U.S. patent application number 12/873969 was filed with the patent office on 2010-12-23 for high torque movable barrier actuation at low speeds utilizing a hub motor.
Invention is credited to Jonathan Becerra, HASSAN TAHERI.
Application Number | 20100319257 12/873969 |
Document ID | / |
Family ID | 40954486 |
Filed Date | 2010-12-23 |
United States Patent
Application |
20100319257 |
Kind Code |
A1 |
TAHERI; HASSAN ; et
al. |
December 23, 2010 |
HIGH TORQUE MOVABLE BARRIER ACTUATION AT LOW SPEEDS UTILIZING A HUB
MOTOR
Abstract
The present invention is a system for high torque operation of a
movable barrier utilizing a compact hub motor device, which may be
directly coupled to a movable barrier without the use of additional
gearing systems. The flat geometry provides high dynamic
acceleration with short electrical and mechanical time constants,
and its planetary gearing system implemented within the device
allows for compact, more efficient access systems. Eliminating a
gear system in accordance with the present invention lowers
maintenance requirements, increases efficiency, and streamlines
operation of movable barriers.
Inventors: |
TAHERI; HASSAN; (Dana Point,
CA) ; Becerra; Jonathan; (Cypress, CA) |
Correspondence
Address: |
JAFARI LAW GROUP, P.C.
801 N. PARKCENTER DRIVE, SUITE 220
SANTA ANA
CA
92705
US
|
Family ID: |
40954486 |
Appl. No.: |
12/873969 |
Filed: |
September 1, 2010 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12033301 |
Feb 19, 2008 |
7816879 |
|
|
12873969 |
|
|
|
|
Current U.S.
Class: |
49/31 ; 49/324;
49/360 |
Current CPC
Class: |
E05Y 2400/612 20130101;
H02K 7/116 20130101; E05Y 2600/452 20130101; E05F 15/643 20150115;
E05F 15/63 20150115; E05Y 2900/00 20130101; E05Y 2900/40 20130101;
E05Y 2800/264 20130101; E05Y 2201/656 20130101; E06B 9/70 20130101;
E05Y 2400/20 20130101; E05Y 2400/614 20130101; G05B 2219/45242
20130101; E05Y 2201/72 20130101; E05Y 2400/628 20130101; E05F
15/635 20150115 |
Class at
Publication: |
49/31 ; 49/360;
49/324 |
International
Class: |
E05F 15/20 20060101
E05F015/20; E05F 15/10 20060101 E05F015/10; E05F 15/12 20060101
E05F015/12; E05F 15/16 20060101 E05F015/16 |
Claims
1. A movable barrier access system comprising: a movable barrier
adapted to move on a track; a hub motor, wherein said hub motor
further comprises: one or more stators magnetically coupled to a
rotor, and one or more internal gears rotably coupled to said
rotor; a sprocket rotably coupled to said internal gears; a chain
directly coupled to said sprocket and said movable barrier in a
manner so that said movable barrier moves at a speed substantially
the same as a rotation speed of said sprocket, wherein said chain
runs substantially parallel to said track; a controller adapted to
control said hub motor; and a sensor connected to said controller,
wherein said sensor is adapted to generate a signal after detecting
a predefined event.
2. The movable barrier access system of claim 1, wherein said
controller activates said hub motor upon the generation of said
signal by said sensor.
3. The movable barrier access system of claim 1, wherein said
sensor comprises a photo-sensor.
4. The movable barrier access system of claim 1, wherein said
sensor comprises an infra red sensor.
5. The movable barrier access system of claim 1, wherein said
sensor comprises a motion detection sensor.
6. The movable barrier access system of claim 1, wherein said
sensor comprises an inductive loop sensor.
7. The movable barrier access system of claim 1, wherein said
movable barrier comprises a swing gate.
8. The movable barrier access system of claim 1, wherein said
movable barrier comprises a roll-up gate.
9. The movable barrier access system of claim 1, wherein said
movable barrier comprises an articulated door.
10. The movable barrier access system of claim 1, wherein said
movable barrier comprises a sliding gate.
11. A movable barrier operator, comprising: a hub motor, wherein
said hub motor further comprises: one or more stators magnetically
coupled to a rotor, and one or more internal gears rotably coupled
to said rotor; a sprocket rotably coupled to said internal gears; a
chain directly coupled to said sprocket and said movable barrier in
a manner so that said movable barrier moves at a speed
substantially the same as a rotation speed of said sprocket,
wherein said chain runs substantially parallel to said track; a
controller adapted to control said hub motor; and a sensor
connected to said controller, wherein said sensor is adapted to
generate a signal after detecting a predefined event.
12. The movable barrier operator of claim 11, wherein said
controller activates said hub motor upon the generation of said
signal by said sensor.
13. The movable barrier operator of claim 11, wherein said sensor
comprises an infra red sensor.
14. The movable barrier operator of claim 11, wherein said sensor
comprises a motion detection sensor.
15. The movable barrier operator of claim 11, wherein said movable
barrier comprises a swing gate.
