NL2018222A - Configurable Mechatronic Lock System - Google Patents

Abstract

The present invention is defined by independent claim 1. The present invention proposes a lock system to create new lock products or retrofit locks e.g. to easily replace standardized conventional cylinder locks or deadbolt locks by normal retrofitting methods. Essential to the described invention is the use of two parallel and at least partially axially overlapping shafts enabling manual operation of the door lock actuating element and increasing the mechanical strength and stiffness of the whole assembly. By placing critical components such as the battery, intelligent control unit and clutch only once and on the inside, overall costs are decreased and robustness against typical tampering methods for mechatronic cylinders is increased. Furthermore by making the lock system late-stage configurable between a single outer knob controlled type and double sided controlled type it can be used in a wide range of applications.

Description

Description

Configurable Mechatronic Lock System

Technical Field [0001] The present disclosed invention describes a configurable wireless mechatronic lock system suitable for creating new lock products or substituting existing standardized locks like cylinder locks, rim locks or deadbolt locks by normal retrofitting methods.

Background Art [0002] Mechatronic lock systems are known and widely applied in various access control applications with a main advantage, compared to conventional mechanical locks, in flexibility with respect to configuration over time and encompassing large numbers of users. Wireless mechatronic lock systems with an incorporated battery are especially advantageous as they do not require any (re)wiring and can communicate with different types of wireless communication devices. Access control using company key cards has been widely adopted in professional applications. Furthermore in recent years there has been an advent of using Bluetooth Radio Frequency communication in consumer home application due to its ubiquitous presence in smartphones.

[0003] A specific advantage of wireless mechatronic locks compared to wired electric locks is the lower total cost of installation because there is no need to pull wires in the application. To even further ease and lower manual labour for a first install or lock retrofit it is advantageous to comply to standard lock interfaces and installation methods. For example by using existing standardized cylinder or deadbolt lock interfaces. Multiple embodiments of the present invention provide such a retrofit solution with the same methods and effort as replacing conventional locks.

[0004] A common approach to creating a wireless mechatronic lock is to mechanically connect and drive the cam or other actuating element by an electronically controlled motor. Such solutions are disclosed in for example: EP2365475 (Bl), US 9024759 (B2), US 2004/0250578 (Al) wherein all essential components such as battery, control unit, clutch and electrical cam shaft drive motor integrated in the inner knob and escutcheon.

[0005] The inventors of the present invention realized that important factors such as overall cost, performance and battery lifetime are adversely affected and for a larger part subject to the amount of energy and maximum power it takes to robustly rotate the cam or other latch or bolt actuating element in order to therewith open or close the door lock.

[0006] This amount of energy and maximum power is therewith largely determined by external factors, such as a jammed door due to weather conditions, and not due to controllable characteristics of the lock system itself.

[0007] It is the first objective of the invention to use manual labour to rotate the cam and therewith increase overall system robustness by decreasing dependence on external factors, decreasing energy usage, increasing battery lifetime and circumventing the need for a dedicated cam shaft drive motor.

[0008] Regarding manually actuated locks there are solutions disclosed that have the clutch fixed to one shaft e.g. the manually operating a first shaft and engaging on the other shaft e.g. the cam actuating one. US 2007/0017265 (Al) and US 2010/0011822 (Al) disclose such a solution with only one controlled side. The latter mentions applying the solution in a symmetric fashion to obtain a double sided controlled lock.

[0009] The inventors of the present invention realized that a symmetric solution consisting of two separate cam driving systems has disadvantages with respect to overall cost.

[0010] Document EP 0976896 (Bl) discloses an asymmetric lock system with two coaxial shafts with a code input unit or receiver of a transponder unit located in the outer knob. The document does not disclose embodiments with a receiver or code input unit on the inside.

[0011] The inventors of the present invention realized that symmetric solutions with two separate systems have a large disadvantage with regard to the freedom of placement of essential components. Components for the outer separated system are located in the outer knob or in between the outer knob and the cam more exposed to weather conditions and tempering such as hits, vibration, increased voltage, electrostatic discharge and magnetic field attacks.

