U.S. patent application number 13/813233 was filed with the patent office on 2013-06-27 for integrated controller for closure operator unit.
This patent application is currently assigned to AUTOMATIC TECHNOLOGY (AUSTRALIA) PTY LTD. The applicant listed for this patent is Geoff Baker, Ray Hawkins, Nikolai Klepikov, Jasbir Singh, Travis William Smith. Invention is credited to Geoff Baker, Ray Hawkins, Nikolai Klepikov, Jasbir Singh, Travis William Smith.
Application Number | 20130162190 13/813233 |
Document ID | / |
Family ID | 45529290 |
Filed Date | 2013-06-27 |
United States Patent
Application |
20130162190 |
Kind Code |
A1 |
Smith; Travis William ; et
al. |
June 27, 2013 |
INTEGRATED CONTROLLER FOR CLOSURE OPERATOR UNIT
Abstract
An integrated controller for an operator unit for powering an
overhead garage roller door or roller shutter is described. The
operator unit comprises a motor, an output drive assembly, a timing
assembly unit, and a clutch assembly for providing selective
engagement between motor powered operation and manual operation
(provided by a chain rotating a chain wheel). The motor is arranged
to drive a shaft which, in turn, provides drive to the roller door
or shutter assembly (not shown), which includes an axle around
which the roller door or shutter is wound. The integrated
controller comprises an inverter for receiving a single phase power
supply and supplying three phase power to drive the motor; and a
drive controller in operable association with the inverter for
providing active management of the operation of the motor.
Inventors: |
Smith; Travis William; (Box
Hill, AU) ; Klepikov; Nikolai; (Carnegie, AU)
; Singh; Jasbir; (Taylors Hill, AU) ; Hawkins;
Ray; (Frankston, AU) ; Baker; Geoff; (Geelong,
AU) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Smith; Travis William
Klepikov; Nikolai
Singh; Jasbir
Hawkins; Ray
Baker; Geoff |
Box Hill
Carnegie
Taylors Hill
Frankston
Geelong |
|
AU
AU
AU
AU
AU |
|
|
Assignee: |
AUTOMATIC TECHNOLOGY (AUSTRALIA)
PTY LTD
Keysborough, VIC
AU
|
Family ID: |
45529290 |
Appl. No.: |
13/813233 |
Filed: |
August 1, 2011 |
PCT Filed: |
August 1, 2011 |
PCT NO: |
PCT/AU11/00965 |
371 Date: |
February 22, 2013 |
Current U.S.
Class: |
318/490 ;
307/328 |
Current CPC
Class: |
H02K 9/04 20130101; H02P
29/024 20130101; H02P 29/0241 20160201; H02K 5/22 20130101; H02P
1/30 20130101; H02K 11/33 20160101; H02K 7/1085 20130101; F16P 3/00
20130101; H02K 7/1004 20130101; E05Y 2900/106 20130101; H02P 31/00
20130101; H02K 5/18 20130101; E06B 9/70 20130101; H02K 5/10
20130101; E05Y 2201/434 20130101; H02P 5/68 20130101 |
Class at
Publication: |
318/490 ;
307/328 |
International
Class: |
H02P 31/00 20060101
H02P031/00; F16P 3/00 20060101 F16P003/00 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 30, 2010 |
AU |
2010903422 |
Claims
1. An integrated controller for an operator unit having a three
phase motor for driving a closure, the controller comprising: an
inverter for receiving a single phase power supply and supplying
three phase power to drive the motor; and, a drive controller in
operable association with the inverter for providing active
management of the operation of the motor.
2. An integrated controller according to claim 1, wherein the
inverter and the drive controller are arranged to be controlled by
a single integrated micro-controller.
3. An integrated controller according to claim 1 or claim 2,
wherein the inverter and the drive controller are arranged on a
common circuit board.
4. An integrated controller according to any preceding claim,
wherein the inverter includes an inverter micro-controller
programmed so as to manage operation of the inverter, the inverter
micro-controller operably interconnected with an inverter driver to
generate the required three-phase waveforms for supply to the
motor, the inverter micro-controller arranged to receive input
signal information relating to the operation and performance of the
inverter driver, and to communicate such information to said drive
controller.
5. An integrated controller according to claim 4, wherein said
information relates to at least one of temperature, current level,
and voltage level.
6. An integrated controller according to claim 5 or claim 6,
further including an electrical power supply module arranged to
supply power to both the drive controller and the inverter
driver.
7. An integrated controller according to any preceding claim,
including a first communication link between the controller and
inverter, to allow first signal information to be sent to the
inverter from the controller, the first signal information
comprising operation instructions for operation of the motor.
8. An integrated controller according to claim 7, including a
second communication link between the controller and the inverter,
to allow second signal information to be sent from the inverter to
the controller, the second signal information comprising status
information relating to the performance of the inverter.
9. An integrated controller according to any preceding claim,
wherein the controller is configured so as to store a history of
events relating to the operation of the operator unit.
10. An integrated controller according to claim 9, wherein the
events include at least one of the open/close cycles of the
closure, and any faults that occur during operation of the operator
unit.