16. The movable barrier operator of claim 1, wherein said movable
barrier comprises a sliding gate.
17. A movable barrier operator comprising: a hub motor adapted to
be directly coupled to a movable barrier in a manner so that said
movable barrier can be adjusted to move at a substantially the same
speed as a rotation speed of said motor, wherein said hub motor
further comprises: at least one stator magnetically coupled to a
rotor, and at least one or more internal gears rotably coupled to
said rotor; an external gear system connected to said hub motor,
wherein said external gear system is adapted to transfer a
mechanical force generated by said hub motor to said movable
barrier; a controller adapted to control said hub motor; and a
sensor connected to said controller, wherein said sensor is adapted
to generate a signal after detecting a predefined event.
18. The movable barrier operator of claim 17, wherein said
controller activates said hub motor upon the generation of said
signal by said sensor.
19. The movable barrier operator of claim 17, wherein said sensor
comprises an infra red sensor.
20. The movable barrier operator of claim 17, wherein said sensor
comprises a motion detection sensor.
Description
PRIORITY NOTICE
[0001] The present application is a continuation application that
claims priority under 35 U.S.C. .sctn.120 to U.S. patent
application Ser. No. 12/033,301 filed on Feb. 19, 2008, the
disclosure of which is incorporated herein by reference in its
entirety.
TECHNICAL FIELD OF THE INVENTION
[0002] The present invention relates in general to a system for
high torque operation of a movable barrier utilizing a compact hub
motor, and in particular, a movable barrier operator comprising an
electromagnetic motor that is retrofitted with internal gearing
capable of high torque at very low speeds, which may be directly
coupled to a movable barrier without the use of additional external
gearing systems.
BACKGROUND OF THE INVENTION
[0003] Typically, automatic and manual operation of movable
barriers, such as garage doors or gates, has included a gear system
which allows for easy movement of a barrier. Many developments in
the gate operator industry have transformed movable barriers,
including the implementation of various kinds of motors and gear
systems to operate one or more gates.
[0004] One of the problems encountered in the gate operator
industry is controlling actuation to achieve smooth, efficient, and
effective operation of movable barriers. The current practice
typically must implement various complex systems of gears and
electronics in order to provide the adequate amount of torque at
the low speeds these operators usually run to actuate a movable
barrier.
[0005] FIG. 1 is a block diagram of the various components
comprising a movable barrier operator typical of the ones found in
the prior art. Typically, the prior art (as shown) comprises of
power source 100, charger 101, battery 102, controller 103, sensors
104, switch array 105, phase control mechanism 106, motor drive
107, motor 108, c-phase mounting 109, gear box 110, output shaft
111, and a belt system 112, which connects to and operates movable
barrier 113.
[0006] Systems with conventional motors usually include phase
control mechanism 106 to monitor and alter the frequency of voltage
applied to the motor--furthermore these motors fail to provide high
torque at low speeds. The gate operation industry has therefore
implemented the use of gear box 100 and belt system 112 to
accomplish the torque required to actuate movable barrier 113.
These complex systems seek to regulate smooth actuation but still
remain inadequate.
[0007] Adding belt system 112, chains, or gear boxes, increases the
volume of the system, adding more moving parts and essentially
additional variables for possible system malfunctions.
Manufacturers in the gate operation industry have attempted to
alleviate this problem but those methods remain inadequate for the
following reasons.
[0008] Some manufacturers have tried to implement c-phase mounting
109 techniques between motor 108 and gear box 110, however, this
method raises the possibility of oil or grease leakage that may
damage a gate operating system--at the very least increased
maintenance and use of additional personnel is required to install
and service these access systems.
[0009] Due to the inadequate methods and systems used to operate
access systems (particularly in industrial applications), the gate
operation industry is flooded with gate operators that are large,
heavy, and complex--requiring relatively large motors and big gear
boxes. For these reasons and others, the prior art has been
inadequate to suit the needs of gate operator users, installers and
manufacturers.
[0010] Therefore, there is a need in the art for a system that
utilizes fewer components to achieve higher precision actuation of
movable barriers without complex gear systems and electronics. It
is desirable to develop a movable barrier operator that contains
fewer parts to minimize maintenance and potential malfunctions,
while retaining the desired control of the operator at low speeds
and generating the desired high torque during actuation. It is to
these ends that the present invention has been developed.
SUMMARY OF THE INVENTION
[0011] To minimize the limitations in the prior art, and to
minimize other limitations that will be apparent upon reading and
understanding the present specification, the present invention
describes a system for high torque operation of a movable barrier
utilizing a compact hub motor.
[0012] The present invention focuses on a system for high torque
actuation of a movable barrier utilizing a hub motor. These motors
are compact and implement their own internal gearing systems that
allow the device to be directly coupled to a movable barrier
applicable in many types of access systems. Their internal gearing,
and typically in planetary configuration, allows for a flat motor
that is compact and delivers very high torque at very low
speeds.