[0012] It is a second objective of the invention to limit overall system cost and better protect essential components of the lock system such as battery, control unit and mechatronic clutch by an asymmetric design and locating them on the inside.

[0013] Document EP 1075050 (Bl) discloses solutions with a manually operated cam and a single mechatronic clutch fixed to and integrated into the cylinder housing body. Such solutions introduce a third axis, rolling or sliding members to keep both the manually operated shaft and cam operating shaft in a controlled coupled or decoupled state during operation. The document does not disclose a single side controlled system which is an important use case for escape route applications.

[0014] The inventors of the present invention realized an important disadvantage of a third axis; rolling or sliding elements are subject to significant wear due to the introduction of a load path through the stationary cylinder housing. Furthermore cost and robustness are adversely affected by the need for miniaturization in order to integrate essential components into the cylinder housing body. Finally while retaining the asymmetry of the disclosed solutions only single side controlled use cases are addressed.

[0015] It is a third objective of the invention to further decrease overall system costs by applying essential and costly components only once and not introducing a third axis with rolling or sliding members while still supporting double sided controlled use cases.

[0016] In addition to the above mention document EP 1075050 (Bl) also documents EP 1079051 (Bl), EP 1079052 (Bl), US 7275402 (B2) disclose a solution with a manual operated cam and single electric clutch integrated into the cylinder body. The latter document discloses a single sided controlled system but does so by physically blocking the outer knob.

[0017] The inventors realized it is an important disadvantage to block the outer knob as it makes the lock system much more prone to failure by vandalism or misuse by rotating the knob using excessive force and thereby breaking essential lock components.

[0018] It is a fourth objective of the present invention to provide for a freely rotatable outer knob when the lock is in the inactive state.

[0019] EP 1719861 (Bl) and DE 10 2005 026 910 (Al) both titled ‘Cylinder lock for an electronic lock system’ disclose a manually operated cam solution with a single clutch in between the inner knob and outer knob. The clutch is fixed to one of the shafts and provides for three distinct states; either the inner knob is mechanically connected to the actuating element, or the outer knob is mechanically connected to the actuating element, or the actuating element is not connected to either of both knobs which is essentially a 'neutral' state.

[0020] The inventors of the present invention realized that an important disadvantage of such a solution is the absence of a state in which both knobs are mechanically connected. An important use case for door locks is the case that a user needs to unlock the door from one side of the door, walks through, and re-locks the door from the other side.

[0021] It is a fifth objective of the present invention to provide for a lock activated state in which both the inner knob and outer knob are mechanically connected to the bolt actuating element. Hereby providing for a door unlocking and locking use case with a single lock activation step.

[0022] With respect to conventional cylinder locks the inventors realised security and robustness against tampering like drilling, attacks by chisel, twisting, resistance to attack by plug/cylinder extraction are primarily determined by standardized mechanical interfaces. More specifically the bridge with retaining screw hole and the cylinder itself with its mechanical complexity and the key plug.

[0023] It is a sixth objective of the present invention to circumvent weaknesses against tampering in both conventional and mechatronic cylinder locks by applying a shaft running across the full axial length of the cylinder.

[0024] As said there are two distinct types of cylinder locks to be used in different applications. First there is the two sided controlled type in which both knobs, the inner and outer knob, freely rotate in the non-activated state. This type is preferred for example when the door has a glass window, mail slot or other characteristic that elicit an opportunity of turning the inner knob from the outside e.g. by breaking the glass, use a tool through the mail slot etc.

[0025] Secondly there is the single sided controlled type in which only the outer knob freely rotates in the non-activated state. The inner knob is always mechanically connected to the cam. This type is preferred in general when the door has no vulnerabilities with respect to turning the inner knob from the outside. In particular this type can be mandatory in many commercial and public space applications as part of the building escape route.

[0026] Existing lock vendors do usually offer both types and different lock designs show modularity for ease and cost of manufacturing. The inventors realized that customers do not necessarily know which type is preferred. Late stage configurability in the application by the end-user is therefore regarded as a valuable feature. It simplifies the purchasing process comforting the potential customer. The inventors of the present invention have not come across prior art that discloses a lock system that is configurable between the two distinct types.

