NZ541409A

NZ541409A - Door opener

Info

Publication number: NZ541409A
Application number: NZ541409A
Authority: NZ
Inventors: Michael Kevin Scheib
Original assignee: Chamberlain Australia Pty Ltd
Priority date: 2005-07-21
Filing date: 2005-07-21
Publication date: 2008-05-30
Also published as: AU2006270591B2; WO2007011244A1; AU2006270591A1

Abstract

A drive assembly for a movable barrier is disclosed. The drive assembly comprises a motor, a shaft connected to the motor, a dog disclosed on the shaft for being driven by the rotation of the shaft and capable of sliding movement along a rotational axis of the shaft, an output drive mounted on the shaft for rotation with the shaft when the dog is moved inwardly along the shaft, and a rotatable control assembly responsive to rotational forces applied to the control assembly for moving the dog inwardly along the shaft.

Description

NEW ZEALAND PATENTS ACT, 1953 No: 541409 Date: 2l July 2005 COMPLETE SPECIFICATION DOOR OPENER We, CHAMBERLAIN AUSTRALIA PTY LIMITED, a company incorporated under the laws of Australia of c/- Level 19, Aurora Place, 88 Phillip Street, Sydney, NSW 2000, Australia do hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The present invention relates to door openers, door opening arrangements and related assemblies, components and methodologies.

Door openers are manufactured and supplied for use in a number of situations.

Door openers such as those that might be used for curtain, sectional or tilt garage or the like doors frequently employ a logic controlled DC or an AC motor to drive the movement of the door through a transmission. Hie transmission maybe to a rotating shaft of a curtain door or a tambour type door or to a tracked carriage associated with a sectional or tilt door.

In many existing garage door assemblies the transmission includes a flexible driving element such as a chain or belt. Therefore one of the components of the drive train is usually a sprocket or pulley.

Hitherto drive assemblies utilising a carried electric motor has involved the difficulty of aligning the motor so as to have an output shaft in concert or parallel to that of the sprocket or pulley rotational axis (whether through a reduction gearbox or otherwise) to derive power therefrom or, and this is more usual, requires some transmission capable of allowing the rotational axis of the motor to be disposed at some oblique or right angle to the rotational axis of the sprocket or pulley. See PCT/NZ2003/000211.

There are many instances where a drive system for such door systems requires calibration so as to ensure that the electric motor (or other prime mover) does not continue to drive or drive effectively in its application beyond limits of that application. For example, in the situation with, for example, garage doors, whether of the curtain, tilt or sectional types it is usual irrespective of whether or not AC or DC motors are being used as the motive force) to provide limits whereby there is a cut-off of the energising power to the motor when the door is either fully open or fully closed.

Frequently such cut-off systems are dependent upon manual inputs byway of screws or the like members that alow the limits to be customised for the particular application.

Our PCT/NZ2003/00212 relates to apparatus and related procedures and the like that has application inter alia in such applications as the limit control of, for example, garage doors but has more widespread application.

Hie full content of our patent specifications PCT/N22003/000211, PCT/NZ2003/000212 and PCT/KZ2003/0013 is herein included, as are all published information on our existing MERLIN™ brand door opener systems particularly to show the background art and also what we hereinafter refer to as control and limit functionalities.

Hie present invention recognises irrespective of motor rotation axis orientation a desirability for an opener capable of routing a door element (e.g. such as that of a curtain or other such door) where k must provide an output drive member that rotates in concert with the central axis of the roll of the curtain door or the equivalent yet which may need to be installed and/or be serviceable in a small gap between the end of the door roll and some structural member of the building having the door opening to be closed or opened.

It is also or is an alternative object of the present invention (some instances an alternative to the aforementioned object) to make provision for support of such a door opener from a mount outstanding from the building or other support but extending as an arm or other structure to the door opener in a direction which is in a plane normal to the rotational axis of the door roll and/or the output drive member.

In also an aspect the invention is a drive assembly for a moveable barrier comprising: a motor; a shaft connected to the motor for rotation thereof; a dog disposed on the shaft for being driven by the rotation of the shaft and capable of sliding movement along a rotational axis of the shaft; an output drive mounted on the shaft for rotation with the shaft when the dog is moved outwardly along the shaft and for substantially free rotation about the shaft when the dog is moved inwardly along the shaft; and a rotatable control assembly responsive to rotational forces applied to the control assembly for moving the dog inwardly along the shaft.

It is yet a further or alternative object to provide a door opener with a telescopic clutch in the drive, a water tight design and/or other features hereinafter described.

In an aspect the invention is a drive assembly for a moveable barrier comprising: a motor; a shaft connected to the motor for rotation thereof; a dog disposed on the shaft for being driven by the rotation of the shaft and capable of sliding movement along a rotational axis of the shaft; an output drive mounted on the shaft for rotation with the shaft when the dog is moved outwardly along the shaft and for substantially free rotation about the shaft when the dog is moved inwardly along the shaft; and a control assembly responsive to rotational forces applied to the control assembly for moving the dog inwardly along the shaft.