11. An integrated controller according to claim 9 or 10 insofar as
dependent on claim 8, wherein status information relating to
inverter faults, comprises diagnostic information specifying the
status of the inverter at the time the fault occurred, said
inverter status information including at least one of the
following: the level of supply voltage at the time fault occurred;
(ii) the level of current at the time fault occurred; (iii) the
motor drive current limit; (iv) the motor drive current level; (v)
the Insulated Gate Bipolar Transistor (IGBT) driver temperature at
fault; and (vi) identification of an IGBT driver fault.
12. An integrated controller according to any one of claims 8 to
11, including a third communications link between the controller
and the inverter, to allow third signal information to be sent to
the inverter from the controller, the third signal information
comprising override instructions to allow the controller to
override existing operational commands previously sent to the
inverter.
13. An integrated controller according to claim 12, said third
communication link configured to allow the controller to provide
override instructions directly to the inverter driver to cease
operation of the motor.
14. An integrated controller according to claim 12 or claim 13,
wherein the controller is configured to instruct the inverter, by
way of the third communications link, to cease operation in the
event that one of the first and second communication links is
lost.
15. An integrated controller according to any one of claims 8 to
14, wherein the communication between the controller and inverter
is arranged so that, in the event of a fault and the motor
operation ceasing, operation of the inverter can be recovered
without terminating operation of the controller.
16. An integrated controller according to any preceding claim,
wherein the controller is configured so as to provide information
to an operator in the event a fault occurs, and to receive reset
instructions from the operator to selectively reset the operation
of the operator unit.
17. An integrated controller according to any one of claims 8 to
16, including a further communications link between a position
sensor and the controller, the position sensor arranged so as to
monitor movement of an output of the operator unit for continually
providing information regarding the position of the closure.
18. An integrated controller according to any one of claims 8 to
17, wherein the operator unit comprises a clutch assembly for
selectively engaging drive between an auxiliary drive and the
closure, the controller including a further communications link
between said clutch assembly and the controller for signalling
whether or not said auxiliary drive has been engaged to drive the
closure.
19. An integrated controller according to any preceding claim,
including or associated with a heat sink assembly arranged in
thermal communication with the inverter for dispersing heat away
from the inverter driver during operation.
20. An integrated controller according to any preceding claim,
wherein the inverter and the drive controller are provided within a
common controller housing.
21. An integrated controller according to claim 20, wherein the
controller housing is arranged so as to be mountable directly to a
housing of the motor.
22. An integrated controller according to claim 21, wherein the
controller housing is arranged so that it cannot be removed from
the motor housing without interrupting the power supply to the
integrated controller.
23. An integrated controller according to claim 21 or claim 22,
wherein the controller housing comprises a subcompartment allowing
access via a removable access cover to a selected portion of the
componentry of the controller, the subcompartment including a
sensor activated on removal of the access cover, and configured to
cut power supply to the controller when the access cover is
removed.
24. An integrated controller according to claim 23, wherein a part
of the subcompartment access cover is arranged to operate a
switch.
25. An integrated controller according to claim 24, wherein said
access cover part is arranged to register with a spring element
contacting the switch.
26. An integrated controller according to claim 24 or claim 25,
configured such that the supply of power to the controller is
restored once the switch registers that the access cover is back in
place.
27. An integrated controller according to claim 21 or any one of
claims 22 to 26 insofar as dependent thereon, wherein the
integrated controller and the motor are arranged for electrical
interconnection using a power connection means, the power
connection means comprising a first connector element provided in
the motor housing, and a complimentary second connector element
provided in the controller housing.
28. An integrated controller according to claim 27, wherein the
second connector element is arranged to project downwardly from the
controller, and the first connector element arranged on an upward
facing part of the motor housing.
29. An integrated controller according to claim 27 or claim 28,
wherein the power connection means is provided with a sealing
assembly to protect against the ingression of foreign matter, the
sealing assembly positioned between the controller housing and the
motor housing when both are brought together.
30. An integrated controller according to claim 29, wherein the
sealing assembly comprises one or more seal elements surrounding
the power connection means, such that interconnecting the
controller housing and the motor housing results in substantially
sealing the power connection means from the environment.
31. A cooling assembly for cooling an inverter of an operator unit
arranged for driving a closure, the inverter arranged in thermal
communication with a heat sink assembly, the cooling assembly
arranged so as to be mountable in close proximity to the heat sink
assembly so as to drive a flow of air over the heat sink to effect
cooling.
32. A cooling assembly according to claim 31, wherein the operator
unit includes a motor driving a motor shaft arranged to provide
output drive to said closure, the assembly including a fan
comprising fan blades mounted on and rotated by said motor shaft,
fan blades arranged to provide a flow of air to effect the cooling
of said heat sink assembly.
33. A cooling assembly according to claim 32, including a fan
housing having apertures to allow air to be drawn in by action of
the fan blades and passed over the heat sink.
34. A cooling assembly according to claim 33, wherein said
apertures are provided in a part of said fan housing at or
proximate to an end of said motor shaft.
