JP4505570B2 - Shutter device overload detection device - Google Patents

Description

The present invention relates to overload detection of a shutter device , and more particularly to overload detection of a shutter device that is opened and closed using a stepping motor as a drive source.

Conventionally, overload detection in an electric switch is determined by some means (for example, a load detection circuit and a comparator) to determine whether it is in an overload state, and when it is determined to be in an overload state, the motor is driven. It was necessary to take a plurality of steps to stop the supply of drive current to the circuit. In addition, in order to detect the load accurately and shorten the processing time until the motor stops, a complicated circuit configuration is required, and further improvement in the function of the microcomputer that controls the motor is required. Incurs high equipment costs.

In an electric shutter device as an electric opening and closing body for buildings, detecting an overload state is important as one means for detecting an obstacle. Regarding the means for detecting the overload state in the electric shutter device, several patent applications have been filed, and all of them detected the overload state in the same manner as described above, and were determined to be in the overload state. In this case, the procedure of stopping the motor is taken.

Patent Document 1 relates to an emergency stop device in an electric switch, and based on the detected current waveform, it is determined whether or not it is in an overload state, and in the case of an overload state, an emergency stop command for the switch is issued. Output.

Patent Document 2 relates to a shutter opening / closing device, which calculates a torque change amount at each predetermined timing, compares it with a preset threshold value, and outputs an obstacle detection signal when the torque change amount exceeds the threshold value. It is.

Patent Document 3 relates to a shutter opening / closing device, compares a detected torque value detected by a torque detecting unit with a set torque value, and determines that the contact with an obstacle is detected when the detected torque value exceeds the set torque value. In addition, the shutter opening / closing is safely controlled.

Patent Document 4 relates to a stop control device for a switch, and compares a drive output of a drive motor detected for each movement range of a slat curtain with a set output set for each movement range, and the drive output signal is a set output signal. On the other hand, when it is outside the set range, a stop signal is transmitted to the drive motor.

Patent Document 5 relates to obstacle detection in an electric shutter, detects the current value or rotation speed of the motor in the process of winding up the shutter body, and when the detected current value or rotation speed exceeds a predetermined management value, A signal indicating that there is an obstacle is generated.

Patent Document 6 relates to an electric shutter, and detects a fluctuation of a load applied to a motor when the shutter curtain is opened and closed to obtain a fluctuation load reference value, and when an abnormal load acts on the motor as compared with the fluctuation load reference value. The motor is stopped.
JP-A-8-93364 JP 10-25980 JP 10-37637 A JP 2000-64750 A JP 2002-1941973 JP2002-194974

An object of the present invention is to easily and reliably detect an overload state of a shutter device by utilizing the characteristics of a stepping motor.

The technical means adopted by the present invention in order to achieve such a problem are as follows:
In the overload detection device of the shutter device using the stepping motor as the drive source,
The apparatus comprises control means for controlling the output of the motor,
The control means sets the output of the stepping motor to the lowest output that can be driven according to the load that varies depending on the position of the shutter curtain,
The minimum driveable output is a value obtained by adding a predetermined offset amount to a load that changes over time according to the position of the shutter curtain, and the offset amount is a slight amount that can occur during normal use. The value is set so that the motor will drive without stepping out when the load changes and the motor will step out when overloaded.
The load that changes over time according to the position of the shutter curtain and the offset amount are stored in a storage unit,
The control means determines and outputs the minimum drivable output at predetermined timings based on the load that changes with time according to the stored shutter curtain position and the offset amount , and outputs the shutter curtain. Open and close drive,
When the load exceeds the minimum output during the opening / closing driving of the shutter curtain, the stepping motor is stepped out to stop the opening / closing driving of the shutter curtain.

The feature of the present invention resides in the positive use of the step out of the stepping motor. The stepping motor rotates in synchronization with the number of pulses, but has the property of losing synchronization and stepping out when overloaded. Since step-out is a state in which the stepping motor is not operating normally, conventionally, stepping motor drive control is performed so that the stepping motor does not step out by setting a large torque margin (torque margin). . On the other hand, in the present invention, the drive control of the stepping motor is performed by setting the motor output so that the stepping motor will step out during overload.

