CROSS-REFERENCE TO RELATED APPLICATIONThis application is a reissue application of U.S. Pat. No. 9,021,740, which issued on May 5, 2015 from U.S. patent application Ser. No. 13/599,287, filed on Aug. 30, 2012, which is hereby incorporated by reference as if fully set forth herein.
TECHNICAL FIELDThis invention relates generally to an operator and rail assembly for raising and lowering a movable barrier, and specifically to the use of a hinged rail trolley operator system to raise and lower a movable barrier.
BACKGROUNDMovable barrier systems are generally known in the industry. One example of such system is a garage door opener. There are several different styles of garage door operators. These operators are typically separated into jackshaft operators and trolley operators. Jackshaft operators attach to the jackshaft of the door, and are generally mounted at the end of the jackshaft. Trolley operators utilize a rail that is attached to and extends from the header, or the area above the barrier, to the operating mechanism.
In certain configurations, there may be a limited amount of headroom, the distance from the top of the garage door to the ceiling, to utilize a standard trolley type system. Doing so can result in a cumbersome installation process. Additionally, when the barrier door follows the track from the vertical (closed) to horizontal (open) position, forces on the trolley rail near the barrier opening require a considerable amount of reinforcement, including using thicker and stronger trolley rail materials in addition to using additional means to secure the trolley rail such as to a ceiling, to provide safe travel of the door.
BRIEF DESCRIPTION OF THE DRAWINGSThe above needs are at least partially met through provision of the hinged rail for barrier operators described in the following detailed description, particularly when studied in conjunction with the drawings, wherein:
FIG. 1 comprises a perspective view of an example hinged rail operator system as configured in accordance with various embodiments of the invention;
FIG. 2 comprises a perspective view of an example hinged rail and trolley for barrier operators as configured in accordance with various embodiments of the invention;
FIG. 3a comprises a perspective view of an example trolley as configured in accordance with various embodiments of the invention;
FIG. 3b comprises a perspective view of an example trolley as configured in accordance with various embodiments of the invention;
FIG. 3c comprises a perspective view of an example trolley as configured in accordance with various embodiments of the invention;
FIG. 4 comprises a schematic view of a portion of an example hinged rail operator system as configured in accordance with various embodiments of the invention;
FIG. 5a comprises a side view of a hinged rail operator system with a first example support configuration as configured in accordance with various embodiments of the invention;
FIG. 5b comprises a side view of a hinged rail operator system with a second example support configuration as configured in accordance with various embodiments of the invention;
FIG. 6 comprises a side view of a guiding rail operator system with a curved guiding rail as configured in accordance with various embodiments of the invention;
FIG. 7 comprises a side view of a hinged rail operator system with a third example support configuration as configured in accordance with various embodiments of the invention;
FIG. 8 comprises a side view of a hinged rail operator system with a fourth example support configuration as configured in accordance with various embodiments of the invention;
FIG. 9 comprises a side view of an example high-lift hinged rail operator system as configured in accordance with various embodiments of the invention;
FIG. 10 comprises a flow chart of an example method of operating a movable barrier as configured in accordance with various embodiments of the invention.
FIG. 11 comprises a flow chart of an example method of installing a movable barrier operator as configured in accordance with various embodiments of the invention.
FIG. 12 comprises schematic view of a portion of an example hinged rail operator system as configured in accordance with various embodiments of the invention.
FIG. 13 comprises a flow chart of an example method of operating a movable barrier as configured in accordance with various embodiments of the invention.
FIG. 14 comprises a side view of an example system for carrying power from the operator to a photobeam system as configured in accordance with various embodiments of the invention.
FIG. 15 comprises a schematic view of a portion of an example trolley system as configured in accordance with various embodiments of the invention.
FIG. 16 comprises a schematic view of a portion of an example system for detecting objects in the movable barrier's path of travel.
FIG. 17 comprises a schematic view of a portion of an example operator as configured in accordance with various embodiments of the invention.
Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions and/or relative positioning of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful or necessary in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of these various embodiments. It will further be appreciated that certain actions and/or steps may be described or depicted in a particular order of occurrence while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used herein have the ordinary technical meaning as is accorded to such terms and expressions by persons skilled in the technical field as set forth above except where different specific meanings have otherwise been set forth herein.