35. An operator unit for driving a closure, the operator unit
including an integrated controller as defined in any one of claims
1 to 30, and/or a cooling assembly as defined in any one of claims
31 to 34.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an integrated controller
for an operator unit for driving a closure. In one aspect, the
invention relates to an integrated controller for an operator unit
having a motor for driving a closure such as an overhead garage
door.
BACKGROUND OF THE INVENTION
[0002] In this specification, where a document, act or item of
knowledge is referred to or discussed, this reference or discussion
is not an admission that the document, act or item of knowledge or
any combination thereof was at the priority date: [0003] (i) part
of common general knowledge; or [0004] (ii) known to be relevant to
an attempt to solve any problem with which this specification is
concerned.
[0005] Power-driven closures--such as roller doors, shutters, gates
and the like--are very widely used for controlling access to
buildings and other areas, such as garages, driveways, warehouses,
factories, etc. Such closures are typically driven by an electric
drive operator unit positioned to one side of the closure. For an
overhead roller door or roller shutter, the output drive shaft of
the operator unit is arranged to rotate a drum or similar assembly
arranged to rotate about an axle, around which the door is wound
and unwound, and the operator unit is mounted at or adjacent to one
end of the axle.
[0006] Such operator units, particularly those for relatively
heavy-duty applications such as industrial doors, gates or
shutters, commonly include three-phase electric motor units for
driving the closure. Such units therefore require the provision of
a three phase power source and a suitable controller for
controlling the operation of the motor via the three phase
supply.
[0007] In such applications, prior art controller and power source
arrangements have generally proven to be relatively complex and
somewhat inconvenient. Installation needs to be completed by
qualified electricians. Further, such arrangements generally
provide limited ability for restoring operation in the event a
fault occurs. In such instances, the services of a qualified
electrician are once again usually required, to perform the
appropriate diagnostic tests to determine the nature of the fault
and restore the controller operation. Such an exercise effectively
removes the operator unit from service until the repair is
complete, which is costly and inconvenient.
[0008] Accordingly, although controller and power supply
arrangements for such operator units are known, there is a need for
an improved solution.
SUMMARY OF THE INVENTION
[0009] According to a first aspect of the present invention, there
is provided an integrated controller for an operator unit having a
three phase motor for driving a closure, the controller comprising:
[0010] an inverter for receiving a single phase power supply and
supplying three phase power to drive the motor; and, [0011] a drive
controller in operable association with the inverter for providing
active management of the operation of the motor.
[0012] The drive controller and the inverter are thus arranged to
function in an integral manner, thereby providing improved
management and control over operation of the motor.
[0013] Preferably, the inverter and the drive controller are
provided within a common controller housing. The controller housing
is preferably mounted directly to a housing of the motor. In one
form, the controller housing cannot be removed from the motor
housing without interrupting the power supply to the integrated
controller.
[0014] Preferably, the inverter includes an inverter
micro-controller programmed to manage operation of the inverter,
operably interconnected with an inverter driver to generate the
required three-phase waveforms for supply to the motor, whereby the
inverter micro-controller is arranged to receive input signals
relating to the operation and performance of the inverter driver,
and to communicate this information to the drive controller. This
information may include temperature, current level or voltage
level.
[0015] The inverter micro-controller may be arranged to receive one
or more input signals relating to the operation and performance of
the inverter, such as temperature, current, or voltage levels, and
to provide such information to the controller.
[0016] In a preferred form, the inverter driver is arranged to
supply the three phase power to the motor at a frequency
controllable between 0 and 120 Hz.
[0017] Preferably, the integrated controller includes an electrical
power supply module arranged to supply power to both the drive
controller and the inverter driver.
[0018] The inverter and the drive controller may be controlled by a
single integrated micro-controller.
[0019] A first communication link between the drive controller and
inverter may be provided to allow first signal information to be
sent to the inverter from the drive controller, the first signal
information comprising operation instructions for operation of the
motor (such as speed and direction instructions).
[0020] A second communication link between the controller and
inverter may be provided to allow second signal information to be
sent from the inverter to the drive controller, the second signal
information comprising status information relating to the
performance of the inverter. The inverter status may thus be
monitored by the controller.
[0021] The controller may be configured to store a history of
events relating to the operation of the unit. Such events may
include open/close cycles of the closure and any faults that occur
during operation.
[0022] In the event that the inverter should develop a fault, the
status information can provide diagnostic information relating to
the status of the inverter at the time the fault occurred (the time
noted and stored by way of a time stamp function). The diagnostic
information may therefore be used to further provide active
performance management of the operation of the inverter. The status
information may include, the following operational parameters:
[0023] the level of supply voltage at the time fault occurred;
[0024] the level of current at the time fault occurred; [0025] the
motor drive current limit; [0026] the motor drive current level;
[0027] Insulated Gate Bipolar Transistor (IGBT) driver temperature
at fault; [0028] IGBT driver fault.