Optionally any one or more of the following applies: there is a resilient apparatus for urging the dog outwardly along the axis of rotation of the shaft; the dog has outer flutes disposed about an outer surface which mate with inner flutes disposed about an inner surface of the output drive; Intellectual Property Office of N.2. (fol -7 JAN 2008 lowed by 3a) the control comprises a clutch collar disposed about the shaft and engaged with the dog for urging the dog inwardly along the axis of the shaft; there is a clutch lever having helical flutes disposed about an inner surface which mate with helical flutes disposed about an outer surface of the clutch collar; there is an apparatus for restraining the clutch lever from outward movement along the axis; and there is a control device for applying rotational forces to the clutch lever thereby forcing the clutch collar and engaged dog inwardly along the axis of the shaft to release the output drive.

In another aspect the invention is a barrier movement operator comprising: a barrier curtain having on end support and disposed on an axle; a final drive connected to a motor and mounted for rotation about the axle; wherein the final drive comprises a pair of mounting receptacles spaced apart from one another and disposed a substantially equal distance from an axis of rotation of the final drive about the axle and each of the receptacles comprise a member for receiving and retaining an extension by which rotational forces are conveyed to the end support of the curtain barrier. Optionally any one or more of the following applies: there is a pair of extension tubes each being disposed upon one of the receptacles; the pair of mounting receptacles each have a cavity disposed therein; and the cavity is configured and arranged to receive the extension.

In an aspect the invention consists in a door opener having a chassis, a final drive unit mounted to die chassis for rotation about an axis of rotation for driven connection to a door for tolling the door about a mounting axle, a motor, and drive means -whereby the motor and drive means earned by the chassis are able to rotate the final drive unit, wherein there is a clutching mechanism in die drive means, or between the motor and drive means, said clutching mechanism having one or more of the following features a dog engagement capable of being axially engaged/disengaged a bias to dog engagement the telescoping against the bias when clutched a helical interaction to provide telescoping in one or either direction a manual input to provide the clutched condition.

In another aspect the invention consists in a door opener of a kind having a chassis, a final drive unit mounted to the chassis for rotation about an axis of rotation for driven connection for rolling the door about a door mounting axle, a motor attached to the chassis, and drive means interconnecting the motor and the final drive unit, wherein the drive means includes a clutching arrangement having one or more of a dog engagement capable of being axially engaged/disengaged a biased dog engagement a telescoping against the bias when clutched a helical interaction to provide telescoping in one or either direction 3b Intellectual Property Office of N.2. ■-7 JAN 2008 a manual input to provide the clutched conditioa Preferably the assembly allows by a waisting of its flank for the inset of the complementary mount (optionally under the rotational axis of die sun gear).

Preferably preferred door openers in accordance with the present invention has any one or more of the following features: 1. Water tight design allowing water shedding and enabling outside use. 2. Pull cord with engagement ball that gives easy visual reference as to whether the drive is engaged or disengaged. 3. Component covers able to be removed for servicing on site without affecting the door. Saves time. 4. Rigid clamp for high torque transfer into main tube.

. Same single point reference and count technology as previously disclosed.

Most preferably the clutching arrangement or mechanism is one involving a helical interaction between two components and a manual or other input is provided to rotate one thereby to move the other as a result of the other helical interaction axially with respect to the other.

Preferably said axial movement is on the axis of the drive to the final drive unit and/or the axis of the axial of the door.

Preferably the overall width flank to flank i.e. in a plane that includes the rotational axis of said final drive unit is less than 150mm and preferably less than 100mm.

Preferably one flank is waisted so as to allow a mount full in part of a bracket or other such structure from the building to support the chassis and/ or door opener and/or axle of the door.

In another aspect the present invention consists in a door opener which has a capability of being mounted in a small space between the end of a door roll of, for example, a curtain door and any impediment spaced therefrom, such door opener having provision whereby despite its need for mounting and/or its lateral extent in the direction of the rotational axis of its output drive member is and will be less than 100mm.

In another aspect the invention consists in a door opener of a kind having a rotatable output member adapted to engage a door to be opened or closed, said output member having an axis of rotation which in use will be at least substantially horizontal and transverse to the longitudinal extent thereof which is in use will be substantially vertical, wherein the opener has its transverse extent in that direction parallel to said axis of rotation less than its transverse extent normal thereto and less than its longitudinal extent, and wherein on that flank of the opener opposite the flank with the output member there is a waisting at a region adapted to receive a or the mount for the opener.