In the present invention, the output of the stepping motor is changed by the control means in accordance with the load that changes depending on the opening / closing amount of the shutter curtain . In the shutter device, the load varies depending on the opening / closing amount of the shutter curtain . In the case of a shutter curtain, the opening is opened and closed by winding the shutter curtain around the take-up shaft or feeding it from the take-up shaft, but the amount of the shutter curtain fed from the take-up shaft (feed amount or delivery) The load changes depending on the amount of the load. Therefore, in the shutter device, the load changes with time between the fully open state and the fully closed state. The present invention is characterized in that the output of the stepping motor is set to the lowest output that can be driven in accordance with the load that varies depending on the opening / closing amount of the shutter curtain , and the stepping motor is stepped out in the event of an overload. Here, the “minimum output that can be driven” means that the motor is driven without stepping out in a slight load change that may occur during normal use (for example, a slight load acting on the shutter curtain due to wind or the like). It is a magnitude output. In one preferred aspect, the setting of “minimum driveable output” is such that the output of the stepping motor is controlled to a value obtained by adding a predetermined offset amount to a load that changes according to the opening / closing amount of the shutter curtain. This is done by setting the offset amount to a value that causes the motor to step out when overloaded.

In a preferred embodiment, the overload detection device according to the present invention is used as an obstacle detection device. In another preferred embodiment, the overload detection device has a step-out detection means, and the upper limit position and / or the lower limit position of the electric opening / closing body may be set using such an overload detection device. Furthermore, in another aspect, the obstacle detection device has a step-out detection unit, and stops supply of drive current to the motor based on the step-out detection, or reversely drives to the motor based on the step-out detection. A current is supplied to reversely drive the open / close body.

In the present invention, since the overload detection is performed by stepping out of the stepping motor, the overload can be automatically detected and the rotation of the rotation shaft of the motor can be stopped, and the motor is stopped after the overload is detected as in the prior art. This eliminates the need for a procedure to stop the motor and easily and reliably detects an overload and stops the motor. In the constant current drive region, the overload detection torque (step-out torque) can be made constant even if the power supply voltage fluctuates.

A preferred example of the electric opening / closing body for construction will be described based on an electric shutter device. In FIG. 1, a shutter device installed in a building opening includes a shutter curtain 1, a winding shaft 2 to which the upper end of the shutter curtain 1 is connected, and an opening / closing device 3 that drives the winding shaft 2 to open and close. . The opening / closing machine 3 has a stepping motor 4 as a driving means, and the rotation shaft of the stepping motor 4 and the winding shaft 2 are connected by transmission to transmit the rotation of the rotation shaft of the stepping motor 4 to the winding shaft 2. Thus, the winding shaft 1 is rotated forward and backward to wind the shutter curtain 1 around the winding shaft 2, or it is fed out from the winding shaft 2 to guide the shutter curtain 1 to the left and right guide rails 5 to open the opening. Open and close.

The opening / closing drive of the shutter device is performed by a command from the switch box 6. A command from the switch box 6 is transmitted to the switch 3 via the control unit 7. The switch box 6 is provided with push button type operation switches PBU, PBS and PBD for raising, lowering and stopping. When the up button PBU is pressed, a shutter up signal is transmitted to the open / close control circuit of the control unit 7, a motor drive current is supplied to the motor 4 of the open / close machine 3, and the motor 4 rotates to wind the shutter curtain 1. Take up around the take-up shaft 2. When the lowering button PBD is pressed, a shutter lowering signal is transmitted to the opening / closing control circuit of the control unit 7, a motor driving current is supplied to the motor 4 of the opening / closing machine 3, the motor 4 rotates, and the shutter curtain 1 is wound. It is fed out from the take-up shaft 2. When the stop button PBS is pressed, a stop signal is transmitted to the open / close control circuit of the control unit 7, the supply of the motor drive current to the motor 4 is interrupted, and the rotation of the motor 4 is stopped.