[0029] A third communications link between the controller and the
inverter may be provided to allow third signal information to be
sent to the inverter from the controller, the third signal
information may comprise override instructions. This allows the
controller to override existing operational commands previously
sent to the inverter, for situations in which, for example a fault
has occurred. In such cases, the controller may provide override
instructions directly to the inverter driver to cease operation of
the motor.
[0030] The controller may be arranged by way of the third
communications link to instruct the inverter to cease operation in
the event that one of the first and second communication links is
lost.
[0031] The communication between the controller and inverter may be
arranged so that, in the event of a fault and the motor operation
ceasing, operation of the inverter can be recovered without the
need to terminate operation of the controller. When a fault occurs,
the controller may be configured to provide information to an
operator who can then selectively reset the operation of the
unit.
[0032] A further communications link may be provided between a
position sensor and the controller. The position sensor is arranged
to monitor movement of an output of the operator unit, such as
rotation of the driven shaft, so to continually provide information
regarding the position of the closure. The controller is thus able
to continuously monitor the position, speed and direction of the
closure throughout its movement cycle between open and closed
positions.
[0033] The transfer of signal information from the position sensor
is coordinated by the controller.
[0034] A further communications link may be established between a
clutch assembly (for selectively engaging drive between an
auxiliary drive and the closure) and the controller, for signalling
whether or not an auxiliary drive has been selectively engaged to
drive the closure. The clutch assembly may include a switch
arranged to detect when an attempt is made to engage the auxiliary
drive to drive the closure, and accordingly to provide an
appropriate signal to the controller. When such a signal is
received, the controller ceases operation of the motor. Once the
auxiliary drive is then disengaged, the controller resumes
operation of the motor.
[0035] The controller may comprise a user console unit, for
operation by a user. The controller is arranged in communication
with the user console unit by way of a further communications link,
such as a serial cable.
[0036] This further communications link may provide wireless
communication between the controller and the user console unit
using a suitable wireless protocol.
[0037] The user console unit may include a display, to provide to
the user information relating to the operation of the operator
unit. This may include drive speed and direction information, and
or fault diagnostic data.
[0038] The user console unit allows the user to interact with the
controller to set and adjust the operational parameters of the
operator unit. For example, the user console unit may allow the
user to program the end limits of travel of the closure, and to set
safety parameters such as the resistance encountered during travel
at which closure operation ceases or reverses.
[0039] The user console unit and/or the controller may be arranged
to interface with a remote control device to allow remote wireless
operation of the operator unit.
[0040] The integrated controller may include a filter module for
suppressing electronic noise signals from affecting the mains
supply, as is commonly required for inverter systems.
[0041] The inverter and the drive controller may be arranged on a
common circuit board fastened to a chassis part of the controller
housing.
[0042] In another embodiment, the filter, controller and inverter
may be arranged on a common circuit board fastened to the chassis
part of the controller housing.
[0043] The integrated controller preferably includes or is
associated with a heat sink assembly arranged in thermal
communication with the inverter for dispersing heat away from the
inverter driver during operation.
[0044] The heat sink assembly may comprise a plurality of planar
elongate fins for effecting heat dispersal to the surrounding
environment.
[0045] The heat sink assembly is arranged to be mounted to the
housing of the integrated controller to prevent the ingress of
foreign matter such as dust and moisture.
[0046] As discussed above, the integrated controller housing may be
mounted directly to the motor housing, and this mounting may be
configured to afford an operable interconnection between the two to
provide a `plug and play` unit. This arrangement offers convenience
to the user, by avoiding the need for the services of a qualified
electrician when the unit is installed or removed for
repair/maintenance purposes.
[0047] This form of the invention may be applicable to controllers
of a wide variety of different types, for use in different types of
operators, and in this aspect the invention therefore provides an
electrical controller for an operator unit having a motor for
driving a closure, the controller having a controller housing
mountable directly to a housing of the motor.
[0048] The controller housing may be fastened to the motor housing
by any suitable fastening means.
[0049] The controller housing may also comprise a subcompartment
allowing access via a removable access cover to a selected portion
of the componentry of the controller.
[0050] This subcompartment may be arranged to house one or more
interface ports used for one or more communications links to the
controller.
[0051] The subcompartment may be formed by a walled section
integrally moulded with the controller housing. The access cover
may be removeably fastened in position to the controller housing by
way of suitable fasteners engaged therewith. The subcompartment may
house at least one fastening means mounting the controller to the
motor, so that the two cannot be separated without removal of the
subcompartment access cover. Further, the subcompartment may
include a sensor activated on removal of the access cover,
configured to cut power supply to the controller when the access
cover is removed. This may be provided in the form of a microswitch
in operative connection with the power supply module. A part of the
subcompartment access cover may register with a spring element
contacting the microswitch. The supply of power to the controller
is restored once the micro-switch registers that the access cover
is back in place.
[0052] The integrated controller and the motor are arranged for
electrical interconnection using a power connection means. This may
comprise a plug-and-socket arrangement, with a first connector
element provided in the motor housing, and a complimentary second
connector element provided in the controller housing.