DETAILED DESCRIPTIONGenerally speaking, pursuant to these various embodiments, a guide rail having first and second rail sections is configured to guide a trolley used to move a movable barrier. In one approach, the apparatus includes an operator for controlling movement of the movable barrier, a trolley operably connected to a movable barrier and the operator, a guiding rail that guides movement of the trolley, and a support structure that connects to the guiding rail to provide additional support during the travel of the movable barrier. In operation, the operator controls movement of the trolley along the length of the guiding rail.
So configured, various approaches to such a guiding rail apparatus provide improved tracking of the movement of the barrier along the guiding rail during movement of the movable barrier. This improved tracking generally results in reduced forces exerted on the rail by the movable barrier while raising or lowering the barrier. The reduced forces in turn allow the use of lower strength materials for the rail, which provides for a lower cost assembly. In addition, various aspects of the guiding rail apparatus reduce the weight of the movable barrier being supported by the ceiling. In one example, the weight of the movable barrier is substantially supported by a support member anchored to a portion of the building structure above the barrier opening (or header) as opposed to mounting the portion of the guiding rail closest to the barrier opening to the ceiling. In such an example, the guiding rail can then be mounted to a lower portion of the header, thus resulting in a simplified installation process. In other applications, the use of a guiding rail in situations in which the header is substantially large (commonly known as high-lift doors) can eliminate the need for additional supporting panels during operation. In another aspect, power can be transmitted from the operator through the guiding rail to a photobeam system associated with the barrier for detecting objects in the path of travel of the movable barrier. So configured, an additional power cord is not needed to operate the photobeam system.
Referring now to the drawings, and in particular toFIG. 1, a hinged railbarrier operator system100 can include, for example, amovable barrier105, anoperator110,support rails115,support member120, supportmember securing device122, upper support member130 (FIGS. 5-9), upper support member securing device132 (FIGS. 7-9),ceiling structure135,building structure140,trolley150, and guidingrail200.
Theoperator110 serves to cause movement of a variety of other components of the operator system.Such operators110 are well known in the art and generally include a motor to power the operator and a spool tensioner to maintain appropriate tension in the operator cables. For the sake of brevity and the preservation of focus, additional details will not be presented here regarding such well understood peripheral structure. Theoperator110 is attached to theceiling structure135 by theupper support member130 and the upper supportmember securing device132 as shown inFIG. 5 and discussed below. Thetrolley150 is coupled to themovable barrier105 and operably connected to theoperator110. Thetrolley150 operatively engages the guidingrail200. Themovable barrier105 operatively engages the support rails115 to travel along the rails. Thesupport member120 is attached to thebuilding structure140 by the supportmember securing device122 and is attached to the guidingrail200 at the second end, which is described in further detail below.
In operation, when theoperator110 causes movement of thetrolley150, thetrolley150 traverses the guidingrail200, thus causing themovable barrier105 to traverse the support rails115 until themovable barrier105 is in an open or closed position. In one example, thetrolley150 transverses the hinged portion of the guidingrail200 without a loss in speed. The details of this travel are described in further detail below.
Referring now toFIGS. 1, 2, 3a, 3b, and 3c, an example of thetrolley150 is provided in further detail. Thetrolley150 includes atrolley arm151, amechanical stop152, a movablebarrier support structure153, and a trolley wheel155. The trolley wheel155 operatively engages the guidingrail200 through a track system contained in the guidingrail200. The track system is well known in the art and other approaches to engaging the guidingrail200 with thetrolley150 can be applied. For example, the trolley wheel155 as illustrated includes two sets of wheels on either side of a curved middle portion. In another example, the trolley may include a low-friction pads on either end, which pads allows the trolley to transverse the guidingrail200 by sliding across a surface contained within the guidingrail200. Thetrolley arm151 includes an aperture156. The movablebarrier support structure153 includes apin154 to rotatably connect thetrolley arm151 to the movablebarrier support structure153. The aperture156 of thetrolley arm151 is sized appropriately to allow thepin154 of the movablebarrier support structure153 to pass through, thus allowing thetrolley arm151 to rotate about thispin154. The movablebarrier support structure153 is secured to themovable barrier105 through traditional methods, including bolting, nailing, stapling, gluing, welding, and/or other known methods. In one approach, themechanical stop152 of thetrolley arm151 is affixed to thetrolley arm151 and protrudes from the surface of thetrolley arm151. Themechanical stop152 is constructed of a metal or any material having similar strength characteristics as thetrolley150.