[0013] A movable barrier access system, in accordance with the
present invention, comprises a movable barrier adapted to move on a
track, a hub motor, wherein said hub motor further comprises one or
more stators magnetically coupled to a rotor, and one or more
internal gears rotably coupled to said rotor, a sprocket rotably
coupled to said internal gears, a chain directly coupled to said
sprocket and said movable barrier in a manner so that said movable
barrier moves at a speed substantially the same as a rotation speed
of said sprocket, wherein said chain runs substantially parallel to
said track, a controller adapted to control said hub motor, and a
sensor connected to said controller, wherein said sensor is adapted
to generate a signal after detecting a predefined event.
[0014] A movable barrier operator, in accordance with the present
invention, comprises a hub motor, wherein said hub motor further
comprises one or more stators magnetically coupled to a rotor, and
one or more internal gears rotably coupled to said rotor, a
sprocket rotably coupled to said internal gears, a chain directly
coupled to said sprocket and said movable barrier in a manner so
that said movable barrier moves at a speed substantially the same
as a rotation speed of said sprocket, wherein said chain runs
substantially parallel to said track, a controller adapted to
control said hub motor, and a sensor connected to said controller,
wherein said sensor is adapted to generate a signal after detecting
a predefined event.
[0015] A movable barrier operator, in accordance with the present
invention, further comprises a hub motor adapted to be directly
coupled to a movable barrier in a manner so that said movable
barrier can be adjusted to move at a substantially the same speed
as a rotation speed of said motor, wherein said hub motor further
comprises at least one stator magnetically coupled to a rotor, and
at least one or more internal gears rotably coupled to said rotor,
an external gear system connected to said hub motor, wherein said
external gear system is adapted to transfer a mechanical force
generated by said hub motor to said movable barrier, a controller
adapted to control said hub motor, and a sensor connected to said
controller, wherein said sensor is adapted to generate a signal
after detecting a predefined event.
[0016] It is an objective of the present invention to provide a
compact design capable of high torque at very low speeds.
[0017] It is another objective of the present invention to
eliminate the need for additional gearing systems for high torque
operations at low speeds.
[0018] It is yet another objective of the present invention to
provide smooth, constant speed actuation of various types of
movable barriers for different designs of access systems.
[0019] Finally, it is yet another objective of the present
invention to provide a movable barrier operation system with
minimal components and high versatility--applicable to a wide
variety of applications.
[0020] These and other advantages and features of the present
invention are described herein with specificity so as to make the
present invention understandable to one of ordinary skill in the
art.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Elements in the figures have not necessarily been drawn to
scale in order to enhance their clarity and improve understanding
of these various elements and embodiments of the invention.
Furthermore, elements that are known to be common and well
understood to those in the industry are not depicted in order to
provide a clear view of the various embodiments of the
invention.
[0022] FIG. 1 is a block diagram of the various components
comprising a movable barrier operator typical of the ones found in
the prior art.
[0023] FIG. 2(a) is a block diagram illustrating how implementation
of a hub motor eliminates the need for various components
traditionally found in the prior art.
[0024] FIG. 2(b) is a diagram illustrating an exemplary
configuration of a hub motor which may be coupled directly to a
movable barrier, in accordance with practice of the present
invention.
[0025] FIG. 3(a) illustrates one embodiment of the present
invention wherein minimal equipment is used in the operation of a
simple sliding gate by eliminating a gear system and implementing a
hub motor with a movable barrier operator.
[0026] FIG. 3(b) illustrates a more detailed view of the various
components that comprise the embodiment shown in FIG. 3(a).
[0027] FIG. 3(c) illustrates a side view of movable barrier
operator 301 shown above in FIG. 3(a) and FIG. 3(b), with housing
315 encasing the installation arrangement of a hub motor used to
operate movable barrier 302 in accordance with one embodiment of
the present invention.
[0028] FIG. 3(d) illustrates the internal configuration of movable
barrier operator 301 which has been housed or encased in housing
315.
[0029] FIG. 4 illustrates yet another embodiment in accordance with
the present invention wherein a movable barrier operator is coupled
directly to a movable barrier, for example a gate, without the need
for external gears or belt systems to optimize actuation, while
preserving space.
[0030] FIG. 5 illustrates one embodiment of the present invention
that is easily adaptable to various shapes and sizes of barriers,
for example different types of gates, do to its small size and lack
of external gear system.
[0031] FIG. 6(a) illustrates another embodiment in which a small
control box contains necessary components for a movable barrier
operator.
[0032] FIG. 6(b) illustrates a similar embodiment of the present
invention wherein a motor hangs from a post; this simpler design
incorporates the use of a remote location for the controller and
power source.
[0033] FIG. 7 illustrates yet another embodiment in accordance with
the present invention, in which a movable barrier operator may be
installed very low to the ground to avoid installing large fixtures
on a user's property and preserve aesthetic appeal, for example, of
an expensive swing gate at the entry point of a large estate.
[0034] FIG. 8 illustrates yet another embodiment in accordance with
the present invention wherein a movable barrier operator is
installed directly to another type of barrier, by way of example, a
roll-up gate, without the need for gears or belt systems to
optimize actuation and preserve space.