[0053] The second connector element may be arranged to project
downwardly (through an aperture formed in a chassis of the
controller) from the controller, and the first connector element
may be arranged on an upward facing part of the motor housing. The
first element may be connector pin plug, and the second element a
complementary socket.
[0054] The power connection means may be provided with a sealing
assembly to address the risk of foreign matter ingression. The
sealing assembly may be configured to be positioned between the
controller housing and the motor housing when both are brought
together. The sealing assembly comprises one or more seal elements
and/or a gland body, to surround the power connection means.
[0055] The gland body may be provided with shaped recesses to
receive respective seal elements. The recesses may be provided in
opposite sides of the gland body so that, when the controller
housing is placed upon the motor housing, each seal element seats
against a respective recess surface.
[0056] According to another aspect of the present invention, there
is provided a cooling assembly for cooling an inverter of an
operator unit according to any one of the embodiments of the first
aspect of the present invention described above, the inverter
arranged in thermal communication with a heat sink assembly, the
cooling assembly arranged so as to be mountable in close proximity
to the heat sink assembly so as to drive a flow of air over the
heat sink to effect cooling.
[0057] The cooling assembly may comprise a fan, mounted to be
driven by the motor of the operator unit. Preferably, this
comprises fan blades mounted on and rotated by the motor shaft.
[0058] The cooling assembly is preferably mounted in close
proximity to the controller heat sink assembly, to drive a flow of
air over the heat sink to effect cooling.
[0059] The fan may be configured to be driven directly by the
motor.
[0060] The fan may be provided with a fan housing having aperture
means such as apertures to allow air to be drawn in by action of
the fan blades and passed over the heat sink.
[0061] The apertures may be provided in a part of said fan housing
at or proximate to an end of said motor shaft.
[0062] According to a further aspect of the invention there is
provided an operator unit for driving a closure, the operator unit
including the above defined integrated controller and a motor. The
operator unit may further include an output drive assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
[0063] An embodiment of the invention will now be explained, by way
of example only, with reference to the accompanying drawings, in
which:
[0064] FIG. 1A shows a perspective view of a roller door operator
unit having an integrated controller in accordance with the present
invention;
[0065] FIG. 1B shows a further perspective view of the roller door
operator unit of FIG. 1A;
[0066] FIG. 2A shows a perspective view of the housing of the
controller of FIG. 1A;
[0067] FIG. 2B shows a diagrammatic representation of the
functionality of the an integrated controller in accordance with
the invention;
[0068] FIG. 3A shows a perspective view of the controller of FIGS.
1A and 1B with the controller housing removed;
[0069] FIG. 3B shows a further perspective view of the controller
of FIG. 3A;
[0070] FIG. 3C is a perspective view of a cutaway section of the
controller of FIG. 3A, sectioned along the longitudinal centre of
the chassis;
[0071] FIG. 4 shows a further perspective view of the controller of
FIG. 2A, with the access panel removed;
[0072] FIG. 5A shows a perspective cutaway view of the connecting
assembly of the controller of FIG. 2A, when sectioned along the
centre longitudinal axis;
[0073] FIG. 5B shows a cross sectional view of the connecting
assembly of FIG. 5A;
[0074] FIG. 6 shows a perspective cutaway view of a portion of the
controller of FIG. 2A;
[0075] FIG. 7A shows a close-up perspective view of the fan and
heat sink assemblies of the controller of FIG. 1B; and
[0076] FIG. 7B shows a perspective cutaway view of the assemblies
of FIG. 7A, sectioned along the axis of the drive shaft.
DETAILED DESCRIPTION OF THE DRAWINGS
[0077] With reference to FIGS. 1A and 1B, there is shown an
operator unit 2 for powering an overhead garage roller door or
roller shutter. Operator unit 2 comprises a motor 4, an output
drive assembly 6, a timing assembly unit 7, and a clutch assembly 8
for providing selective engagement between motor powered operation
and manual operation (provided by a chain 10 rotating a chain wheel
11). Motor 4 is arranged to drive a shaft 12 which, in turn,
provides drive to the roller door or shutter assembly (not shown),
which includes an axle around which the roller door or shutter is
wound. Operator unit 2 is supported in position by a mounting 14.
The operator unit 2 further includes an integrated controller 16
for providing power to and control of the operation of the motor 4.
The skilled reader will appreciate that the output drive shaft
could readily be arranged to operate other types of closures such
as chain-driven overhead doors, sliding doors, sectional doors,
shutters, gates and the like.
[0078] The integrated controller 16 of FIGS. 2A and 2B comprises an
inverter schematically represented by reference 18, arranged for
receiving a high voltage single phase power supply 20 and supplying
three phase power 22 to motor 4. Controller 16 further comprises a
drive controller 24 arranged in operable association with the
inverter 18 for providing active management of the operation of the
motor 4. The controller 24 and inverter 18 are configured to
function in an integrated manner for providing management of the
operation of the motor 4.
[0079] The controller 24 and inverter 18 are arranged in
communication with one another via a first 26a, a second 26b and a
third 26c communications link.