In operation, when theoperator110 causes thetrolley150 to move themovable barrier105 towards an open or closed position, the trolley wheel155 traverses the distance of the guidingrail200. The angle between the trolley arm155 and the guidingrail200, as well as the angle between thetrolley arm151 and themovable barrier105, differ throughout the course of travel of thetrolley150. In one example and as seen inFIG. 3b, when the angle formed between the inner surface of themovable barrier105 and the bottom surface of thetrolley arm151 exceeds a determined amount, themechanical stop152 abuts an upper portion of the movablebarrier support structure153 to restrict the angle from further increasing, thus limiting the potential forces exerted on thetrolley150 by the weight of themovable barrier105. Generally speaking, these angles occur when theoperator110 is vertically displaced due to the varying forces exerted upon it, and immediately after thetrolley150 traverses afirst rail section210. Themechanical stop152 therefore prevents the trolley arm155 from swinging into the guidingrail200 during this movement. In another example and as seen inFIG. 2c, when the angle formed between the inner surface of themovable barrier105 and the bottom surface of thetrolley arm151 is less than a determined amount, themechanical stop152 abuts a lower portion of the movablebarrier support structure153 to restrict the angle from further decreasing, again limiting the potential forces exerted on thetrolley150 by the weight of themovable barrier105.
Referring again toFIGS. 24,5a, and5b, an example of the guidingrail200 is provided in further detail. The guidingrail200 includes afirst rail section210, asecond rail section220, and a hinged connectingpoint230. Thefirst rail section210 andsecond rail section220 are operably connected to the hinged connectingpoint230 to allow thetrolley150 to transverse therail sections210,220 upon operation of theoperator110. In one aspect, thefirst rail section210 is operably attached to theoperator110 at its second end.
Referring now toFIGS. 4, 5a, and 5b, thesecond rail section220 is provided in further detail. Thesecond rail section220 is pivotally secured to thebuilding structure140 by the second railsection securing device222. In the illustrated example, thesecond rail section220 includes anaperture221. The second railsection securing device222 includes apin223. Theaperture221 of thesecond rail section220 is sized appropriately to allow thepin223 of the second railsection securing device222 to pass through, thus allowing thesecond rail section220 to pivot about thispin223. The second railsection securing device222 is secured to thebuilding structure140 through traditional methods, including bolting, nailing, stapling, gluing, welding, and/or other known methods.
As previously mentioned and referring again toFIGS. 4, 5a, and 5b, thesupport member120 is attached to thebuilding structure140 by the supportmember securing device122. In this example, thesupport member120 includes anaperture121. The supportmember securing device122 includes apin123. Theaperture121 of thesupport member120 is sized appropriately to allow thepin123 of the supportmember securing device122 to pass through, thus allowing thesupport member120 to rotate about thispin123. The supportmember securing device122 is secured to thebuilding structure140 through traditional methods, including bolting, nailing, stapling, gluing, welding, and/or other known methods.
In one example, and as seen inFIG. 4, the opposite end of thesupport member120 is secured to the hinged connectingpoint230 of the guidingrail200. This opposite end of thesupport member120 is secured to the outer surface of the hinged connectingpoint230 to allow continuous movement of thetrolley150 as it traverses the entire length of the guidingrail200.
In another example, and as seen inFIG. 5a, the opposite end of thesupport member120 is secured to thefirst rail section210 and is configured to allow continuous movement of thetrolley150 as it traverses the entire length of the guidingrail200. In another example, and as seen inFIG. 5b, the opposite end of thesupport member120 is secured to thesecond rail section220 and is configured to allow continuous movement of thetrolley150 as it traverses the entire length of the guidingrail200.