Preferably the transverse extent parallel to said axis of rotation is less than 100mm. In another aspect the invention is a door opening arrangement including ■ a (cored, spooled, axled or equivalent) curtain door assembly capable of being iotatably unwound and wound, thereby to close and open respectively a door opening of a building, a door opener engaging an end of the curtain door assembly capable of being initiated to cause the curtain door assembly to unwind and/or wind, and a mount for the door opener from the building a clutched drive between a motor and the engagement with the end of the curtain door assembly, the clutched drive having one or more of a dog engagement a bias to dog engagement a telescoping against the bias when clutched a helical interaction to provide telescoping in one or either direction — a manual input to provide the clutched condition.

Preferably the mount is into a waisted region of one flank of the door opener.

In another aspect the invention consists in a door opener adapted to open and/or close or allow to close a curtain door, the door opener having at least: at least partial housing assembly that includes support (directly or indirectly for the remaining features ("the assembly"), a sun gear carried by the assembly, a drive member or members to rotate as the sun gear rotates and adapted externally of the assembly to engage and to rotate a complementary door curtain assembly, a pinion or spur gear ("pinion") meshed to rotate the sun gear, an electric motor, a transmission from the motor to the pinion by which the pinion rotates responsive to motor movement, and a clutch in said transmission whereby the motor rotates or does not rotate the pinion and thus the sun gear and the drive members), wherein the clutch includes one or more of a dog engagement a bias to dog engagement a telescoping against the bias when clutched a helical interaction to provide telescoping in one or either direction - a manual input to provide the clutched condition.

Preferably or optionally control and limit functionalities for the motor, the transmission and/or clutch are present.

Preferably the assembly allows for an inset support thereof (e.g. by a complementary mount) at least in part under part of the assembly when, as is desired, the sun gear of the door opener is to be oriented such that it rotates about a substantially horizontal axis, and optionally wherein the greatest dimensional extent of the opener in a direcdon parallel to the rotational axis of the sun gear from the exterior of the sun gear (ignoring the drive members) to the other side of the opener is less than 150mm).

Preferably the greatest extent is from 125 to 85mm.

Preferably the greatest extent is from 110mm to 90mm.

Preferably the greatest extent is about 100mm, Preferably the drive member(s) includes one or more dogs, fingers or the like (optionally extendable e.g. by extension fingers, tubes or the like) adapted to engage into a rotatably mounted and/or supported end and/or end member or assembly of a door curtain.

Preferably an axle member (whether a full or stub axle) of a said complementary door curtain assemblyis adapted to pass through the sun gear.

Preferably the transmission is controllable under the action of the functionalities to allow or disallow engagement and/ or disengagement of the pinion that meshes with the internal gearing of the sun gear.

In a further aspect the invention consists in a door opening arrangement including a (spooled or equivalent) curtain door capable of being rotatably unwound and wound thereby to close and open respectively a door opening of the building, a door opener engaging in end of the spooled or equivalent curtain door actuable to route the door curtain spool or equivalent and a mount for the door opener from the building, such mount extending substantially to the door opener in a plane or planes substantially normal to the spool or equivalent axis, wherein the greatest extent of the opener (save for any engagement penetrating into the spooled or equivalent curtain door in a direction parallel to die rotational of the spooled or equivalent curtain door is less than 150mm).

Preferably the door opener is engaged to said mount in a recessed region thereof on a flank thereof opposite to that flank which has means to functionally engage said spool or equivalent curtain door.

In preferred forms of the present invention the door opener has any of the features hereinafter described with or without reference to the specific of any one or more of the accompanying drawings.

In yet a further aspect the present invention consists in the use of a door opener of any one of the preceding claims in conjunction with a door roll of, for example, a curtain door.

In yet a further aspect the present invention consists in any assembly of a door opening or closing system which involves the use of a door opener or a door opener assembly in accordance with the present invention.

As used herein the term "and/or" means "and" or "or", or both.

As used herein the term "s" following a noun means the singular and/or plural forms of that noun.

As used herein the term "curtain door" refers to any closure member whether for a window, door, shutter or other closure purpose, whether or not there is edge guiding of the door as it deploys or not, and irrespective of whether or not there is an axle through the door roll or not.

