AU2003204985B2 - Controller system and method for controlling the operation of a movable closure - Google Patents

Description

P/OQ/O 11 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION Invention title: CONTROLLER SYSTEM AND METHOD FOR CONTROLLING, THE OPERATION OF A MOVABLE CLOSURE The following statement is a full description of this invention, including the best method of performing it known to us: chbm M01 I 1320046vi 305188070 CONTROLLER SYSTEM AND METHOD FOR CONTROLLING THE OPERATION OF A MOVABLE CLOSURE Field of the invention The invention relates to a controller system and a method for controlling the operation of a movable closure. More particularly, it relates to a system and method for use in installation of automated doors and similar closure devices.

Background of the invention Whilst the following description concerns roller door systems, it will be readily apparent that the invention relates to any type of moving closures arranged for automated operation, including roller and panel garage doors, gates, and window shutters.

Remote-controlled powered roller door arrangements are well known, and typically include a chassis supporting a motor with an associated drive train, connecting to a final drive unit (eg. a gear drum) which meshes with the drive train. The final drive unit is connected. to the roller door to cause it to move up or down by operation of the motor.

The roller door is mounted on an axle held in position at both ends by end supports.

The position of the door during its travel is monitored by way of a position encoder coupled to the door operator drive system, which greatly simplifies the system by avoiding the need for microswitches separately sensing the position of the door, for example to govern the limit positions of the door.

Operation of the motor is governed by an electronic controller, programmed to move the roller door between an open and closed position (and vice versa) on receiving an appropriate signal from a user's remote device. The controller is customised to the roller door on installation, at which time it is necessary to set the individual coding of the remote device intended to operate the roller door, the positions of the motor corresponding to the open and closed positions of the door; and optionally the load profile over the travel of the door, prescribing a trip point for each door position at which load the door travel will reverse or stop to cater for obstructions. Once these criteria are set, the controller is switched from a "SETTING" mode to an "OPERATE" mode for subsequent normal operation. A RESET switch allows the setup to be cancelled and a new setup programmed if required.

A roller door system and a controller are respectively described in AU-716640 and AU- 745478 to the present applicants, the content of which documents is incorporated herein by reference.

The setup of a roller door controller is generally a complex and time consuming process, particularly so when (as is often the case) the installer needs to use a ladder to access the switches of the controller in programming the system. To set the closed (lower) door limit, the installer must drive the door to its closed position, which requires close visual monitoring of the lower edge of the roller door. Unless two persons collaborate to set the limit positions, this process is usually a slow one, as the installer must repeatedly ascend and descend the ladder. The object of the present invention is to at least partially address the shortcomings of the prior art.

In this specification, where a document, act or item of knowledge is referred to or discussed, this reference or discussion is not an admission that the document, act or item of knowledge or any combination thereof was at the priority date part of common general' knowledge, or known to be relevant to an attempt to solve any problem with which this specification is concerned.

Summary of the invention In accordance with the invention in a first aspect, there is provided a controller system for controlling the operation of a movable closure, the closure operable in response to command signals from a remote device to move between respective limit positions, wherein the remote device is operable to set one or more of the limit positions of the closure during an installation phase.

In this way, the remote device to be used in the OPERATE mode can be used in the SETTING mode in the installation phase to remotely set the limit positions of the closure, without the installer needing to otherwise access the controller in the installation phase.

In a preferred form, the controller system includes an electrical operator unit, wherein the closure is drivable by an electric motor coupled to the electrical operator unit, the operator unit adapted to receive said command signals from said remote device and, in response, to store data representative of one or more of the limit positions of the closure.

Preferably, the closure is arranged to operate in two modes, a SETTING mode and an OPERATE mode, whereby the installation phase is carried out in the SETTING mode and, once the one or more limit positions have been set, the operator unit is operable to be switched to the OPERATE mode, in which mode receipt of command signals causes the closure to move between the respective limit positions.

The remote device preferably includes a plurality of command switches, the system arranged such that continued activation of at least one of said switches in the SETTING Smode causes the closure to move in a prescribed direction, and activation of a different command switch sets a limit position.

In a preferred embodiment, the system is arranged such that, in the SETTING mode, continued activation of at least one of said switches results in movement of the closure, and release of that switch-results in such movement ceasing.

This is a so-called 'deadman' functionality for setting said limit positions, so that the installer can accurately control the position of the closure in setting the limit positions. In contrast, when the controller in the OPERATE mode, activation of a selected switch results in movement of the closure regardless of release of that switch, the movement only ceasing on further activation of the switch (or reversing on activation of another switch), or on reaching a limit position.