The control unit (control unit) 7 includes a microcomputer, and the microcomputer includes a CPU and a storage unit, and an IC memory constituting the storage unit further includes a ROM and a RAM (at least of the IC memory). Some are non-volatile memories such as EPROM, EEPROM, non-volatile RAM). The driving of the stepping motor 4 is controlled by a microcomputer. That is, the stepping motor outputs a predetermined driving torque (switch output) by sending a predetermined driving current controlled by the microcomputer to the motor. In the present invention, the drive current supplied to the motor is set in accordance with the position of the shutter curtain (shutter curtain feed amount).

A rotary encoder (not shown) is attached to the rotating shaft of the motor 4 constituting the opening / closing machine 3, and counts the number of pulses output according to the rotation of the rotating shaft. The nonvolatile movement memory of the microcomputer stores the maximum movement amount of the shutter curtain, counts pulses output from the rotary encoder with the upper limit position or the lower limit position as the origin position, and stores them in the RAM. When the count value matches the value corresponding to the origin position and the value corresponding to the maximum movement amount, it is determined that the upper and lower limit positions have been reached, and the drive current supply to the motor is stopped. The data of the origin position is stored in the microcomputer RAM by operating the setting switch by stopping the shutter curtain at the upper limit position or the lower limit position when the shutter is installed in the building opening. Further, the rotational speed and rotational speed of the rotating shaft of the motor can be calculated by the rotary encoder. Furthermore, it is possible to detect the position of the shutter curtain (shutter curtain feed amount) based on the counted number of pulses.

In order to open and close the shutter curtain with the switch, the output of the switch (drive torque of the motor) needs to exceed the load (determined by the shutter moment), but the shutter shaft is rotated by rotating the winding shaft. The shutter moment when moving up and down is the amount that the shutter curtain is unwound from the take-up shaft in the process from the fully open state to the fully closed state and in the process from the fully closed state to the fully open state. Accordingly, the load that changes with time due to the amount of extension of the shutter curtain when the shutter curtain is opened and closed is referred to as the shutter moment. The shutter moment when opening and closing the shutter curtain is determined by the balance between the shutter curtain feed amount and the spring built in the take-up shaft, so the load changes depending on the shutter curtain feed amount that changes when the shutter curtain opens and closes. (The shutter moment is an unbalanced moment that changes over time).

The present invention pays attention to the fact that the minimum output (drive torque) of the opening / closing device (motor) required to open and close the opening by moving the shutter curtain up and down differs depending on the position (feeding amount) of the shutter curtain. The load (shutter moment) that changes when the curtain is opened and closed is monitored and detected over time, and the output of the switch with the value offset by a predetermined offset amount with respect to the detected load (minimum output that can be driven) The output of the stepping motor is controlled so that The motor output is controlled by controlling the drive torque by controlling the drive current supplied to the motor. Then, when the load applied to the motor exceeds a preset minimum driveable output, the stepping motor is stepped out to stop the opening / closing drive of the shutter curtain.

Load information (shutter moment) that changes by monitoring and detecting the load over time from the fully open state of the shutter curtain to the fully closed state or from the fully closed state to the fully open state is acquired and stored in the storage unit. . In one aspect, the current value is stored in the storage unit as equivalent to the load (the value of the moment of the shutter) by detecting a change in the load using the current detection device. Although the load is equivalent to the current value, the relationship between the drive current and the torque is determined by the motor used, and therefore the load torque can be calculated if the drive current is known.