In another example and as provided inFIG. 6, thesecond rail section220 replaced by acurved section235 approximately matching the curvature of the support rails115 (not shown). Thecurved section235 connects thefirst rail section220. Such a construction may result in separate rail sections being connected to one another to form the guidingrail200. Alternatively, the guidingrail200 may be constructed to consist of a single member having a first and second rail sections. In still another approach, the first rail section and second rail sections are two separate and optionally straight sections connected by a curved section, in which case, each section may be physically separate pieces or constructed as a single, integral rail. In any of the above approaches, therail200 may be constructed of separate pieces or as a single, integral rail.
In operation, when theoperator110 causes themovable barrier105 to move from a closed to an open position or vice-versa, thesupport member120 counteracts the forces exerted on the guidingrail200. Thesupport member120 is pivotally secured to the supportmember securing device122 through thepin123 to counteract the forces exerted on the guidingrail200 through traditional methods, including bolting, nailing, stapling, gluing, welding, and/or other known methods. An example of the connection between theoperator110 to theceiling structure135 is illustrated inFIGS. 7 and 8. Theoperator110 is attached to one end of theupper support device130. The second end of theupper support member130 is attached to the upper supportmember securing device132, which is in turn secured to theceiling structure135. The upper supportmember securing device132 is secured to theceiling structure135 through traditional methods, including bolting, nailing, stapling, gluing, welding, and/or other known methods.
In operation, when themovable barrier105 effects a force on thetrolley150, thetrolley150 in turn effects a force on the guidingrail200. In previous arrangements, to the extent this force was a vertical downward force, the guiding rail needed to be supported directly by the ceiling or end wall or through theupper support device130 of theoperator110. In various approaches described herein, instead, a tensile force results on thesupport member120 to counteract this vertical downward pull on the guidingrail200. To the extent that this force on the guidingrail200 has a vertical component not offset by thesupport member120, thesupport member120 will support the remaining portion of the force, which should be reduced because the largest forces are experienced where the trolley is disposed closest to the barrier opening. When providing a tensile support, the supportmember securing device122 transfers this force on thesupport member120 into thebuilding structure140, thus properly displacing the weight of themovable barrier105 from thefirst section210 of theguide rail200 throughout its direction of travel. So configured, theguide rail200 needs less structural strength and support to adequately support thetrolley150 andmovable barrier105.
In one example, theupper support member130 is made of a non-rigid material such as, for example, rubber or springs. When the vertical forces exerted by themovable barrier105 are reduced or minimized (for example, when the movable barrier is in the closed position or is traveling along thesecond rail section220 of the guide rail200), the non-rigidupper support member130 returns to its original orientation, as shown by the distance x inFIG. 7. When themovable barrier105 travels towards an open position along thefirst section210 of theguide rail200, theupper support member130 at least partially counteracts the vertical forces by elongating as the vertical forces increase. Upon the movable barrier reaching the fully open position, theupper support member130 counteracts the vertical forces by elongating to a maximum distance as depicted by the distance y inFIG. 8. The elastic nature of theupper support member130 is desirable in some applications because it absorbs the vertical forces exerted by themovable barrier105 and thus reduces the forces exerted on the upper supportmember securing device135, reduces the overall system cost, and allows for easier replacement in the event thesupport member120 fails. In another example, theupper support member130 is made of a rigid material such as, for example, a metal, metal alloy, or plastic.
Referring now toFIG. 9, anotherexample guiding rail200 includes athird rail section910. This example can be used in situations where themovable barrier105 has an elongated headroom to traverse. Thethird rail section910 is connected to either thefirst rail section210 orsecond rail section220 at an end point of either rail section through an additional hinged connectingpoint930. The additional hinged connectingpoint930 is connected to theadditional support member920, which is attached to theceiling structure135 using the same methods as previously described with regards to the second railsection securing device222 as depicted inFIGS. 4 and 5. The hinged railbarrier operator system100 performs in the same manner as previously described, with the exception of thetrolley150 traversing the additional hinged connectingpoint930 and thethird rail section910.