[0080] Inverter 18 includes a micro-controller 28 arranged to
manage operation of the inverter, and an inverter driver 30 to
generate and provide the required three phase waveforms for motor 4
at a required voltage and at a desired frequency between 0-120
Hz.
[0081] Inverter micro-controller 28 manages operation of the
inverter driver 30, and is further arranged to receive input
signals relating to the operation of inverter driver 30, such as,
for example, temperature and current/voltage levels, and to provide
such information to the controller 24.
[0082] The controller 16 is arranged to receive a single phase
power supply from the mains supply 38 (through connection means 39)
by way of a power receiving module 36. This supplies power to both
the controller 24 and the inverter 18. The power receiving module
36 is associated with a filter module 32 for filtering the power
supplied to the unit, in order to suppress electronic noise signals
which might otherwise feed back into the mains supply, as is common
with such devices.
[0083] Signal information from the controller 24 to the inverter 18
by way of first communications link 26a comprises instructions for
changing operational parameters (speed and the direction of motor
4). Signal information from the inverter 18 to the controller 24 by
way of second communications link 26b comprises status information
relating to the operational performance of the inverter, which is
monitored by the control module 24.
[0084] The controller 24 is configured to maintain (by way of an
internal memory storage means) a history of the last 64 operational
events, being open/close cycles of the closure and the faults (and
types of those faults) that have occurred during operation. It will
appreciated that the amount of information that can be stored will
be dependent on the memory capacity of the controller 24. In
addition, the controller 24 may be configured to maintain a record
of the number of instances a particular type of fault occurs.
[0085] Once a fault is detected, the controller 24 may initiate a
fault state which remains effective until the user acknowledges the
fault by, for example, pressing a button on the user console unit
(see below), or switching the controller power off and on.
[0086] The controller 24 may be arranged so that, if a fault occurs
in the inverter 18, the status information provides diagnostic
information on the status of the inverter 18 and the time the fault
occurred (by way of a time stamp utility), to further afford active
performance management of the operation of the inverter 18. The
status information may include, for example, the following
operational parameters: [0087] the level of supply voltage at the
time fault occurred; [0088] the level of current at the time fault
occurred; [0089] the motor drive current limit; [0090] the motor
drive current level; [0091] Insulated Gate Bipolar Transistor
(IGBT) driver temperature at fault; [0092] IGBT driver fault.
[0093] Third communications link 26c is provided for override
instruction signals from the controller 24 to the inverter 18, in
the event a fault is detected. For example, if the controller
detects that the operating temperature of the inverter driver 30 is
too high, it ceases operation of motor 4. Such instructions may
operate to directly instruct the inverter driver 30, overriding the
inverter micro-controller 28. Further, the controller 24 is
programmed in such a way that if a disparity is detected between
the output of inverter 18 and commands issued by the controller
(for example, the status does not correspond to the speed and
direction instructions), the override is used to discontinue
operation of the inverter driver.
[0094] As a further failsafe measure, controller 24 is programmed
to instruct inverter 18 to cease operation of the motor in the
event communication of the first 26a or second 26b communications
links is lost.
[0095] The controller 16 is programmed so that, in the event a
fault occurs with the inverter 18 and motor 4 is shut down,
operation can be readily recovered by an operator, without the user
having to disconnect power to the controller 16 (see below for
further discussion of the user console).
[0096] A further communications link means 27a,b is provided
between timing assembly unit 7 and controller 24. Timing assembly
unit 7 is arranged to monitor rotation of the output drive assembly
6. The timing assembly 7 comprises an absolute position encoder
(not shown) arranged to detect the absolute position of the closure
at any point in the movement cycle--between preset limit points
corresponding to the full range of travel of the closure. The
transfer of signal information from timing assembly unit 7 is
coordinated by the controller 24. The absolute position encoder
provides the signal information for transfer to controller 24 to
enable the latter to continuously monitor position (27a) and speed
(27b) of the closure. It will be appreciated that the speed
information is calculated in real time from the position
information provided by the position encoder, and this calculation
can be done by timing assembly unit 7 or by controller 24.
[0097] A further communications link 29 between clutch assembly 8
and controller 24 provides a signal in response to engagement of an
auxiliary drive (such as a manually-driven chain wheel 11) with
drive shaft 12. The clutch assembly 8 includes a micro-switch (not
shown) arranged to detect engagement of the chain wheel 11 with
shaft 12. Controller 24 is programmed to override operational
commands to cease operation of motor 4 when the auxiliary drive has
been engaged, and to resume normal operation once the auxiliary
drive is disengaged.
[0098] The controller 24 is arranged in communication with a user
control unit 34 by way of a further communications link 31 (a
serial cable or the like) for operation by a user. The user control
unit 34 is installed at a location readily accessible to the user.
Communications link 31 may be a wireless link, using any
appropriate wireless protocol.