DETAILED DESCRIPTION OF THE DRAWINGS
[0035] In the following discussion that addresses a number of
embodiments and applications of the present invention, reference is
made to the accompanying drawings that form a part hereof, and in
which is shown by way of illustration specific embodiments in which
the invention may be practiced. It is to be understood that other
embodiments may be utilized and changes may be made without
departing from the scope of the invention.
[0036] In the following detailed description, an access system is a
system of one or more movable barriers positioned on any premises
to provide access in or out of said premise, for example into a
neighborhood, a building, a large compound, a small residence, an
industrial site, an agricultural site, a roadway system, a parking
structure, or any other type of premise for which controlled access
may be desired.
[0037] Furthermore, in this disclosure, an access system may also
include controlled access systems to airways, waterways, or even
pipelines that control fluid or gas flow.
[0038] A movable barrier operator, or gate operator, can be any
system that controls a barrier to an entry, an exit, or a view. The
movable barrier could be a door for a small entity (i.e. a
vehicle), or a gate for a large entity (i.e. a building) which can
swing out, slide open, pivot, fold or even roll upwards.
[0039] In the present disclosure, a movable barrier operator in
accordance with the present invention moves a barrier from an open
position to a closed position and vice-versa, retrofitted with a
hub motor to actuate or operate the barrier without the need for an
external gearing system.
[0040] A hub motor, as described herein, may be any type of motor
that uses a pancake motor configuration, usually, and without
limiting the scope of the present invention, making the motor wider
than longer. This is desirable over cylindrically configured motors
due to a pancake motor's compact design. Typically, the direction
of the magnetic flux is axial, that is, parallel to the axis of
rotation, which is an advantage when implementing an internal
planetary gearing system.
[0041] Thus, a hub motor, in accordance with the present invention,
is a device comprising an electromagnetic motor and an internal
gear system in a single compact configuration. A hub motor may
comprise a DC brush motor, a DC brushless motor, or any permanent
magnet motor in which magnets are specially arranged so as to give
the motor a flat, compact shape.
[0042] Hub motors may be customized depending on the necessary load
or weight of a particular movable barrier, which makes these types
of motors highly adaptable. For example, a hub motor may be
adjusted by known methods to exert a specified amount of force.
Furthermore, the internal gearing may be configured in any known
way; in an exemplary embodiment, a planetary gear configuration may
be desirable to achieve a flat compact design.
[0043] The fact that these motors can be configured with internal
gearing is an advantage over conventional movable barrier operator
motors that utilizes external gear boxes, belt systems, or similar
additional components, to achieve the desired torque at low speed
actuation of movable barriers.
[0044] By implementing a hub motor in accordance with the present
invention, gear box 110 and beltway 112 may be eliminated.
Eliminating gear box 110 will obviously further eliminate the need
for an installer to utilize c-phase mounting 109 techniques.
Removal of such parts creates a more compact design in which work
efficiency may be maximized, maintenance may be significantly
minimized, and with less components, the improved movable barrier
operator is more versatile; a single device capable of adapting to
numerous embodiments.
[0045] Furthermore, a hub motor in accordance with the present
invention has high torque, which enables a movable barrier operator
to actuate a gate (for example) without the need for phase control
mechanism 106; devices commonly used to regulate a voltage
frequency so that actuation is smooth throughout and in between
opening and closing commands.
[0046] For example, FIG. 2(a) is a block diagram illustrating how
implementation of a hub motor eliminates the need for various
components traditionally found in the prior art.
[0047] The illustrated embodiment comprises a basic system to
operate movable barrier 206 without the need for additional
components, for example, motor drive 107, gear box 110, belt system
112 have been removed, motor 108 replaced with hub motor 205.
Movable barrier operator 200 may be any type of movable barrier
operator without deviating from the scope of the present invention.
Thus, a hub motor such as hub motor 205 may be implemented in a
wide variety of applications for access systems in various
fields.
[0048] Movable barrier operator 200 comprises of minimal components
and thus may be compacted to fit numerous designs and ultimately
streamline prior designs that commonly require many components and
sub-components.
[0049] Typically, movable barrier operator 200 comprises power
source 201, battery 202, controller 203, and hub motor 205.
Additionally, and also typical, is sensors 204 which are utilized
to detect or sense an event, for example a vehicle approaching
movable barrier 206.
[0050] Hub motor 205 is typically coupled directly to movable
barrier 206 and wired to controller 203 where components to monitor
and control motor 205 may be installed, including any additional
features necessary to operate movable barrier 206, for example
sensors 204.
[0051] In an exemplary embodiment, hub motor 205 is a brush motor
which utilizes electromagnetic forces combined with an internal
planetary gearing system to provide movable barrier operator 200
with high enough torque to smoothly actuate movable barrier 206 at
very low speeds.
[0052] Power source 201 may be any known power source such as a gas
powered generator, an electrical power supply from power lines, a
photovoltaic power supply such as from power cells, or any other
source of power capable of supplying and charging battery 202 with
enough power to energize hub motor 205 and controller 203. Battery
202 is preferably a rechargeable battery to allow movable barrier
operator 200 a back-up power supply.