Referring now toFIG. 10, an example of a method of operating a movable barrier is described. Thetrolley150, in response to actuation of theoperator110, traverses1010 one of therail sections210,220 of the guidingrail200. Upon movement of thetrolley150, the weight of the hingeddoor105 exerts a force on the guidingrail200. Thesupport member120 and theupper support member130 counteract1015 these forces caused by themovable barrier105 in a first particular way by distributing the forces into thebuilding structure140 and theceiling structure135. Thetrolley150 then traverses1020 the hinged connectingpoint230, which is configured to allow the trolley wheel155 to traverse the rail sections smoothly and without a loss of speed. More specifically, a portion of the trolley wheel155 has a scalloped or curved edge, which allows the trolley wheel155 to remain in contact with the guidingrail200 throughout operation and therefore provides for the smooth travel. Thetrolley150 then traverses1030 the second of therail sections210,220 of the guidingrail200. Upon thefurther traversal1030 of thetrolley150, the weight of the hingeddoor105 exerts a force on the guidingrail200 in a second direction and distribution different than the first. Thesupport member120 and theupper support member130 then counteract1035 these forces caused by themovable barrier105 in a second particular way by distributing the forces into thebuilding structure140 andceiling structure135.
Those having skill in the art will recognize that the steps of traversing1010,1030 the rail sections can include thetrolley150 beginning at the first rail section210 (thus resulting in the movable barrier moving into a closed position) or the second rail section230 (thus resulting in the movable barrier moving into an open position). As the trolley traverses thefirst rail section210, the upper support member30 is primarily, but not exclusively, responsible for distributing the forces of themovable barrier105 into theceiling structure135. When the trolley traverses thesecond rail section230, thesupport member120 is primarily, but not exclusively, responsible for distributing the forces of themovable barrier105 into thebuilding structure140.
In an alternative example, and in accordance withFIGS. 9 and 10, the method of operating the movable barrier includes the additional steps of traversing a second hinged connectingpoint930 and athird rail section910 after thetrolley150 has traversed the first orsecond rail portions210,220. Because of the previously-mentioned configuration of the trolley wheel155, a smooth transition occurs when the trolley traverses the second hinged connectingpoint930 andthird rail section910, therefore minimizing both the amount thesystem100 moves and bounces during operation as well as any loss of speed of the trolley.
Referring now toFIG. 11, an example of a method of installing a movable barrier operator configured to move a barrier to open and close an opening in a building structure is provided in further detail. Theoperator110 is mounted1110 to theupper support structure135 with theupper support member130. It will be appreciated that thisupper support member130 can be either a rigid material or non-rigid material as previously described. Thesecond rail section220 is mounted1120 to thebuilding structure140 above the opening through the second railsection securing device222 as previously described such that an angle between thebuilding structure portion145 opposite of the opening and thesecond rail section220 that is less than about 90 degrees is formed. The angle formed between thebuilding structure portion145 opposite of the opening and the second rail section is denoted by the symbol a, as depicted inFIG. 7. The first end of thesupport member120 is mounted1130 to thebuilding structure140 through the supportmember securing device122 as previously described. The second end of thesupport member120 is mounted1140 to the guidingrail200 as previously described inFIGS. 4, 5, and 6. Thefirst rail section210 is mounted1150 to thesecond rail section220 through the hinged connectingpoint230 as seen inFIG. 4. Thefirst rail section210 is also coupled1160 to the operator. Thetrolley150 is coupled1170 to the guidingrail200 and coupled1180 to theoperator110 such that when in motion, thetrolley150 traverses the guidingrail200 with minimal resistance. As previously stated, thetrolley150 can be equipped with wheels for traversing the guidingrail200 or low-friction pads.
In another example, and in accordance withFIG. 12, a movablebarrier support shaft1210 and counterbalance spring are configured to be installed through an opening defined by thebuilding structure140,support structure120, andsecond rail section220. The movablebarrier support shaft1210 with a counterbalance spring provides counterbalancing support to themovable barrier105. This configuration results in reduced system size and allows installations in space-constrained areas.