[0099] The user control unit 34 allows the user to selectively
access and display (via an LCD display or similar) information
relating to the operation of operator unit 2. Unit 34 may display
fault diagnostic data provided when a fault occurs, allowing the
user to determine the nature of the fault and to take the necessary
steps to resume operation. It will be appreciated that such
information may be accessed, displayed and stored using any
suitably appropriate functionality, such as by way of a menu-based
format. For example, user control unit 34 may be arranged so that
the load profile of the operator unit 2 over its range of travel is
graphically presented on the LCD display during operation, eg as a
bar graph or similar.
[0100] As mentioned above, the user control unit 34 allows a user
(once fault diagnosis information has been assessed) to reset the
controller without the need to disconnect power from the operator
unit, which is conventionally required for closure operators with
fault shutdown functionality. Under instruction from the user,
controller 24 is programmed to issue the appropriate operational
commands to resume operation, in accordance with prescribed
criteria.
[0101] The user control unit 34 allows the user to interact with
the controller 24 to set and adjust the operational parameters of
the operator unit 2. For example, unit 34 may be configured to
allow the user to set the speed of the closure, or to program the
limits of travel of the closure.
[0102] Controller 24 is programmed to cease operation of the motor
in the event that communication from the user control unit 34 by
communications link 31 is lost.
[0103] User control unit 34 or controller 24 may be arranged to
communicate with a remote control device (not shown) for operation
by the user.
[0104] Subsequent firmware revisions may be installed in the
controller 24 by way of the user control unit 34. Current systems
require a handheld programmer device to be plugged directly into
the controller circuitry--which may be installed well above ground
level. In the present invention, firmware for the controller 24 may
be installed (eg. during servicing of the operator unit) by
plugging the programmer device being plugged into the user control
unit 34, which is installed at a position readily accessible from
ground level. This has the effect of placing unit 34 in a
`pass-through` mode to relay instructions to the controller 24 via
the interface to the controller.
[0105] With reference to FIGS. 3A, 3B and 3C, the circuitry
(schematically represented by reference 37) of controller 24 and
inverter circuitry 18 are arranged on a common circuit board 44
which is fastened to a chassis 45 by screws 43. The circuit board
44 thus comprises all the circuitry for both the controller and the
inverter, but their respective circuits are isolated from each
other on different regions of circuit board 44.
[0106] With reference to FIG. 4, integrated controller 16 comprises
a housing 68 to house all the componentry, so that it can be
provided as a modular unit for attachment to operator unit 2.
Controller housing 68 provides a shield for preventing foreign
matter (in particular, dust and moisture) from reaching the
interior. Chassis 45 is arranged to be removably fastened to
controller housing 68 by screws 71 (shown in FIGS. 3A and 3B) which
screw into respective holes (not shown) provided in the underside
of a peripheral skirt 69 of the housing 68.
[0107] Controller housing 68 features a fastening arrangement 90
for removable attachment to operator unit 2. As shown in FIGS. 4
and 7A, controller housing 68 features four holes 90a through which
respective bolts 90b are inserted. Bolts 90b are inserted within
respective holes (not shown) formed in a housing of a cooling
assembly 46 (see below) and fastened with respective nuts (not
shown). Bolts 90b (as shown in FIG. 7A) also pass through holes 90c
(see FIGS. 3A, 3B and 3C) in chassis 45. The skilled reader will
appreciate that many other fastening arrangements known in the art
may be employed to fasten controller housing 68 in position.
[0108] The controller housing 68 also comprises a subcompartment 92
to allow access--via a removable access cover 94 (see FIGS. 1A and
2A)--to be gained to a portion of circuit board 44. Subcompartment
92 provides access to interface ports 96 to receive respective
connectors for inputs such as the micro-switch harness connecting
to clutch assembly 8, the harness connecting to timing assembly 7,
and the RS485 serial cable connecting to user control unit 34.
Subcompartment 92 is defined by walled sections integrally moulded
into the controller housing 68. Access cover 94 is removeably
fastened in position to the controller housing 68 using five screws
95a (FIG. 2A) in respective threaded holes 95b provided in the
moulded surrounds as shown. This allows the access cover 94 to be
removed while the controller housing 68 remains in place on the
operator unit, but prevents access to the remainder of the
integrated controller. It will be appreciated that some of the
bolts which attach controller housing 68 to the operator unit can
only be accessed by way of subcompartment 92.
[0109] Integrated controller 16 further comprises a heat sink
assembly 40 arranged in thermal communication with inverter driver
30 for dispersing heat away from the inverter during operation. As
shown in FIGS. 3A, 3B and 3C, heat sink assembly 40 is arranged at
one end 88 of the controller housing 68, in close proximity to
inverter driver 30. Heat sink assembly 40 comprises a plurality of
planar elongate fins 42 for effecting heat dispersal to the
surrounding environment.
[0110] Heat sink assembly 40 is attached to the outer face of a
flange 49 upstanding from chassis 45 by way of screws 41. Flange 49
features an aperture 53 to afford direct thermal communication of
the inverter driver 30 to heat sink assembly 40. A gasket 47 is
clamped between flange 49 and heat sink assembly 40 to prevent
ingress of foreign matter which might otherwise enter interior of
housing 68 by way of aperture 53.