A preferred form of the present invention will now be described with reference to the accompanying drawings in which Figure 1 is a perspective view of the waisted flank of a preferred opener in accordance •with the present invention, Figure la is a similar view, but more from below, of the same flank of the door opener of Figure 1, Figure la showing a cord to allow the engagement of the drive or, as shown in Figure la, to hold the clutching mechanism against its bias, Figure 2 is a perspective view of the other flank not showing tube extension members fitted into the final drive unit or to act as fingers for engaging the door, Figure 3 is a similar view to that of Figure 2 but showing extension tubes fitted and able to be retained in the receiving sockets therefor, the arrangement thereby permitting the making up of the overall final drive unit even in confined spaces, Figure 4 is an exploded view of the preferred assembly of the door opener of Figures 1 to 3, Figure 5 is a side elevational view of the door opener of Figures 1 to 4 showing the waisting in the left hand flank and the provision of the extension tubes of the final drive member, Figure 6 is an elevational view of that flank shown in Figure 1, Figure 7 is a section at AA with respect to Figure 6, Figure 8 is a section BB with respect to Figure 6, Figure 9 is a view in elevation to show the meshing of the pinion with the sun gear and the relationship thereof spatially with respect to other important components within the assembly, Figure 10 shows the pinion, Figure 11, shows the shaft sleeve to co-act with the pinion of Figure 10, Figure 12 shows a shaft sleeve, Figure 13 shows the clutch component to be levered showing its helical features, Figure 14 shows the complementary clutch component showing its helical features, Figure 15 shows (albeit with a different housing or chassis appearance) a mounting (with its cross arm supporting the door opener relative to a door axle reliant upon a clearing provided by the flank being waistedas shown.

Figure 16 shows an end view of a curtain door assembly.

Figure 17 shows a perspective view of a partially assembled drive mechanism.

Figure 18 shows a perspective view of a partially assembled drive mechanism.

B Description Generally, roller or curtain garage door assembles include an axle extending between two large wheels, with door material extending between and rotating around the wheels in a drum-like configuration. As shown in FIG. 16, each wheel 100 typically has three spokes 101, although other numbers of spokes are contemplated. The wheels 100 are free to turn around the axle 103, which is constrained from rotation. The door material typically comprises a plurality of steel slats 105 that ride within a track 104 on both sides of the door area and extend between the two wheels 100. The steel slats 105 are attached to each wheel 100 by at least one attachment point 106 to form a drum. A spring (not shown) is generally located between the wheels 100 to counterbalance the system. In the described embodiment, the steel slats 105 are said to comprise a door, however they may as equally make any type of movable barrier, such as a rolling window, window protector, or an awning.

The garage door is raised and lowered using a door operator 50, as shown in FIG. 15. Operators for this type of door are generally attached to a point of reference, such as the axle or the bracket, and are also engaged with the wheel. Typically, the operator engages with the spokes of the wheel to thereby rotate the wheels with the axle remaining stationary.. As shown in FIG. 15, the door operator 50 is mounted to and supported by a bracket 31 comprised of a mount part 32, an arm 34, and a gusset 33. On the side of the door operator 50 facing the wheel, the door operator 50 is engaged with a spoke of the wheel by extensions projecting from the final drive unit of the door operator (not shown). With the operator engaged with the spoke of the door assembly, die operator is able to raise and lower the door as needed.

Generally, the door operator comprises a motor that is drivingly connected to a pinion gear by a drive mechanism. The pinion gear drives a wheel gear, wherein the wheel gear is located inside the final drive unit. The rotation of the wheel gear inside the final drive unit causes the final drive unit to rotate around its axle. As mentioned, the final drive unit includes drive unit extensions that project from the final drive unit and engage with the wheel of the garage door and cause the wheel to rotate. 4 The door operator serves to rotate one of the wheels about the axle 103 to thereby control the raising and lowering of the door. Generally, the door operator comprises a drive mechanism that interconnects a motor and a final drive unit that engages with and rotates the wheel. The drive mechanism further comprises a clutch assembly that engages or disengages the gear serving to rotate the final drive unit and thus controlling rotation of the wheel. The clutch assembly may be used to manually detach the drive unit from the wheel (and thus the door) so that the door can be manually opened and closed.

A door operator 50 is shown in FIG. 1. The door operator 50 is contained in an operator housing comprising a base housing 7, an upper housing cover 8 and a lower housing cover 9. Referring now to FIG. 4, an exploded view of the door operator 50 is shown. A motor 14 is mounted to a motor housing 19 in the base housing 7 of the door operator 50. As shown in FIG. 17, a drive shaft 51 of the motor is inserted through a hole 52 in the motor housing 19, with clearance space in the hole 52 between the drive shaft 51 and the motor housing 19. The end of drive shaft 51 of die motor culminates in a pinion gear 15 that engages with the wheel gear 20 of the final drive unit A drive mechanism 99 interconnects the motor 14 and a final drive unit 200 (FIG. 2) by means of a pinion gear 15. The drive mechanism 99 includes a shaft sleeve 16 affixed on the motor shaft 51 by means of fluting on the outer surface of the motor shaft 51 and corresponding fluting 60 on an inner surface of the shaft sleeve 16 to force an engagement with the fluting of the motor shaft 51. In addition, an outer surface 61 of the shaft sleeve 16 also has flutes 62 on a portion of the length of die outer surface 61. The flutes 62 extend from a base portion 63 of the shaft sleeve and cover approximately 2/3 of the length of the outer surface 61 of the shaft sleeve 16. The individual components of the drive mechanism are illustrated in FIGS. 10-14 and perspective views of partially assembled states of the drive mechanism are shown in FIGS. 17 and 18.