Referring now toFIG. 13, an example of a method of operating a movable barrier1300 is provided in further detail. While themovable barrier105 is in a closed position, themovable barrier105 is supported1310 in part by the guidingrail200 through thesupport member120 coupled to the guidingrail200 at one end and thebuilding structure140 at the other end. As themovable barrier105 moves towards an open position, thetrolley105 coupled to themovable barrier105traverses1320 the guidingrail200 in a first direction parallel to that of thesecond rail section220. This traversing1320 causes thesupport member120 to increasesupport1323 of themovable barrier105 and causes theupper support member130 to increase itssupport1327 on the guidingrail200 through its attachment to theceiling support structure135. As themovable barrier105 continues towards an open position, thetrolley105 coupled to themovable barrier105traverses1330 the guidingrail200 in a second direction parallel to that of thefirst rail section210. This traversing1330 causes theupper support member130 to further increase itssupport1335 on the guidingrail200 through its attachment to theceiling support structure135. So configured, the method will distribute the forces into the support members in a manner similar to those previously stated above. It is understood and appreciated that thesupport member120 andupper support member130 are secured to their respective support structures through the methods previously mentioned herein.
In another example, and in accordance withFIGS. 14-17, a system for carrying power from theoperator110 to aphotobeam system1410 is provided in further detail. The system utilizesoperator cables1420, which include afirst operator cable1423 coupling theoperator110 to thetrolley150 in conjunction with asecond operator cable1425 beginning at thetrolley150 that extends to the end of thesecond rail portion220 of the guidingrail200 and back up the guidingrail200 to theoperator110. So configured, theoperator cables1420 act as conductors that terminate at thetrolley150. In one example, theoperator cables1420 are constructed from nylon coated wire rope, but alternatively can be any suitable conducting material. To provide thephotobeam system1410 with power and communications capabilities, the twooperator cables1423 and1425 are provided to thephotobeam system1410 through the use ofadditional cables1440 that travel from thetrolley150 to thephotobeam system1410 as illustrated inFIG. 15. Theseadditional cables1440 are constructed from insulated copper wire, but alternatively can be any suitable conducting material. Theadditional cables1440 include aphotobeam system connector1445 which plugs into thephotobeam system1410 to provide it with power. As illustrated inFIG. 16, in this example, thephotobeam system1410 includes aseparate emitter1418 and detector (not shown), each mounted to the bottom edge of the barrier. Aphotobeam system1410support plate1414 is coupled to themovable barrier105 through ahinge1412. Additionally, thesupport plate1414 is coupled to theemitter1418 and detector through ahinge1416 configured to fold up upon striking the floor when the barrier closes and optionally are configured to shut off in response to the hinging to conserve power.
So configured, there is no need to supply a cord that traverses the entire distance between the operator and the photobeam system separately from the operator system itself. In a first example, theoperator cables1420 are the same cables that connect theoperator110 to thetrolley150 and thus cause movement of themovable barrier105 as well as power thephotobeam system1410. In a second example, theoperator cables1420 are distinct from the operator cables configured to cause movement of themovable barrier105. These cables can then power a door-mounted obstacle detector system such as the example hinged photobeam illustrated inFIG. 16.
Referring now toFIG. 17, an example of anoperator drum system1700 is provided in further detail. Theoperator drum1710 includes copper spring brushes1720 that slide along a printed circuit board (not shown) mounted opposite theoperator drum1710. Theoperator cables1420 are electrically coupled to thecopper spring bushes1720. Theoperator drum1710 also contains grooves orribs1730, which allow theoperator cables1420 to rest therein during movement of theoperator drum1710. In operation, a motor effects rotation of theoperator drum1710 about its central axis, thus pulling on the cables, which pull on the trolley to cause movement of themovable barrier105. Additionally, when theoperator drum1710 is provided with electricity, it provides thecopper spring bushes1720 with electricity, which in turn supplies theoperator cables1420 with electricity, thus providing electrical power to theoperator cables1420 andphotobeam system1410. The manner of powering and communicating with a barrier obstacle detector system over two wires is well known to those of skill in the art and need not be described herein.
Those skilled in the art will recognize that a wide variety of modifications, alterations, and combinations can be made with respect to the above described embodiments without departing from the scope of the invention, and that such modifications, alterations, and combinations are to be viewed as being within the ambit of the inventive concept.