[0111] A connecting assembly 74 provides electrical connection
between controller 16 and motor 4. When engaged, connecting
assembly 74 establishes electrical contact between the motor 4 and
the circuitry of inverter 18. The connecting assembly 74 comprises
a plug-and-socket arrangement comprising a four pin connector plug
76 in the motor housing 64 and a complimentary connector socket 78
in integrated controller 16, the two releasably interengaging when
the controller 16 is placed in position on motor housing 64 (see
FIGS. 3C, 5A and 5B). As shown in the figures, controller 16 is
arranged for mounting on top of motor housing 64 (with the operator
unit 2 in its installed position).
[0112] Connector socket 78 projects downwardly from circuit board
44 through an aperture 51 formed in chassis 45 so as to receive
connector plug 76. Connector plug 76 projects upwardly from the
motor housing 64.
[0113] With specific reference to FIGS. 5A and 5B, connecting
assembly 74 is provided with sealing means 80--configured to be
positioned between the chassis 45 and the motor housing 64 when
both are brought together--to prevent ingress of foreign matter to
the electrical contacts. As shown, sealing assembly 80 comprises
seal elements 82 such as rubber `o` rings arranged mounted in
recesses 89 on upper an lower surfaces of a gland body 83 shaped to
surround the aperture 51. When the integrated controller is
fastened to the motor housing, each seal element 82 compresses
against its respective adjacent surface to provide the required
seal. The gland body 83 further comprises a downwardly-directed
peripheral skirt 85 to surround the electrical contacts of the
connecting assembly. When the integrated controller 16 is to be
removed from the operator unit 2, the access cover 94 must first be
removed by removing screws 95a. With particular reference to FIG.
6, controller 16 includes a sensing assembly 84 arranged to
register the presence of access cover 94, to interrupt the power
supply to the controller when the cover is removed. The sensing
assembly 84 comprises a micro-switch 86 in electrical communication
with the power receiving module 36 of the controller 16.
Micro-switch 86 is operatively associated with a leaf spring member
87 arranged to be engaged by a projection (not shown) extending
from the underside of access cover 94. When the access cover 94 is
placed in position on controller housing 68, the projection locates
within aperture 93 and depresses leaf spring member 87, activating
micro-switch 86, which then permits mains power to be supplied to
power receiving module 36. When housing 68 is removed, the power
supply is cut off from certain parts of the controller circuitry in
order to reduce the risk of persons coming into contact with high
voltages. The interior of subcompartment 92 cannot therefore be
accessed without suppressing the power supply to the controller
circuitry, and without accessing the interior of subcompartment 92
electrical interface ports 96 cannot be accessed, and the bolts
fastening the controller housing 68 to the operator unit 2 cannot
be removed. This provides a failsafe design ensuring that the
integrated controller cannot be accessed or removed without
suppressing potentially dangerous power supply.
[0114] This arrangement enables controller 16 to be provided as a
`plug-and-play` unit, avoiding the need for the services of a
qualified electrician for installation and removal of the unit.
Like controllers 16 are readily interchangeable with other like
operator units 2 if required.
[0115] With reference to FIGS. 7A and 7B, the controller 16 further
includes a cooling assembly 46 comprising a fan assembly 48 which
includes a fan 50 for cooling inverter driver 30. The fan 50 is
arranged to be driven by motor 4 and comprises a plurality of
blades 52 equi-spaced around a hub splined to motor drive shaft 12.
As shown, cooling assembly 46 is provided in close proximity to and
directly below the controller heat sink assembly 40, so that
operation of the fan 50 drives a flow of air over the heat sink
fins 42 to effect cooling.
[0116] Fan assembly 48 comprises a fan housing 58 enclosing fan 50,
the fan housing removably fastened to motor housing 64, and
comprising a plurality of air inlet holes 62 in an axial face, and
outlet vent hole 60 through which air driven by the blades is
directed to the fins of heat sink assembly 40.
[0117] It will be appreciated that heat sink fins 42 extend across
substantially the entire width of controller housing 68 to maximise
the cooling effect. The diameter of fan blades 52 is of a similar
dimension.
[0118] With the cooling arrangement illustrated and described
above, the inventors have determined that the controller is
operable in an ambient temperature of up to around 55 degrees
celsius.
[0119] The housings of the various assemblies discussed above are
formed from a suitably durable plastic material capable of
injection moulding or similar manufacturing processes. The heat
sink assembly is constructed of suitable metallic material having a
high co-efficient of thermal conduction. All gaskets, glands and
sealing components comprise a suitable resilient material such as
rubber.
[0120] In particular, cover seals for the integrated controller 16
may comprise Santoprene.TM. 111-45, and the materials used for
shielding electrical wire, joints and/or connectors may comprise
ethylene vinyl acetate (EVA) or similar closed cell foam
materials.
[0121] The word `comprising` and forms of the word `comprising` as
used in this description and in the claims do not limit the
invention claimed to exclude any variants or additions.
Modifications and improvements to the invention will be readily
apparent to those skilled in the art. Such modifications and
improvements are intended to be within the scope of this
invention.
* * * * *