indicative of the status of the detection device and the battery. The door system also includes a motor to drive the door, and a controller to control the motor. The controller includes a user interface and a memory. The door system also includes a base module coupled to the controller for receiving signals from the remote module. The received signals are indicative of the status of the detection device and the battery. The base module also sends signals related to successful transmission acknowledgements to the remote module.