[0053] Sensors 204 may be inductive loop sensors, capacitance
sensors, a magnetic sensor, an ultrasonic sensor, a retro
reflective sensor, an optical sensor, a photo beam sensor, an
infrared sensor, or any other type of sensors known in the art
without departing from the scope of the present invention.
[0054] The elimination of a gear box means the illustrated movable
barrier operator 200 may be implemented for a wide variety of
applications. For example, and without limiting the scope of the
present invention, movable barrier operator 200, may be a swing
gate operator, a window operator, a garage door operator, a slide
gate operator, a roll-up door operator, a sliding-door operator, a
regular door operator, a revolving door operator, a car door
operator, or a car top operator for a convertible vehicle.
[0055] By eliminating the need for a gear box 110 and even the need
for a beltway system 112, hub motor 205 may be virtually directly
coupled to any movable barrier with few modifications. Thus, it is
preferable that hub motor 205 be manufactured in a small compact
size for most embodiments, however, having a larger size hub motor
for other applications would not deviate from the scope of the
present invention, for example, hub motor 205 may be a large motor
installed directly to a movable water barrier, wherein controller
203 and sensors 204 are utilized to control water flowing through a
dam. Other such embodiments wherein large barriers are utilized may
require larger versions of hub motor 205.
[0056] Implementing a gear box or gear system does not necessarily
deviate from practice of the present invention however, and there
may be some applications in which some gearing may be helpful. In
such cases, the advantages of a compact design may be compromised,
but the internal gearing of hub motor 205 will nevertheless provide
still more torque and power than conventional operators utilizing
conventional motors.
[0057] FIG. 2(b) is a diagram illustrating an exemplary
configuration of one embodiment of hub motor 205 that may be
coupled directly to movable barrier 206 in accordance with practice
of the present invention, wherein at least one stator and a rotor
are directly coupled to a system of planetary gears for rotating
hub motor 205's output shaft 211.
[0058] Hub motor 205 comprises of motor components 207 and internal
gearing system 208 which helps drive output shaft 211 with high
torque. Typically, motor components 207 comprises of at least one
stator and rotor which are magnetically coupled together. Motor
components 207 may also be a permanent magnet (PM) motor, a PM
brush motor, a PM brushless motor, or any type of DC motor, without
deviating from the scope of the present invention. Motor components
207 are coupled to internal gearing system 208 to provide a
mechanical advantage, thus multiplying the applied force of motor
components 207 and generating the desired torque through output
shaft 211.
[0059] Internal gearing system 208 further comprises of an internal
cavity 209 in which a series of gears 210 are configured to provide
the mechanical advantage at output shaft 211. Gears 210 may be any
type of gear configuration, however, in an exemplary embodiment,
gears 210 are in planetary configuration so that cavity 209 is
reduced in size, making hub motor 205 of a flatter more compact
design.
[0060] When hub motor 205 is directly coupled to movable barrier
206, movable barrier 206 will be able to move at substantially the
same speed as the rotation of output shaft 211. The advantage being
that external gearing components or similar external mechanisms
used to give conventional motors the desired mechanical advantage
may be eliminated thereby reducing costs and minimizing maintenance
of movable barrier operator 200.
[0061] In turn, with reference to the remaining figures, a number
of examples of other various embodiments, including some examples
already disclosed, will be discussed in greater detail.
[0062] FIG. 3(a) illustrates one embodiment of the present
invention wherein minimal equipment is used in the operation of a
sliding gate by eliminating an external gear system, and
retrofitting a movable barrier operator with a hub motor in
accordance with the present invention.
[0063] FIG. 3(a) illustrates access system 300 comprising movable
barrier operator 301, gate 302, controller 303, chain 304
(connected to gate 302 with chain bolt 305), and a gate support
structure 308. By simply attaching chain 304 onto gate 302, gate
302 may be configured to operate automatically without the need for
heavy equipment, complex installation, or additional components
such as a gear box. One advantage in this design is its compact
configuration. While conventional designs would require a larger
control box or housing for movable barrier operator 301, a smaller
and more efficient movable barrier operator 301 may be housed more
efficiently, for example see FIG. 3(d).
[0064] Typically, gate 302 travels on track 306 utilizing chain 304
to transfer the mechanical force generated by movable barrier
operator 301. Chain 304 may be coupled or attached to gate 302 by
any appropriate method without deviating from the scope of the
present invention. It may be desirable to implement a simple method
of connecting chain 304 such as by using chain bolt 305 to attach
said chain 304 to a lower portion of gate 302. This offers an
inexpensive method in accord with the simplicity of the present
invention.
[0065] FIG. 3(b) illustrates a more detailed view of the various
components that comprise the embodiment shown in FIG. 3(a), more
specifically, FIG. 3(b) illustrates some inner components of
movable barrier operator 301, which are controlled by controller
303 from a remote location to save space and further compact
movable barrier operator 301.