Preferably, in the SETTING mode, a particular switch of the remote device is operable to toggle between functions of at least one of the other switches, the functions including continuous, movement of the closure, and movement in a series of small increments.

In this way, when setting a particular limit position; the installer can activate and hold the appropriate switch to 'inch' the closure towards the desired limit position, in order to provide fine control in setting the limit positions.

Alternatively or additionally, the system may be arranged such that, in the SETTING mode, a particular switch of the remote device is operable to toggle between functions of at least one of the other switches, the functions including movement of the closure at a plurality of different speeds.

Further, in the SETTING mode, the closure may be operable to accelerate from a slow speed such as a few mm/s to a greater speed after a selected time of activation, to enable accurate setting of the limit positions.

The operator unit may also features a plurality of command switches which may be used to set the limit positions in the SETTING mode. In this way, the operator may therefore choose whether to set the closure limit positions using the remote device, or using the controller itself, or both.

Preferably, the controller system is arranged to store a closed limit position and two or more open limit positions for the closure, the remote device being operable to select between alternative open limit positions for opening said closure.

When the final limit position has been set in the installation phase, the operator unit may be arranged to automatically switch to the OPERATE mode.

Further, once the final limit position has been set, the system may be arranged to automatically move the closure through at least one full open and close cycle to store a profile of characteristics of the closure (eg a load profile), before the controller is switchable to the OPERATE mode.

In a preferred form, the system is arranged such that activation of a particular switch of the remote device in the SETTING mode transmits to the controller a storable code characteristic of the particular remote device, and further activation of that switch provide a command signal to the operator unit indicating achievement of the one or limit positions.

The system preferably includes a motor with a drive shaft to drive the closure via a geartrain, the data characterising the limit positions of the closure corresponding to positions of a part of said geartrain.

In accordance with the invention in a second aspect, there is provided a method for setting the limit positions of a movable closure, the closure operable in response to command signals from a remote device, the method including, during an installation phase, operating said remote device to set the limit positions of the movable closure.

Brief Description of the drawings The invention will now be further described by way of non-limiting example with reference to the accompanying drawings, in which: Fig. 1 shows an installed automated garage roller door system; Fig. 2A shows a remote transmitter device forming part of the system of Fig. 1; Fig. 2B shows a programmable electronic controller operator panel of the system ofFig.

1; and Fig. 3 is a more detailed view of the controller of the system of Fig. 1.

Detailed Description of the Drawings The roller door system 10 of Figure 1 includes a drum-mounted roller door 20 on an axle mounted to two end brackets 40. At one end of the axle is mounted a drive unit including a stepping motor (not shown) and a drive train (not shown), as well as an electronic controller 60 protected by a plastic light diffuser. Drive unit 50 is provided with a disengagement pull handle 70 for disengagement of the drive train if manual operation of the roller door is required at any time.

Controller 60 includes an integrated circuit chip (not shown) programmable to manage the various functions of system, electrically connected to a controller operator panel Panel 80 includes operating controls for installation and setup of roller door system and includes the following components (see Figure 2B): 81. Set button for setting (and resetting) controller functions 82. Open Stop Close command test button 83. Open drive button /Increment button 84. Open limit LED Force margin set button 86. Auto close time button 87. Close limit LED 88. Close drive button /Decrement button 89. Remote device code set button Light code button 91. Coding LED.

The functions of the operator panel components will be explained further below.

Controller 60 includes a radio receiver means for receiving radio control commands from user's remote transmitter device 92 (Figure 2A). Remote device 92 typically includes four control buttons A, B, C, D, which may be set up as desired during installation to enable user's remote control over operation of roller door 20. If desired, for example, all four buttons can be set to operate the door.

A further view of controller 60 is provided in Figure 3, showing operator panel 80 in place, and illustrating also integral courtesy light sources 95, drive disengagement pull handle 70, and manual wall switch 100, for manually closing roller door 20 after operation.

The installation and set up of roller door system 10 will now be described. The controls of controller operator panel can be used to set all of the variables of the system.

However, the present invention concerns the use of the controls of remote device 92 to program the major functions of controller 60, including the roller door limit positions.

Once drive unit 50 has been fitted (to the right- or left-hand side of door 20, depending on available space) and connected to an electrical power source, remote device 92 transmitter code is stored in controller 60. The installer presses and holds code set button 89, and then presses one of the remote device buttons A-D until coding LED 91 illuminates and an audible beep is heard. Once this code is stored, controller 60 will accept remote command signals coming from that remote device. Additional remote devices may also be used to program the controller so that door 20 can be operated by multiple devices, eg held by different members of a single household. The system may include an optional 'vacation mode' functionality to allow the first remote device to be used to selectively lock out access by any other remote devices whose codes may be programmed into the controller (or, optionally, only by others with 'vacation mode' functionality), in order to minimise the risk of unauthorised access through door during periods of augmented risk.