Referring again to FIG. 17, a compression spring 18 is positioned around the base 63 of the shaft sleeve 16. Referring now to FIG. 18, the drive mechanism 99 further includes a shaft sleeve dog 17 positioned over the shaft sleeve 16 and the spring 18. The shaft sleeve dog 17 (FIG. 11) has an inner surface 70 with flutes 73 covering an upper portion thereof, wherein the inner flutes 73 of the shaft sleeve dog 17 are configured and arranged to mate and engage with the flutes 62 on the outer surface 61 of the shaft sleeve to 16. The outer surface 71 of the shaft sleeve dog 17 also has flutes 74 covering an upper portion of the outer surface 71. The flutes 74 cover approximately 1/3 of the length of the outer surface 71 of the shaft sleeve dog 17.

A retainer clip 1 (FIG. 4) is positioned on an end of the shaft sleeve 16 to retain the shaft sleeve dog 17. The shaft sleeve dog 17 is forced against the retainer,clip 1 by the force of the spring 18 positioned on the shaft sleeve 16. Thus, the shaft sleeve dog 17 is limited in travel in the final assembly so as to always be engaged with the shaft sleeve 16. The spring force from the spring 18 is also used to keep the clutch engaged.

The drive mechanism 99 further comprises a clutch mechanism. A clutch lever collar 21 is positioned around the base of the shaft sleeve dog 17. The shaft sleeve dog 17 has an outside flange 72 which mates and bears on an inside flange 80 of the clutch leva: collar 21 (FIG. 14). This configuration allows the clutch lever collar 21 to pull the shaft sleeve dog 17, as discussed further below.

The clutch lever collar 21 has three flanges 81 projecting from a circular base section 82 and toward the motor 14. Each flange 81 is comprised of two generally triangular projections 85. The two projections 85 of each flange 81 are spaced apart such that the projections of the flange can engage with projection features 53 on the motor 14 to prevent any rotational movement of the clutch lever collar 21 while allowing the clutch lever collar 21 to move along the axis of rotation of the motor shaft 51. This engagement can be seen in FIG. 18.

The clutch lever collar 21 has angled or helical flutes 84 surrounding an outer surface 83 of the circular base section 82. The angled flutes 84 serve to engage with a clutch lever 22 (FIG. 13) that is positioned around the clutch lever collar 21, as shown in FIG. 18. The clutch lever 22 has angled or helical flutes 91 on an inner surface 90 of the clutch lever 22 that are configured and arranged to mate with the angled flutes 84 of the clutch lever collar 21. Further, the clutch lever 22 has a tab ring 94 having a hole 95 therethrough, for connecting to the release mechanism (discussed below). The clutch lever 22 is shown positioned around the clutch lever collar 21 in FIG. 18.

The pinion gear 15 is positioned over the shaft sleeve 16 and shaft sleeve dog 17 assembly. The pinion gear 15 (FIG. 10) has flutes 65 on a portion of its length along an inner surface 66 of the pinion gear 15. The flutes 65 extend a relatively short distance \\ down the length of the inner surface 66 of the pinion gear 15. The flutes 65 on the inner surface 66 can engage with the flutes 74 on the outer surface 71 of the shaft sleeve dog 17. The pinion gear 15 is also retained by the retainer clip 1 positioned on the shaft sleeve 16.

When engaged with the flutes 74 of the shaft sleeve dog 16, the pinion gear 15 drives a wheel gear 20 (FIG. 4), which drives the final drive unit 200 (FIG. 2) to rotate about its axle, which by connection to the wheel 100 will raise and lower the door. Alternatively, the outer flutes 74 of the shaft sleeve dog 17 can also be disengaged from the inner flutes 65 of the pinion gear 15, so as to allow the door to be moved independent of the door operator.

The clutch lever collar 21 and clutch lever 22 assembly form a clutching mechanism that serves to disengage the shaft sleeve dog 17 from the pinion gear 15. As shown in FIG. 13, the clutch lever 22 has a flange 92 on an outer surface 93 which contacts and bears against the motor housing 19. The spring 18 creates the pushing force to keep the clutch lever 22 bearing against the base motor housing 19. Further, the spring 18 biases the operator towards engagement of the corresponding mating flutes on the shaft sleeve 16 and the shaft sleeve dog 17. As discussed above, the inner surface 90 of the clutch lever 22 has angled flutes 91 which engage with the outside angled flutes 84 of the clutch lever collar 21. When the clutch lever 22 is rotated by a release mechanism 36 (as shown in FIG. 1A and discussed further below) the rotation will force the clutch lever collar 21 to move away from the pinion gear 15 and closer to the motor 14 due to the angled engagement of the mating angled flutes.