[0027] It's a seventh objective of the present invention to have the lock system end-user configurable between two distinct application driven types having either a single controlled side or two controlled sides.

Disclosure of Invention [0028] In short summary to the above the present invention: [0029] is robust in operation, uses limited energy and therewith has a long battery lifetime by driving the actuating element using manual labour.

[0030] Has an increased resistance against typical tampering methods associated with mechatronic lock systems by an asymmetric design and positioning all essential components on the inside relative to the door lock actuating element or cam (020).

[0031] Decreases overall cost and proneness to wear by limited complexity, limited miniaturization, applying electrical components only once and limiting the system architecture to two axles for operation.

[0032] Increases robustness against break failure by providing for a freely rotatable outer knob in the lock system inactive state.

[0033] Increases ease of use by mechanically connecting both the inner and outer knob in the lock system active state.

[0034] Increases resistance against conventional tampering methods by applying a shaft over the full length of the cylinder lock, rim lock or deadbolt lock body.

[0035] The present invention proposes a lock system shaped and dimensioned as a standard cylinder lock, rim lock or deadbolt lock with all essential components located in or near the inner knob. Furthermore the lock system consist of a shaft running from the outer knob to the inner knob assembly and another shaft running from the inner knob to the cam.

[0036] In a first state of the described lock system an authorized wireless communication device triggers the intelligent control unit activating the clutch and thereby mechanically coupling both shafts. While the lock is active manual power is applied to rotate the cam. It is essential to the described invention that both shafts are placed parallel and are at least partially overlapping in the axial direction in order to position the clutch on the inside relative to the cam.

[0037] In a second state of the described lock system the inner knob assembly is fixed to the cam rotating shaft therewith providing for a direct and fully mechanical operating lock from the inside. This is an essential requirement in applications like escape route door locks.

[0038] The lock system can be configured between the two described different states.

[0039] In another embodiment of the described invention the inner lock is equipped with a push button or other sensory means to detect user presence or lock operation from the inside. In this case the lock can be automatically activated circumventing the need to use a wireless communication device for user exit use cases.

[0040] In another embodiment of the described invention the battery is partly or fully replaced by a solar, kinetic or other energy harvesting unit.

[0041] In another embodiment of the described invention the robustness against tampering is further increased by physically separating both shafts.

[0042] In another embodiment of the described invention the robustness against tampering is further increased by locking the cam operating shaft with respect to the housing in a decoupled state of the electrically actuated clutch.

[0043] In another embodiment of the described invention one or both shafts have a feature that enables a controlled failure when excessive force is applied to them e.g. via tampering attempts such as a hit at the inner or outer knob.

[0044] In different embodiments of the described invention the lock can be actively or automatically controlled by all sorts of wireless communication devices such as: a key fob, a keypad, a radio frequency identification card or tag, a fingerprint reader and/or other biometric identification device, a identifying implant, a personal handheld device, a smartphone, a smartwatch and/or other wearable device, a portable computer. Furthermore the lock can be connected to a local network or the internet via a gateway enabling off-premise control.

Technical Problem [0045] Considering cylinder locks there are two distinctly different types of lock: [0046] - A two-sided controlled lock meaning both in inner and outer knob rotate freely when the cylinder lock in inactive and. This type is preferred when a door has windows, a mail slot or for other reasons there's a risk of turning the inner knob while still being outside e.g. by braking the window or using special tools.

[0047] - a single-sided controlled lock meaning only the outer knob is rotating freely when the cylinder lock is inactive and the inner knob is permanently rotationally fixed to the latch operating cam. This type is preferred and sometimes mandatory on escape route doors.

[0048] Furthermore it is not always clear to the end-user or installer which type is required hampering the purchasing process or keeping a costly inventory.

[0049] As mentioned above the seventh objective is to have a late-stage configurable lock system providing for both types using a single product.

[0050] Available lock systems and prior art show modularity to manufacture or even late stage assembly the two different types. They do so by applying costly components multiple times. Furthermore such lock systems [0051] - pose a higher security risk due to vulnerable components on the outside, [0052] - are less easy to use as the user often has to authenticate twice to keep the door locked before and after entering/leaving.