[0066] Movable barrier operator 301 is typically mounted on a frame
structure such as a chassis or frame 309. Movable barrier operator
301 is retrofitted with sprocket 310 so that sprocket 310 may be
coupled with chain 304. Guiding wheels or idle sprockets 311 may be
attached or installed onto frame 309 in order to keep chain 304
properly mounted and coupled with sprocket 310.
[0067] Although the embodiment illustrated shows movable barrier
operator 301 located in a lower portion of gate 302, movable
barrier 301 operator may be installed in any other location as long
as movable barrier operator 301 is mechanically coupled to chain
304 in order to transfer the desired mechanical force from
generated by its hub motor device to actuate and control said gate
302.
[0068] Typically, controller 303 is connected to movable barrier
operator 301 using wire conduit 307 which runs from gate 302 to
some remote location on the premise where movable barrier operator
301 has been installed. Controller 303 serves as the means to
monitor and control movable barrier operator 301 so it is typically
accessible to personnel which may access controller 303. However,
and without limiting the scope of the present invention, controller
303 may be mounted directly onto frame 309.
[0069] In an exemplary embodiment, wire conduit 307 provides a
direct line of communication between movable barrier operator 301
and controller 303 in addition to providing movable barrier
operator 301 with a power source. This configuration may be
desirable to keep movable barrier operator 301 simple to install
without the need for other components.
[0070] However, and without deviating from the scope of the present
invention, in another embodiment, movable barrier operator 301 may
be battery powered. A battery (not shown), connected to a small
controller (not shown) may be installed or coupled to frame 309.
Such controller may then be able to send and receive information
wirelessly thus circumventing the need for wire conduit 307 and
controller 303. Notably, this embodiment would require more
sophisticated technology (presently available) which may increase
the cost of movable barrier operator 301 and ultimately access
system 300. Furthermore, attaching a controller and battery
directly to frame 309 may require stronger materials for frame 309
and additional maintenance to movable barrier operator 301 to for
example, assure that said battery is properly charged, etc.
[0071] In an exemplary embodiment, frame 309 supports hub motor
314, battery 313 (see FIG. 3(d)) and is covered by housing 315 to
protect the various components and mechanical parts such as
sprocket 310, idle wheels 311 and their mechanical contact with
chain 304.
[0072] FIG. 3(c) illustrates such embodiment. FIG. 3(c) illustrates
a side view of movable barrier operator 301 shown above in FIG.
3(a) and FIG. 3(b), with housing 315 encasing the installation
arrangement of a hub motor used to operate gate 302 in accordance
with one embodiment of the present invention.
[0073] Housing 315 may be made of any known material proper for
protecting movable barrier operator 301 from common wear and tear
and in particular to protect its components from the elements.
Housing 315 is shown with opening 312 to allow movement of chain
304 and protect movable barrier operator 301's connectivity with
chain 304 and ultimately gate 302. While such covers or housings
such as housing 315 are known in the art, they usually house a
number of components including various types of electronics that
must be implemented to smoothly actuate a movable barrier such as
gate 302.
[0074] FIG. 3(d) illustrates the internal configuration of movable
barrier operator 301 which has been housed or encased in housing
315. Hub motor 314 is supplied with an electrical power source via
a rechargeable battery 313. Hub motor 314 is controlled via wire
conduit 307 to operate gate 302. This simplistic design comprises
attaching said hub motor 314 to frame 309 and coupling sprocket 310
to output shaft 316.
[0075] In an exemplary embodiment, sprocket 310 may be installed in
a manner so that its mechanical contact with chain 304 allows hub
motor 314 to move gate 302 at a substantially similar speed as the
rotation of output shaft 316, with idle wheels 311 helping to keep
chain 304 in proper place.
[0076] For example, and without limiting the scope of the present
invention, hub motor 314 may be retrofitted with sprocket 310
directly on output shaft 316. As output shaft 316 is turned by hub
motor 314, sprocket 310 and idle wheels 311 keep chain 304 in
continuous contact so that the energy produced by hub motor 314 is
properly used as mechanical energy to move chain 304 and operate
gate 302. By rotating its output shaft 316 clock-wise and
counter-clockwise, hub motor 314 is able to move chain 304 in a
horizontal plane, thus sliding gate 302 back and forth, to and
from, opened and closed positions; such movement being dictated by
predetermined parameters a user may program via controller 303.
[0077] Hub motor 314 may receive a wide variety of signals
pertaining to such parameters. For example, and without limiting
the scope of the present invention, such parameters may include
limits of operation for the close position of movable barrier
operator 301, limits of operation for the open position, time
delays for automatic functions such as automatic closing of gate
302, time delays for sending commands to a device such as another
movable barrier in the same premises as access system 300, levels
of sensitivity in detecting obstructions, voltage of operation for
related devices, internal control voltages for different power
supplies, and motor parameters such as speed and gate
positions.
[0078] Depending on the complexity of the access system for which
movable barrier operator 301 will be utilized, it may be desirable
to adapt housing 315 and frame 309 in a manner so that the internal
components of movable barrier operator 301 are especially
protected.