As the clutch lever collar 21 moves towards the motor 14, the engagement of the inside flange 80 of the clutch lever collar 21 and the outside flange 72 of the shaft sleeve dog 17 causes the shaft sleeve dog 17 to also move linearly towards the motor 14 and retract away from the pinion gear 15. As a result, and also due to the relatively short length of the flutes 65 of the pinion gear 15, the shaft sleeve dog 17 is pulled out of engagement with the pinion gear 15 and the flutes of the shaft sleeve dog 17 and the pinion gear 15 will no longer be engaged. Thus, the gear drive is disengaged and the door can be operated independently of the door operator, such as by manual opening and closing. When no forces are applied to rotate the clutch lever 22 the motor is engaged with the pinion gear 15. Alternatively, when rotational forces are applied to the clutch lever 22 the pinion will be released from the motor and the barrier can be manually moved.

Such a telescopic arrangement as contemplated allows for the maximum flank to flank dimension, ignoring the extension fingers of the final drive (Le. which are usually received within the end of the door roll), to be very thin, thus enabling usage of the opener in confined spaces mtwithstanding a desire, reliant on the waisted region 30, of having (see within the embodiment of Figure 15) a bracket 31 mounted by part 32 thereof from a building to have a gusset 33 supported arm 34 underlying the region 35 of the door opener assembly and carrying indirectly the axle 36 of the door rolL It can be seen that the clutch includes: a dog engagement a bias to dog engagement a telescoping against the bias when clutched a helical interaction to provide telescoping in one or either direction a manual input to provide the clutched condition.

A release mechanism is used to disengage the pinion gear from the motor by rotating the clutch lever 22. As shown in FIG. 1 A, the release mechanism 40 includes a latch mechanism 28 attached to the base housing 7 of the door operator 50. A pulling cord 26 extends through the latch mechanism 28, and has a bead or ball 27 fixedly disposed thereon. An end of the pulling cord 26 is connected to the tab ring 94 of the clutch lever 22, such as, for example, by inserting the end of the cord through the hole 95 and tying or otherwise affixing the cord to remain in place. The latch mechanism 28 includes an inner tube 41 located closest to the door operator 50 and an outer tube 42 located farthest from the door operator 50. The inner tube 41 has a diameter larger than that of the ball 27 disposed on the pulling cord 26, thereby allowing the ball 27 to travel through the tube. The outer tube 42 has a diameter smaller than that of the ball 27, such that the ball catches on the end of the tube and cannot travel through the tube. A slot 44 having a width greater than the diameter of the pulling cord 26 is present along the entire length of the separation of tubes 41 and 42 so that the pulling cord 26 can be moved from one tube through the slot into the other tube. 13 The pinion gear 15 and the shaft sleeve dog 17 are engaged when the pulling cord 26 is freely traveling through the larger inner tube 27 such that no rotational force is exerted on the clutch lever 22. When the pinion gear 15 and the shaft sleeve dog 17 are to be disengaged, to thus disengage the drive mechanism and allow the door to operate independently of the door operator, a force is exerted on the pulling cord 26 by pulling on a lower end 43 of the pulling cord 26. Pulling on the Iowa- end 43 of the pulling cord 26 causes the opposite end of the pulling cord 26 that is attached to the tab ring 94 of the clutch lever 22 to exert a torque on the clutch lever 22 to thereby rotate the clutch lever 22.

The effect of pulling cord 26 so that its bead or ball 27 is caught by the transparent guide and latch 28 is to clutch the drive by its action on component 22 which by virtue of its helical engagement with component 21 disengages. Item 21 (dutch Collar) is moved in a linear direction away from the Pinion Gear 15. Item 21 engages a shoulder on Shaft dog 17 and disengages it from the Pinion Gear 15. On releasing the cord and the tension on Clutch Lever 22, Clutch Collar 21 is also free to move back towards the Pinion Gear 15. The Shaft Dog 17 with the assistance of Spring 18 is able to reengage with Pinion Gear 15 at the next rotational alignment. The Motor 14 drives Sleeve 16 which drives Shaft Dog 17 and then the Pinion Gear 15.

When the lower end 43 of the pulling cord 26 is pulled down, the ball 27 correspondingly moves downward with the pulling cord 26 and is thus fully exposed and located outside of and below the latch mechanism 28. Preferably, die ball 27 is of a particular indicator color, such as, for example, green, such that the sight of the ball 27 outside of the latch mechanism indicates the disengagement of the door operator.