[0053] Given the technical approach of creating the disclosed lock system, using two parallel shafts with all vulnerable electronics on the inside it is specifically challenging to: [0054] - Have a single mechatronic clutch lock activation unit act on either the first or the second shaft, [0055] While simultaneously, [0056] - Mechanically fixing the other shaft to the intelligent inner knob.

Brief Description of Drawings [0057] 001 First Configurable State 002 Second Configurable State 010 Outer Knob 020 Cam 030 Inner Knob Assembly 100 Lock System 110 First Shaft 210 Second Shaft 310 Inner Knob Housing 320 Lock Configuration Unit 330 Mechatronic Clutch 340 Wireless Control Unit 350 Energy Accumulator 410 Cylinder Housing 510 Wireless Communication Device [0058] Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings in which: [0059] Figure 1 schematically shows the disclosed lock system (100) with its main user interfaces; the outer knob (010), the inner knob (030) and two example wireless communication devices (510, 510’) in this case a key fob and a numeric keypad.

[0060] Figure 2a schematically shows the disclosed lock system (100) and it’s functional subassemblies; the first shaft (110), the second shaft (210) and the inner knob assembly (030).

[0061] Figure 2b schematically shows the disclosed lock system (100) in a first configurable state (001) in which the inner knob assembly (030) is fixed to the first shaft (110) depicted as a solid line, and electromechanically interfacing with second shaft (210) depicted as a dashed line, effectively creating a two sided controlled lock.

[0062] Figure 2c schematically shows the disclosed lock system (100) in a second configurable state (002) in which the inner knob assembly (030) is fixed to the second shaft (210) depicted as a solid line, and electromechanically interfacing with first shaft (110) depicted as a dashed line, effectively creating a single side controlled lock.

[0063] Figure 3a schematically shows the disclosed lock system (100) in which the inner knob assembly (030) comprises a lock configuration unit (320, 320’) and a mechatronic clutch unit (330, 330’). Both shafts (110, 210) are depicted with separate interfaces for the configuration and mechatronic activation function.

[0064] Figure 3b schematically shows the disclosed lock system (100) in a first configurable state (001) in which the lock configuration unit (320) is set to create a fixed mechanical connection with the first shaft (110) and the mechatronic clutch (330’) is interfacing with the second shaft (210) effectively creating a two sided controlled lock.

[0065] Figure 3c schematically shows the disclosed lock system (100) in a second configurable state (002) in which the lock configuration unit (320') is set to create a fixed mechanical connection with the second shaft (210) and the mechatronic clutch (330) is interfacing with the first shaft (110) effectively creating a single sided controlled lock.

[0066] Figure 4a schematically shows a side view section cut of the disclosed lock system (100) in a first configurable state (001). The first shaft (110) assembly including the outer knob (010) is configured to be mechanically connected to the inner knob assembly (030) comprising; an inner knob housing (310), a mechatronic clutch (330), a wireless control unit (340) and an energy accumulator element (350).

[0067] The mechatronic clutch (330) is arranged to electromechanically couple and decouple with the second shaft (210) rotating the cam (020) within the cylinder housing (410).

[0068] Fig. 4b shows a bottom view section cut of the same embodiment of the disclosed lock system (100) in the same configurable state (001). For explanation purposes the lock configuration unit is shown consisting of two parts in a locked position (320) and unlocked position (320').

[0069] Figure 5a schematically shows a side view section cut of the disclosed lock system (100) in a second configurable state (002). The second shaft (210) assembly including the cam (020) which is freely rotating in the cylinder housing (410) is configured to be mechanically connected to the inner knob assembly (030) comprising; an inner knob housing (310), a mechatronic clutch (330), a wireless control unit (340) and an energy accumulator element (350).

[0070] The mechatronic clutch (330) is arranged to electromechanically couple and decouple with the first shaft (110) rotating the outer knob (010).

[0071] Fig. 5b shows a bottom view section cut of the same embodiment of the disclosed lock system (100) in the same configurable state (002). For explanation purposes the lock configuration unit is shown consisting of two parts in a locked position (320) and unlocked position (320').