Controller 60 is now in a SETTING mode, permitting the installer during an installation phase to set the limit positions for the door, and in accordance with the invention this is realised with remote device 92, avoiding the undesirable need for the installer to access operator panel 80 while visually monitoring the precise position of door 20 as it is moved to its limit positions. In this installation phase, buttons A-D are designated as follows: 92 A. Set button 92 B. Open drive button 92 C. Close drive button 92 D. Toggle button, between 'inching' and 'continuous' modes.

Once the remote device code has been stored, the installer uses button 92B to drive door to its open limit position, additionally using button 92C if necessary to adjust up and down to reach the precise desired position. Depressing button 92D alternates between a continuous mode whereby depressing (and holding) button 92B/92C results in continuous upward/downward movement of the door until it is released and an 'inching' mode, whereby depressing (and holding) button 92B/92C results in an upward/downward movement of the door in a series of small incremental steps (through appropriate control of the drive unit stepping motor) until it is released. This functionality allows extremely precise control of the doors movement by the installer, until the door reaches the desired open limit position. At this point, the installer depresses button 92A and the open limit (represented as a measured count on an optoencoder element coupled to the motor drive) is automatically stored in controller The installer then uses open drive button 92C, again in combination with drive mode toggle button 92D, to drive the door to a desired close limit position. The installer then presses button 92A again and the close limit is stored in controller As an alternative, toggle button 92D may instead serve to alternate between normal and slow speed continuous mode operation. In this alternative, setting a limit position involves the installer driving door 20 at normal speed in the direction of the desired limit position (up or down) by depressing button 92B/92C until the door is close to the desired limit position. The installer then releases button 92B/92C and depresses button 92D in order to switch to slow speed continuous operation, before again using button 92B/92C to move the door at slow speed to the precise desired position, at which point button 92A is depressed to store the limit position.

The limit positions being set, the controller then automatically runs door 20 through an uninterrupted open-and-close cycle, in order to store a door load profile for the entire door travel. The controller is programmed with an obstruction force margin (which can be changed using operator button 85), the force margin and the stored door load profile providing a varying resistance level over the door cycle at which the door will automatically reverse (on encountering an obstacle). A suitable method and apparatus for setting and operating a movable closure with respect to a stored load profile is.described in applicant's Australian patent 745478.

An additional open limit position may be programmed into controller 60 if desired, being a 'pet mode' open position selected to allow door 20 to be opened just sufficiently to allow passage by a family pet. If the controller allows for a pet mode open limit position, this can be set using buttons 92B, 92C and 92D in the same way as the other limit positions are set, before automatic door profiling is implemented, without the need for the installer to access the operator panel 80. For remotely operated swinging or sliding gates, a similar system can be used to set a 'pedestrian mode' open position.

Once the door load profile has been successfully stored, controller 60 automatically switches from its 'SETTING' mode to the 'OPERATING' mode for normal operation by the roller door user. Further command signals received from remote device 92 are thus interpreted simply as door open/close commands. For example, in the OPERATING mode, depressing button 92D or 92C can serve to move the door to its closed limit position, with a further operation of the button halting the movement before reaching the limit position if required. Depressing button 92A can serve to move the door to its open limit position (with a further operation of the button halting the movement if required), whilst depressing button 92B can serve to move the door to a pet mode open limit position.

If controller 60 needs to be reprogrammed at any time, this can be done using reset button 81, at which time the controller is switched back to its SETTING mode.

The invention thus provides a great benefit to those installing or adjusting moving closure systems, providing a significant reduction in the time needed to set up a newly installed system, or to reset an existing one, whilst ensuring high accuracy and reliability of the system.

Modifications and improvements to the invention will be readily apparent to those skilled in the art. Such modifications and improvements are intended to be within the scope of this invention.

Claims (24)

1. A controller system for controlling the operation of a movable closure, the closure operable in response to command signals from a remote device to move between respective limit positions, wherein the remote device is operable to set one or more of the limit positions of the closure during an installation' phase.

2. The controller system of claim 1 including an electrical operator unit, wherein the closure is drivable by an electric motor coupled to the electrical operator unit, the operator unit adapted to receive said command signals from said remote device and, in response, to store data representative of one or more of the limit positions of the closure.