To maintain the door operator in the disengaged position, while the pulling cord 26 is in the pulled down position with the ball 27 exposed on a lower end of the latch mechanism 28, the pulling cord 26 is moved away from the door operator and into the narrower outer tube 42 through the slot 44. When the pulling cord 26 is moved to the outer tube 42, the ball 27 will catch on the latch mechanism 28 due to the outer tube 42 being narrower than the ball 27. When the ball 27 catches on the latch mechanism 28, the pulling cord 26 will remain stationary in the downward position, thus maintaining the clutch lever 22 in the rotated position and the door operator disengaged. When it is desired to reengage the door operator, the pulling cord 26 is moved back to the larger, inner tube 41, thus allowing the pulling cord 26 and ball 27 to travel freely through the inner tube 41, thereby releasing tension on the pulling cord 26 and the clutch lever 22. With the assistance of the spring 18, the shaft sleeve dog 17 is able to reengage with the pinion gear 15 at the next rotational alignment.

When the clutch mechanism is engaged such that the motor 14 drives the wheel gear 20 by means of the pinion gear 15, the final drive unit 200 will rotate to thereby rotate the wheel 100 and raise and lower the door. In order to move the door, the final drive unit 200 of the operator engages the wheel by engaging a spoke 101 of the wheel 100. Generally, the spoke is engaged by two prongs extending from the final drive unit in a generally U-shaped configuration, wherein the spoke of the wheel is captured by one of the prongs extending along each side of the spoke. As discussed below, the present invention provides for the prongs to be customizable such that the lengths of the prongs can be varied according to the requirements and configurations of the door and opener.

In the present invention, the pinion gear 15 drives a wheel gear 20 (FIG. 9), wherein the wheel gear 20 is located inside the final drive unit 200. The rotation of the wheel gear 20 causes the final drive unit to rotate around its axle. A rotating face 201 of the final drive unit 200 has two drive unit extensions 202 extending therefrom. The two drive unit extensions 202 are spaced apart from each other a distance that is slightly larger than the width of a spoke of the wheel. As the wheel gear 20 rotates about its axle, the rotating face 201 of the final drive unit 200 having the drive unit extensions 202 extending therefrom will also rotate The two drive unit extensions 202 each have a cavity 203. The cavity 203 is configured and arranged to receive an extension tube 25, as shown in FIG. 3. The cavity 203 of the drive unit extension 202 can be configured and arranged to accept extension tubes 25 of any size or type. In a preferred embodiment, the cavity 203 of each drive extension unit 202 is a round cavity sized to accept a large (1.5 inch) conduit to create the U-shaped prongs to engage the spoke. The conduit would be attached and secured in the cavity by placing the conduit into the cavity and using a bolt to hold it in place. The conduit would then be sized to extend the appropriate length to engage the spoke.

The extension tubes can be any kind of tube or pole generally known in the art and can be solid or hollow and constructed of any appropriate material. The cavity 203 of the drive unit extension 202 can be configured and arranged to accept extension tubes of any shape or type, such as, for example, standard round pole pieces or square stock metal or wood. Further, the tubes may be of any size that is generally available and known in the art, such as, for example, a 3A inch galvanized pipe. The tubes may be secured, for example, by a bolt or by being press fit into the cavities. Alternatively, the tubes may be threaded, with the cavities also being correspondingly threaded.

In an alternate embodiment, if hollow extension tubes 25 are used, the drive unit extensions 201 can be inserted into an opening of the hollow extension tube. Thus, the drive unit extensions 201 can be sized to mate with the size and shape of the end opening of the extension tube 25 such that the drive unit extension 201 will fit into the extension tube 25. In addition, in this embodiment, the drive unit extensions 201 can be solid projections, without a cavity located therein.

The extension tubes 25 can be sized to extend the appropriate length for engaging with the spoke 101 (FIG. 16). When installing a door and door operator, the configurations of the door, operator, and other components may vary based on the installation location or other installation parameters, such that the spoked wheel of the roller door may be spaced at variable distances from the operator depending on the specific location of the installation. Thus, the extension tubes 25 are customizable and can be sized at the appropriate length such that they extend far enough from the operator to engage the spoke. The extenders thus remove the need for a specialized or customized extender or the need for an installer to carry a plurality of extenders of varying lengths to adapt to the particular door/spoke configuration to be used in conjunction with the door operator.

In the assembly as shown, the pinion 15, when the drive to it is enabled by the clutch mechanism, has the effect of rotating the sun gear 20 with its driving component typified by the extension tubes 25.

When the pinion 15 drives the wheel gear 20, as shown in FIG. 9, the extension tubes 25 mounted to the reverse side 201 of the wheel gear aiso rotate with the wheel gear. As discussed above, the extension tubes are sized to extend to the spoke, such that the spoke is captured on each side by an extension tube prong. Thus, as the extension tubes rotate with the wheel gear 20, the tubes exert a torque on the spoke to thereby rotate the wheel. This rotation moves the barrier up and down according to the direction of rotation of the wheel gear 20.

Table 1 is a convenient listing of the drawing references.