[0079] For example, and without limiting the scope of the present
invention, it may be desirable to construct frame 309 of a rigid
material such as light metal. Housing 315 on the other hand may be
preferred in a lightweight plastic that is durable and able to
withstand various weather conditions. Frame 309 may be made of any
material strong enough to hold a small motor such as hub motor 314
and the additional weight of chain 304, or may be adapted to
support various other components such as sensor components,
controller components, monitoring components, or any other
additional hardware that be utilized with movable barrier operator
301. Additionally, housing 315 and frame 309 may be configured in
such a way as to provide different mounting options for several
types of gates or other kinds of movable barriers.
[0080] In one embodiment a metal material is used to manufacture
frame 309 which may be drilled or retrofitted with mounting
fixtures in order to allow installation of frame 309 directly onto
a structure, for example to rest on a top portion of gate support
structure 308 and hang over gate 302. Such embodiment would further
comprise of positioning chain 304 on a top portion of gate 302 so
as to make mechanical contact with movable barrier operator 301. In
another embodiment, discussed below in reference to FIG. 5, frame
309 may be configured for universal installation on a variety of
sizes of gates.
[0081] In yet another embodiment, it may be desirable to add a
cosmetic cover to frame 309 for aesthetic purposes. A cover may
provide protection from exposure and keep sprocket 308, sprockets
310 and hub motor 314 from being damaged by the weather.
[0082] FIG. 4 illustrates yet another embodiment in accordance with
the present invention wherein a movable barrier operator is coupled
directly to a movable barrier, for example a gate, without the need
for external gears or belt systems to optimize actuation, while
preserving space. A simple design utilizing a hub motor can achieve
these objectives wherein the hub motor is placed underneath a
gate.
[0083] Movable barrier operator 400 comprises hub motor 401 which
has been mounted underneath gate 403. Movable barrier operator 400
further comprises casing 402 installed at least partly underground,
articulated arm 404 which connects with hub motor 401's output
shaft 405, and is supplied power from a remote source (not shown)
via conduit 406.
[0084] Hub motor 401 may be held in place against casing 402 by
bolts; hinge 407 allows casing 402 to swing open and allow a user,
for example an installer, to access motor 401. Furthermore, to add
stability, casing 402 may be reinforced against post 408 via bolts
or any other known method.
[0085] This simple, compact design allows for movable barrier
operator 400 to be placed at nearly any type of access system
including access systems designed for indoors. For example, and
without limiting the scope of the present invention, movable
barrier operator 400 may be installed at premises wherein a high
level of security is required, thus requiring heavy barriers or
gates that must be automated in order to actuate. Such doors
typically require high torque which is usually attained with heavy
gearing, beltways or pulley systems. Utilizing movable barrier
operator 400 with hub motor 401 may streamline such access systems
with fewer components, less maintenance, and higher power
output.
[0086] Turning to the next figure, FIG. 5 illustrates one
embodiment of the present invention that is easily adaptable to
various shapes and sizes of barriers, for example different types
of gates, do to its small size and lack of external gear
system.
[0087] Movable barrier operator 500 is similar to movable barrier
operator 301, however, movable barrier operator 500 has been
configured to be universally adaptable. As shown, movable barrier
operator 500 may be installed on post 501 so as to be able to slide
up and down post 501 depending on the size of gate 502 or
positioning desired for a particular application.
[0088] For example, and without deviating from the scope of the
present invention, gate 502 may be a gate located in a geographical
are wherein harsh weather such as snow often fall. To prevent rust
and damage, an installer or user may decide to mount movable
barrier operator 500 at high position on post 501. Naturally, chain
504 and chain bolt 503 would need to be similarly position so as to
allow proper operation of gate 501.
[0089] In another example, gate 502 is located in a luxurious gated
community wherein aesthetically pleasing designs are preferred. In
such embodiment movable barrier operator may be placed very low to
the ground in an inconspicuous place so as to position chain 504
running along a covered foot of gate 502.
[0090] FIG. 6(a) illustrates another embodiment in which a small
control box contains all necessary components for a movable barrier
operator, and FIG. 6(b) illustrates a similar embodiment of the
present invention wherein a motor hangs from a post; this simpler
design incorporates the use of a remote location for the controller
and power source.
[0091] Both embodiments consist of gate 600, articulated arm 601,
clutch 602, hub motor 603, and wire conduit 604. The embodiment
illustrated in FIG. 6(a) further comprises a control box 607 which
houses controller 605 and hub motor 603. This embodiment may be
desirable to protect a movable barrier operator from tough
conditions, for example in agricultural settings or geographical
locations that experience extreme weather. Typically control box
607 is constructed of a durable light weight material and may be
easily removed for maintenance or updating controller 605's
firmware.
[0092] As hub motor 603 rotates, its output shaft generates
mechanical energy, thus clutch 602, being attached to said hub
motor 603, turns articulated arm 601 to swing open gate 600.
Naturally, the embodiment illustrated in FIG. 6(b) operates gate
600 in a similar fashion.
[0093] A desirable advantage of the later embodiment is the
elimination of parts and components to operate gate 600. Instead of
controller case 607, hub motor 603 hangs from a support beam 606,
for example a post or similarly simple fixture--this provides easy
access to the motor in case a replacement is required or
adjustments need to be performed. In an exemplary embodiment,
support beam 606 is adjustable to allow users flexibility when
installing.