3. The controller system of claim 2, the closure arranged to operate in two modes, a SETTING mode and an OPERATE mode, whereby the installation phase is carried out in the SETTING mode and, once the one or more limit positions have been set, the operator unit is operable to be switched to the OPERATE mode, in which mode receipt of command signals causes the closure to move between the respective limit positions.

4. The controller system of claim 3, including a remote device, wherein the remote device includes a plurality of command switches, the system arranged such that continued activation of at least one of said switches in the SETTING mode causes the closure to move in a prescribed direction, and activation of a different command switch sets a limit position.

5. The controller system of claim 4 arranged such that, in the SETTING mode, continued activation of at least one of said switches results in movement of the closure, and release of that switch results in such movement ceasing.

6. The controller system of claim 4 or claim 5 arranged such that, in the SETTING mode, a particular switch of the remote device is operable to toggle between functions of at least one of the other switches, the functions including continuous movement of the closure, and movement in a series of small increments.

7. The controller system of claim 4 or claim 5 arranged such that, in the SETTING mode, a particular switch of the remote device is operable to toggle between functions of at least one of the other switches, the functions including movement of the closure at a plurality of different speeds.

8. The controller system of any one of claims 3 to 7, wherein said operator unit also features a plurality of command switches which may be used to set the limit positions in the SETTING mode.

9. The controller system of any preceding claim arranged to store a closed limit position and two or more open limit positions for the closure, the remote device being operable to select between alternative open limit positions for opening said closure.

The controller system of any one of claims 3 to 9 arranged such that, when the final limit, position has been set in the installation phase, the operator unit automatically switches to the OPERATE mode.

11. The controller system of any one of claims 3 to 10 arranged such that, once the final limit position has been set, the closure is automatically moved through at least one full open, and close cycle to store a profile of characteristics of the closure (eg a load profile), before the controller is switchable to the OPERATE mode.

12. The controller system of any one of claims 3 to 11, arranged such that activation of a particular switch of the remote device in the SETTING mode transmits to the controller a storable code characteristic of the particular remote device, and further activation of that switch provide a command signal to the operator unit indicating achievement of the one or limit positions.

13. The controller system of.any preceding claim, the system including a motor with a drive shaft to drive the closure via a geartrain, wherein the data characterising the limit positions of the closure correspond to positions of a part of said geartrain.

14. A method for setting the limit positions of a movable closure, the closure operable in response to command signals from a remote device, including the step of, during an installation phase, operating said remote device to set the limit positions of the movable closure.

The method of claim 14, wherein the movable closure is operable by means of an electric motor coupled to an electrical operator unit, including the step of sending command signals from the remote device to the operator unit thereby to store in the operator unit data representative of one or more of the limit positions of the closure in the operator unit.

16. The method of claim 15, including operating the closure in a SETTING mode during said installation phase to set the one or more limit positions with the remote device, and then operating the closure in an OPERATE mode to move the closure between the respective limit positions.

17. The method of claim 16, whereby a remote device including a plurality of command switches is used, the method including activating one of said switches in the SETTING mode to move the closure in a prescribed direction, and activating a different command switch to set a limit position.

18. The method of claim 17 including, in the SETTING mode, activating at least one of the switches to move the closure, and releasing that switch to halt such movement.

19. The method of claim 17 or 18 including operating a particular switch of the remote device to toggle between functions of at least one of the other switches, the functions including continuous movement of the closure, and movement in a series of small increments.

The method of claim 17 or 18 including operating a particular switch of the remote device to toggle between functions of at least one of the other switches, the functions including movement of the closure at a plurality of different speeds.

21. The method of any one of claims 14 to 20, including storing a closed limit position and two or more open limit positions for the closure, and operating the remote device to select between alternative open limit positions for opening said closure.

22. The method of claim 16 or any one of claims 17 to 21 insofar as dependent on claim 16, including the step of, when the final limit position has been set in the installation phase, switching the operator unit to the OPERATE mode.

23. The method of claim 16 or any one of claims 17 to 22 insofar as dependent on claim 16, including the step of, when the final limit position has been set, moving the closure through at least one full open and close cycle to store a profile of characteristics of the closure (eg a load profile), and then switching the operator unit to the OPERATE mode.

24. The method of claim 16 or any one of claims 17 to 23 insofar as dependent on claim 16, including using a particular switch of the remote device in the SETTING mode to transmit to the controller a storable code characteristic of the particular remote device, and then using same switch to provide a command signal to the controller indicating achievement of the one or limit positions. Automatic Technology Australia Pty Ltd 26 June 2003