The offset amount to be added to the detected load is that the driving torque (load detected at a certain time + offset amount) does not fall below the torque when the shutter curtain is normally opened and closed, and there is an obstacle on the moving shutter curtain. The magnitude of the load acting on the shutter curtain when it hits is set to a value that exceeds the drive torque (the load detected at a certain time + the offset amount). That is, in the overload state, the offset amount is set to such a value that the load exceeds the driving torque and the stepping motor constituting the switch is stepped out. In a specific aspect, the offset amount is set as a current value, and a current value obtained by adding the offset amount to a current value equivalent to the detected load is supplied to the motor as a drive current. By doing so, overload detection is performed by stepping out the stepping motor at the time of overload, and when the motor steps out, the rotation of the rotating shaft stops and the shutter curtain opening / closing drive stops. When the shutter curtain is opened and closed, the drive current is determined over time (every predetermined timing) based on a preset offset amount and a current value equivalent to the detected load. The offset amount is set to a value such that the motor output becomes the lowest output that can be driven according to the load (shutter moment) that varies depending on the opening / closing amount of the shutter curtain. The offset amount determines a margin such that the motor is driven without stepping out in a slight load change that can occur during normal use (for example, a slight load that acts on the shutter curtain due to wind or the like). The offset amount directly affects the detection sensitivity of overload detection, and the offset amount may be updated as necessary in the process of opening / closing the shutter curtain. In one embodiment, the offset amount is stored as a table in the ROM of the microcomputer, and an appropriate offset amount is selected from the table.

FIG. 2 is a diagram for explaining the output control of the switch. The shutter moment (load), which changes depending on the amount of shutter curtain being sent when the shutter curtain is opened and closed, is monitored and detected at predetermined timings (1.7 seconds in the embodiment). In one aspect, the current value is considered a load as described above. The load (current value) detected at a predetermined timing (1.7 seconds) is stored in a nonvolatile storage memory or RAM of the microcomputer. Based on the detected shutter moment (current value) and a preset offset amount (current value), the drive current supplied to the motor of the switch is determined every predetermined timing (1.7 seconds), and a predetermined drive torque ( Output) is output every predetermined timing (1.7 seconds) to drive the shutter curtain to open and close. In a normal opening / closing operation of the shutter curtain, the load does not exceed the output of the motor, so that the shutter curtain is driven to open / close with a driving torque output by a predetermined driving current.

If an obstacle hits the shutter curtain when the shutter curtain is opened and closed, the load acting on the shutter curtain exceeds the motor output and the stepping motor steps out. When the stepping motor steps out, the rotation of the motor rotation shaft stops, so that the shutter curtain opening / closing drive stops. That is, the overload state is automatically detected when the stepping motor steps out.

For the opening / closing drive control of the shutter curtain after detecting the overload state, the stepping motor step-out is detected by the step-out detecting means. The stepping motor step-out is in a state in which the rotation of the motor is not synchronized with the input pulse. Therefore, the stepping motor is detected by detecting the rotation of the motor rotation shaft with the rotary encoder and the presence or absence of the output pulse of the encoder. Can be detected. As a processing procedure when a stepping motor step-out is detected, in one aspect, the motor driving current supplied to the motor is cut off to completely stop the motor. In another aspect, after the motor is completely stopped or after a step-out is detected, a motor driving current that reverses the shutter curtain is supplied to the motor for a predetermined time, and the shutter curtain is moved for a predetermined time. Reverse operation is performed.

Obstacle detection using overload detection according to the present invention will be described. FIG. 3 and FIG. 4 are diagrams showing obstacle detection during ascent. When the obstacle hits the shutter curtain and the rail resistance increases while the shutter curtain is rising, the load exceeds the motor output. That is, in the upper graph of FIG. 4, the left unbalance amount exceeds the right switch output. Then, when the load exceeds the motor output, the stepping motor constituting the switch is stepped out, thereby detecting an obstacle and stopping the rotation of the rotation shaft of the motor. When stepping motor step-out is detected, a driving current that reverses and lowers the shutter curtain is sent to the motor for a predetermined time, and the shutter curtain reverses and lowers for a predetermined time. After a predetermined time has elapsed, the drive current to the motor is stopped and the shutter curtain is stopped.