[0072] While several inventive embodiments have been described and illustrated herein, those of ordinary skill in the art will readily envision a variety of other means and/or structures for performing the function and/or obtaining the results and/or one or more of the advantages described herein, and each of such variations and/or modifications is deemed to be within the scope of the inventive embodiments described herein.

[0073] More generally, those skilled in the art will readily appreciate that all parameters, dimensions, materials, and configurations described herein are meant to be exemplary and that the actual parameters, dimensions, materials, and/or configurations will depend upon the specific application or applications for which the inventive teachings is/are used. Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific inventive embodiments described herein.

[0074] It is, therefore, to be understood that the foregoing embodiments are presented by way of example only and that, within the scope of the appended claims and equivalents thereto inventive embodiments may be practiced otherwise than as specifically described and claimed.

[0075] inventive embodiments of the present disclosure are directed to each individual feature, system, article, material, kit, and/or method described herein. In addition, any combination of two or more such features, systems, articles, materials, kits, and/or methods, if such features, systems, articles, materials, kits, and/or methods are not mutually inconsistent, is included within the inventive scope of the present disclosure.

[0076] All definitions, as defined and used herein, should be understood to control over dictionary definitions, definitions in documents incorporated by reference, and/or ordinary meanings of the defined terms.

[0077] The indefinite articles “a” and “an,” as used herein in the specification and in the claims, unless clearly indicated to the contrary, should be understood to mean “at least one.” [0078] The phrase “and/or,” as used herein in the specification and in the claims, should be understood to mean “either or both” of the elements so conjoined, i.e., elements that are conjunctively present in some cases and disjunctively present in other cases.

[0079] Multiple elements listed with “and/or" should be construed in the same fashion, i.e., “one or more" of the elements so conjoined. Other elements may optionally be present other than the elements specifically identified by the “and/or" clause, whether related or unrelated to those elements specifically identified.

[0080] Thus, as a non-limiting example, a reference to “A and/or B”, when used in conjunction with open-ended language such as “comprising" can refer, in one embodiment, to A only (optionally including elements other than B); in another embodiment, to B only (optionally including elements other than A); in yet another embodiment, to both A and B (optionally including other elements); etc.

[0081] As used herein in the specification and in the claims, “or” should be understood to have the same meaning as “and/or" as defined above. For example, when separating items in a list, “or” or “and/or" shall be interpreted as being inclusive, i.e., the inclusion of at least one, but also including more than one, of a number or list of elements, and, optionally, additional unlisted items.

[0082] Only terms clearly indicated to the contrary, such as “only one of" or “ exactly one of," or, when used in the claims, “consisting of," will refer to the inclusion of exactly one element of a number or list of elements. In general, the term “or” as used herein shall only be interpreted as indicating exclusive alternatives (i.e. “one or the other but not both") when preceded by terms of exclusivity, such as “either," “one of," “only one of," or “exactly one of." “Consisting essentially of," when used in the claims, shall have its ordinary meaning as used in the field of patent law.

[0083] As used herein in the specification and in the claims, the phrase “at least one," in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but not necessarily including at least one of each and every element specifically listed within the list of elements and not excluding any combinations of elements in the list of elements.

[0084] This definition also allows that elements may optionally be present other than the elements specifically identified within the list of elements to which the phrase “at least one" refers, whether related or unrelated to those elements specifically identified.

[0085] Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B," or, equivalently “at least one of A and/or B") can refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including elements other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including elements other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc.

[0086] It should also be understood that, unless clearly indicated to the contrary, in any methods claimed herein that include more than one step or act, the order of the steps or acts of the method is not necessarily limited to the order in which the steps or acts of the method are recited.

[0087] In the claims, as well as in the specification above, all transitional phrases such as “comprising," “including,” “carrying,” “having,” “ containing,” “involving,” “holding,” “composed of,” and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases “consisting of" and “consisting essentially of” shall be closed or semi-closed transitional phrases, respectively.

Industrial Applicability [0088] The disclosed invention is applicable to new door lock designs as well as retrofitting conventional cylinder locks or refurbishing other locks. The disclosed lock system is applicable in consumer home applications as well as professional applications including escape route use cases.