[0094] Furthermore, instead of installing the controller by gate
600, controller 605 (not shown in FIG. 6(b)) is positioned in a
remote location accessible to an installer or user. For example,
and without deviating from the scope of the present invention,
controller 605 is located inside a building which provides a power
source (not shown) and communicates with hub motor 603 for remotely
monitoring or operation purposes via conduit 604.
[0095] FIG. 7 illustrates yet another embodiment in accordance with
the present invention, in which a movable barrier operator may be
installed very low to the ground to avoid installing large fixtures
on a user's property and preserve aesthetic appeal, for example, of
an expensive swing gate at the entry point of a large estate. This
embodiment of the present invention comprises swing gate 700,
articulated arm 701, hub motor 702, base 703, conduit 704, and
controller 705.
[0096] Hub motor 702 is exposed so as to provide easy access in
case of repair or replacement. A power source may be located inside
a home, for example, and provided to Hub motor 702 via conduit 704.
Similarly, controller 705 may too be located inside said home (not
shown) for access by users.
[0097] Base 703 supports hub motor 702 while allowing a clearance
from the ground. By placing clutch 706 low to the ground,
articulated arm 701 is able to operate swing gate 700 without
interfering with the aesthetic appeal of swing gate 700. This
configuration is very desirable in the gate industry with
particular preference of clients that spend many thousands of
dollars on such expensive gates, and who desire to have components
such as articulated arm 701 hidden away or away from view of, for
example, swing gate 700.
[0098] Since the present invention for a movable barrier operator
eliminates the need for complex belt systems, additional external
gear boxes, or phase control mechanisms, a user is provided with
the flexibility to position, mount, or install a movable barrier
operator in accordance with the present invention, in a wide range
of configurations depending on a user's needs.
[0099] FIG. 8 illustrates yet another embodiment in accordance with
the present invention wherein a movable barrier operator is
installed directly to a barrier's drive mechanism, for example a
roll-up gate, without the need for gears or belt systems to
optimize actuation and preserve space.
[0100] Normally a roll-up door such as roll-up door 800 must use
beltway systems or a gearbox in order for a conventional motor to
properly and smoothly actuate door 800. And even with the use of
conventional gear systems to move such barriers, actuation and
operation is often rough due to the low torque at slow speeds. Such
conventional means of moving a barrier need additional components
in order to control the frequency of a voltage fed to a
conventional motor. Without the use of any external gear box or
additional external gearing, hub motor 801 may be mounted and
installed directly into door 800's main drive mechanism via output
shaft 804 with few modifications.
[0101] The remaining equipment would only comprise conduit 803 to
provide communication and power from controller 802, where users
may monitor and control door 800's operation. Upon actuation, door
800 may be rolled up or rolled down, being held in place and guided
by tracks 805, from a close position to an open position and
vice-versa.
[0102] Hub motors in accordance with the present invention are a
compact motor that uses electromagnetic properties to create
mechanical work with minimal energy loss. These motors offer very
high torque at very low speeds thus making these motors ideal tools
to implement with an access system.
[0103] A movable barrier operator in accordance with the present
invention can be used with any access system that controls a
barrier to an entry, an exit, or a view, utilizing hub motors. The
barrier could be a door for a small entity (i.e. a vehicle), or a
gate for a large entity (i.e. a building), which can swing out,
slide open, fold or even roll upwards.
[0104] A compact movable barrier operator in accordance with the
present invention may be implemented in a variety of embodiments
for a wide range of applications. For example, and without limiting
the scope of the present invention, a hub motor operated movable
barrier operator in accordance with the present invention may be a
swing gate operator, a window operator, a garage door operator, a
slide gate operator, a roll-up door operator, a sliding-door
operator, a regular door operator, a revolving door operator, a
vehicular door operator, or a vehicular top operator (e.g. a top
for a convertible vehicle).
[0105] Furthermore, this disclosure does not necessarily exclude
the implementation of any type of gearing system in conjunction
with a hub motor operated movable barrier operator as defined
herein, however, the reduction of external parts, reduced
maintenance, and all other advantages served by a system which
excludes external gearing is desirable. Nevertheless, an embodiment
in which some type of gearing system is implemented with a hub
motor does not deviate from the scope of the present invention.
[0106] A system for high torque operation of a movable barrier
utilizing a compact hub motor device has been described. Clearly,
many of the components described in the various embodiments of the
present invention may be substituted with other equivalent
components without deviating from the scope of the present
invention. For example, pulleys and belts may substitute chains and
sprockets utilized to actuate a movable barrier. The foregoing
description of the various exemplary embodiments of the invention
has been presented for the purposes of illustration and disclosure.
It is not intended to be exhaustive or to limit the invention to
the precise form disclosed. Many modifications and variations are
possible in light of the above teaching. It is intended that the
scope of the invention not be limited by this detailed description,
but by the claims and the equivalents to the claims.
* * * * *