In one aspect, the detection sensitivity (offset amount) is changed by detecting an obstacle. When obstacle detection is performed by stepping out of the stepping motor, the obstacle detection position is stored. Then, the obstacle detection offset amount is increased by a predetermined amount from 1.7 seconds before the obstacle detection to 3.4 seconds after the obstacle detection. If there is no obstacle detection at the same position at the next opening, the offset amount is lowered to the offset amount before the obstacle detection.

FIG. 5 and FIG. 6 are diagrams showing obstacle detection during lowering. When the seat plate of the shutter curtain hits the obstacle during lowering of the shutter curtain, the load exceeds the motor output. That is, in the upper graph of FIG. 6, the left unbalance amount exceeds the right switch output. Then, when the load exceeds the motor output, the stepping motor constituting the switch is stepped out, thereby detecting an obstacle and stopping the rotation of the rotation shaft of the motor. When stepping motor step-out is detected, a drive current that reverses and raises the shutter curtain is sent to the motor for a predetermined time, and the shutter curtain reverses and rises for a predetermined time. After a predetermined time has elapsed, the drive current pulse to the motor is stopped and the shutter curtain is stopped.

In one aspect, the detection sensitivity (offset amount) is changed by detecting an obstacle. When obstacle detection is performed by stepping out of the stepping motor, the obstacle detection position is stored. Then, the obstacle detection offset amount is increased by a predetermined amount from 1.7 seconds before the obstacle detection to 3.4 seconds after the obstacle detection. If no obstacle is detected at the same position at the next closing, the offset amount is lowered to the offset amount before the obstacle detection.

The overload detection according to the present invention can be used to set the upper limit position and the lower limit position of the shutter curtain. In other words, when the shutter curtain is raised or lowered by driving by a stepping motor, the motor steps out due to overload when it comes into contact with the lintel or drainer, thereby detecting the upper limit position and lower limit position of the shutter curtain. Can be detected.

In a preferred example, the overload detection according to the present invention can be used for an obstacle detection device for an electric shutter.

It is the schematic which shows the whole structure of an electric shutter apparatus. It is a flowchart which shows control of the switch output concerning this invention. It is a flowchart of the obstacle detection during shutter curtain raising. It is a figure relevant to the obstacle detection during shutter curtain raising, the upper figure shows the state by which the obstacle was detected, and the lower figure is a figure which shows the detection sensitivity change based on an obstacle detection. It is a flowchart of the obstacle detection in shutter curtain descending. It is a figure relevant to the obstacle detection in the shutter curtain descending, the upper figure shows the state in which the obstacle was detected, and the lower figure is a figure which shows the detection sensitivity change based on an obstacle detection.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Shutter curtain 2 Winding shaft 3 Opening / closing machine 4 Stepping motor 7 Control part

Claims (3)

In the overload detection device of the shutter device using the stepping motor as the drive source,
The apparatus comprises control means for controlling the output of the motor,
The control means sets the output of the stepping motor to the lowest output that can be driven according to the load that varies depending on the position of the shutter curtain,
The minimum driveable output is a value obtained by adding a predetermined offset amount to a load that changes over time according to the position of the shutter curtain, and the offset amount is a slight amount that can occur during normal use. The value is set so that the motor will drive without stepping out when the load changes and the motor will step out when overloaded.
The load that changes over time according to the position of the shutter curtain and the offset amount are stored in a storage unit,
The control means determines and outputs the minimum drivable output at predetermined timings based on the load that changes with time according to the stored shutter curtain position and the offset amount , and outputs the shutter curtain. Open and close drive,
An overload of the shutter device, wherein the stepping motor is stepped out to stop the opening / closing drive of the shutter curtain when the load exceeds the minimum output during the opening / closing drive of the shutter curtain. Detection device. 2. The overload detection device for a shutter device according to claim 1, wherein the control means includes step-out detection means for detecting step-out of the stepping motor. An obstacle detection device using the overload detection device according to claim 1.

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