Sequence Listing Free Text [0089]

Claims (15)

Conclusion 1. A lock system (100) consisting of at least; a first shaft (110) mechanically connected to and / or integrated with a user-operated outer knob (010) and mechanically connected to a lock configuration module (320) and a mechatronic coupling module (330); a second shaft (210) mechanically connected to and / or integrated with a door lock actuator element (020) and mechanically connected to said lock configuration module (320) and said mechatronic coupling module (330); both shafts (110, 210) are positioned in parallel and at least partially overlapping in the axial direction; a user-operated inner button (030) composed of at least one inner button housing (310), an energy accumulator element (350), a wireless communication control module (340), said mechatronic coupling module (330) and said lock configuration module (320); said wireless communication control module (340) communicates wirelessly with a wireless communication device (510) and controls said mechatronic coupling module (330); said mechatronic coupling module (330) provides the lock system with an activation function by coupling and disconnecting said inner button (030) with said first axis (110) or said second axis (210) depending on the condition of the lock system (001) , 002); said slot configuration module (320) provides a configuration function between two slot system states (001, 002); a first lock system state (001) wherein said inner button (030) is non-rotatably attached to said first axis (110) and said mechatronic coupling module (330) is mechanically connected to said second axis (210) thereby causing a mechatronic control lock system is created for both buttons (010, 030); a second lock system state (002), wherein said inner button (030) is non-rotatably attached to said second axis (210) and said mechatronic coupling module (330) is mechanically connected to said first axis (110) causing a mechatronic controlled lock system is created for only the outside button (010); a housing element (410) which at least partially encloses said shafts (110, 210). Conclusion A lock system (100) according to Claim 1 wherein said lock configuration module (320) and said mechatronic link module (330) are integrated in one mechatronic module and thereby combine the configuration function and the activation function. Conclusion A lock system (100) according to Claim 1 wherein said lock configuration module (320) is at least partially operated by, but not limited to; a linear translation or rotation of said inner knob (030); by applying a rotating or linear cam; by applying a mechatronic module. Conclusion A lock system (100) according to Claim 1, wherein both said shafts (110,210) are coaxially positioned. Conclusion A lock system (100) according to Claim 1, wherein the geometry of at least one said housing element (410) is configured to conform to a standardized mechanical interface for cylinder locks, support locks, dead bolt locks, and / or other lock interfaces. Conclusion A lock system (100) according to Claim 1 wherein said inner button (030) and / or said outer button (010) protrudes into said housing element (410). Conclusion A lock system (100) according to Claim 1 characterized in that both said shafts (110, 210) are physically separated by a stationary element that is mechanically connected to and / or integrated with said housing element (410). Conclusion A lock system (100) according to Claim 1, wherein a manual button and / or other sensory element is provided to detect the presence of the user and / or determine use of said inside button (030). Conclusion A lock system (100) according to Claim 1, wherein said energy accumulator element (350) is supplemented and / or completely replaced by an energy gathering module. Conclusion A lock system (100) according to Claim 1, wherein the radial position of said second axis (210) is mechanically coupled to at least one of said housing element (410) in an inactive lock system. Conclusion A lock system (100) according to Claim 1, wherein said first axis (110) and / or said outer knob (010) is defined with a mechanical interface to add elements and / or partially or completely said outer knob (010) ) to replace. Conclusion A lock system (100) according to Claim 1, wherein at least one of said shafts (110, 210) is mechanically defined with a physical feature that causes controlled mechanical failure of at least one of said shafts (110, 210) ). Conclusion A lock system (100) according to Claim 1, with said wireless communication device (510) being, but not limited to; a hand-held transmitter, a keypad, a radio frequency identification card or label; a fingerprint reader and / or other biometric identification device; a mobile device; a smartphone; a smartwatch and / or other portable device; a portable computer. Conclusion A lock system (100) according to Claim 1 with said wireless communication device (510) consisting of and / or integrated with; a fixed and / or replaceable user-operated outside button (010). Conclusion A lock system (100) according to Claim 1, being said wireless communication device (510); a connected communication gateway adapted to forward network-supported communication from a network-connected input device and / or software.