Table 1 1 Retainer Clip 2 Microswitch 3 Gear - Idler Set 4 PCB for FD04 DC Transformer 6 Micro Switch Cam 7 Base Housing 8 Upper Housing Cover 9 Lower Housing Cover Diffuser 11 Bolt 12 Clamp Bracket 14 Motor Pinion Gear 16 Shaft Sleeve 17 Shaft Sleeve Dog 18 Spring 19 Motor Housing Wheel Gear 21 Clutch Lever Collar 22 Clutch Lever 23 Clutch Cord Latch 24 Button 17 26 27 28 31 32 33 34 36 40 41 42 43 44 50 51 52 53 60 61 62 63 70 71 Extension Tube Pulling Cord Bead/Ball Latch Waisted Region Bracket Mount part Gusset Arm Region Axle Release Mechanism Inner Tube Outer Tube Lower End of Pulling Cord Slot Door Operator Motor Drive Shaft Motor Housing Hole Motor Projection Features Shaft Sleeve Inner Fluting Shaft Sleeve Outer Surface Shaft Sleeve Outer Flutes Shaft Sleeve Base Section Shaft Sleeve Dog Inner Surface Shaft Sleeve Dog Outer Surface Shaft Sleeve Dog Outside Flange 18 73 Shaft Sleeve Dog Inner Flutes 74 Shaft Sleeve Dog Outer Flutes 80 Clutch Lever Collar Flange 81 Clutch Lever Collar Projecting Flanges (3) 82 Clutch Lever Collar Circular Base Section 83 Clutch Lever Collar Outer Surface 84 Clutch Lever Collar Angled Flutes 85 Triangular Projections 90 Clutch Lever Inner Surface 91 Clutch Lever Angled Flutes 92 Clutch Lever Outer Flange 93 Clutch Lever Outer Surface 94 Tab ring 95 Through hole 99 Drive Mechanism Assembly 100 Wheel 101 Spoke 102 Door 103 Axle 104 Track 105 Steel slats 106 Attachment point 200 Final Drive Unit 201 Rotating Face of Final Drive Unit 202 Drive Unit Extensions 203 Cavity 19 In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.

Claims

WHAT WE CLAIM IS:

1. A drive assembly for a moveable barrier comprising: a motor; a shaft connected to the motor for rotation thereof; a dog disposed on the shaft for being driven by the rotation of the shaft and capable of sliding movement along a rotational axis of the shaft; an output drive mounted on the shaft for rotation with the shaft when the dog is moved outwardly along the shaft and for substantially free rotation about the shaft when the dog is moved inwardly along the shaft; and a rotatable control assembly responsive to rotational forces applied to the control assembly for moving the dog inwardly along the shaft.

2. The drive assembly as claimed in claim 1 comprising a resilient apparatus for urging the dog outwardly along the axis of rotation of the shaft.

3. The drive assembly as claimed in claim 1 wherein the dog has outer flutes disposed about an outer surface which mate with inner flutes disposed about an inner surface of the output drive.

4. The drive assembly as claimed in claim 2 wherein the control comprises a clutch collar disposed about the shaft and engaged with the dog for urging the dog inwardly along the axis of the shaft.

5. The drive assembly as claimed in claim 4 comprising a clutch lever having helical flutes disposed about an inner surface which mate with helical flutes disposed about an outer surface of the clutch collar.

6. The drive assembly as claimed in claim 5 comprising an apparatus for restraining the clutch lever from outward movement along the axis.

7. The drive assembly as claimed in claim 6 comprising a control device for applying rotational forces to the clutch lever thereby forcing the clutch collar and engaged dog inwardly along the axis of the shaft to release the output drive.

8. The drive assembly of claim 1 wherein the output drive comprises a pair of mounting receptacles spaced apart from one another and disposed a substantially equal distance from an axis of rotation of the output drive about the shaft and each of the receptacles comprise a member for receiving and retaining an extension by which rotational forces are conveyed to an end support of an curtain barrier.

9. The drive assembly of claim 8 comprising a pair of extension tubes each being disposed upon one of the receptacles. Intellectual Property Office of N.Z. 21 - 7 JAN 2008 D C O C I \/ c n

10. The drive assembly of claim 8 wherein the pair of mounting receptacles each have a cavity disposed therein.

11. The drive assembly of claim 10 wherein the cavity is configured and arranged to receive the extension.

12. The drive assembly of claim 1 wherein the drive assembly further comprises a clutching mechanism, the clutching mechanism being adapted to provide an engagement for said dog such that the dog is capable of being axially engaged/disengaged.

13. The drive assembly of claim 12 further comprising a bias to the dog engagement.

14. The drive assembly of claim 13 wherein the dog engagement telescopes against the bias when clutched.

15. The drive assembly of claim 12 wherein clutching mechanism comprises a helical interaction to provide telescoping in at least one direction.

16. The drive assembly of claim 12 wherein the clutching mechanism further comprises a manual input to request a clutched condition. END OF CUIMS Intellectual Property Office of N.Z. 0 5 MAR 2008 RECEIVED 22