DOOR OPERATOR

• US 20110094160A1
• Filed: 10/22/2009
• Published: 04/28/2011
• Est. Priority Date: 10/22/2009
• Status: Active Grant

• Current Assignee: ASSA ABLOY Accessories and Door Controls Group, Inc.
• Original Assignee: Yale Security Incorporated (Assa Abloy AB)
• Inventors: Houser, Blue
• Granted Patent: US 8,407,937 B2
• Time in Patent Office: Days
• US Class Current: 49/31
• CPC Class Codes: E05F 15/63 operated by swinging arms
• CPC Class Codes: E05F 2003/228 Arrangements where the end of the closer arm is sliding in a track
• CPC Class Codes: E05F 2015/631 the end of the arm sliding in a track; Slider arms therefor
• CPC Class Codes: E05Y 2201/216 Clutches
• CPC Class Codes: E05Y 2201/236 using force or torque
• CPC Class Codes: E05Y 2201/41 for closing
• CPC Class Codes: E05Y 2201/422 for opening
• CPC Class Codes: E05Y 2201/434 Electromotors; Details thereof
• CPC Class Codes: E05Y 2400/326 of the angular type
• CPC Class Codes: E05Y 2400/354 End positions
• CPC Class Codes: E05Y 2400/51 of position, of back drive
• CPC Class Codes: E05Y 2900/132 Doors
• CPC Class Codes: Y10T 29/49009 Dynamoelectric machine
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

A door operator for selectively opening and closing a side hinge door. The door operator may include a motor with a drive shaft, an operator arm assembly, a door position sensor, and a controller. The operator arm assembly may include an output shaft operatively coupled to the drive shaft, an operator arm, and a clutch assembly mounted to the output shaft. The door position sensor, which may be electro-magnetic, signals the controller when the door is not closed. If the door has been manually pushed open, the controller signals the motor to rotate the drive shaft in the closing direction. In automatic mode, the output shaft and the operator arm are operatively engaged, but manual force to open the door overcomes static friction between the operator arm and friction discs in the clutch assembly, operatively disengaging the operator arm and output shaft until the manual force is removed.

Claims

1. A door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position, the door operator comprising:

a motor including a drive shaft rotatable in a first direction adapted to open the door and in a second direction adapted to close the door; and

an operator arm assembly including;

an output shaft operatively coupled to the drive shaft;

a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, wherein the operator arm is adapted to have a closed position coincident with the closed position of the door and a fully open position coincident with the fully open position of the door; and

a clutch assembly mounted to the output shaft and conditionally operatively engageable with the operator arm, wherein when a force is manually applied to move the operator arm towards the fully open position the output shaft and operator arm are not operatively engaged, and when no manual force is applied the output shaft and the operator arm are operatively engaged.

2. The door operator of claim 1, further comprising:

a support member for directly or indirectly supporting the motor and that is adapted to be mounted to a door frame or structure proximate to the door frame; and

a level mounted to the support member.

3. The door operator of claim 2, wherein the support member defines a recess in which the at least a portion of the level is received.

4. The door operator of claim 1, further comprising:

a door position sensor for sensing the position of the operator arm; and

a controller in communication with the motor and the door position sensor,

wherein when the operator arm is manually moved towards the fully open position from the closed position, the operator arm operatively disengages from the clutch assembly, the sensor indicates to the controller that the operator arm position is not closed, the controller signals to the motor to rotate the drive shaft in the direction adapted to close the door, and the motor rotates the drive shaft in the direction adapted to close the door.

5. The door operator of claim 4, wherein when force is no longer applied to move the operator towards the fully open position manually, the operator arm operatively reengages with the clutch assembly and the operator arm begins to move towards the closed position.

6. The door operator of claim 5, wherein the clutch assembly comprises at least one friction disc on each side of the operator arm and parts adjacent to the friction discs, through all of which the output shaft passes, wherein the operator arm may be an adjacent part to at least one friction disc.

7. The door operator of claim 6, wherein the clutch assembly further comprises a spring disposed around the output shaft, wherein the spring biases the friction discs and the operator arm towards each other.

8. The door operator of claim 7 wherein the clutch assembly further comprises a retaining nut that applies adjustable force to the spring.

9. The door operator of claim 4, wherein the door position sensor is an electro-magnetic sensor, and further comprising a first magnet that rotates about the axis of the output shaft as the output shaft turns.

10. The door operator of claim 9, wherein the first magnet demarcates the closed position of the operator arm.

11. The door operator of claim 10, further comprising a second magnet that rotates about the axis of the output shaft as the output shaft turns and is angularly spaced from the first magnet relative to the central axis of the output shaft, wherein the second magnet demarcates the fully open position of the operator arm.

12. The door operator of claim 11, wherein the first and second magnets are disposed on the operator arm.

13. The door operator of claim 11, wherein the operator arm defines an annular channel that encircles the output shaft, and the first and second magnets are disposed in the channel.

14. The door operator of claim 11, further comprising a magnet holding member mounted to the output shaft that rotates about the axis of the output shaft as the operator arm moves and on which the first and second magnets are disposed.

15. The door operator of claim 4, wherein when the controller receives a signal for the door operator to move the operator arm towards the fully open position automatically and the motor powers the operator arm to reach a fully open position, the door position sensor indicates to the controller that the operator arm is in the fully opened position and the controller, either immediately or after a delay, sends a signal to the motor to reverse rotation of the drive shaft so as to cause the operator arm to move to the closed position, the door position sensor indicates to the controller when the operator arm is in the closed position, and the controller sends a signal to the motor to cease rotation of the drive shaft.

16. A door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position, the door operator comprising:

a motor including a drive shaft rotatable in a first direction adapted to open the door and in a second direction adapted to close the door;

an operator arm assembly including;

an output shaft operatively coupled to the drive shaft;

a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, wherein the operator arm is adapted to have a closed position coincident with the closed position of the door and a fully open position coincident with the fully open position of the door; and

means for conditionally operatively engaging the output shaft with the operator arm, wherein when a force is manually applied to move the operator arm towards the fully open position the output shaft and operator arm are not operatively engaged, and when no manual force is applied the output shaft and the operator arm are operatively engaged;

means for sensing the position of the operator arm; and

a controller in communication with the motor and the sensing means.

17. The door operator of claim 16, wherein the means for conditionally operatively engaging the output shaft with the operator arm comprises a clutch assembly including at least one friction disc on each side of the operator arm and parts adjacent to the friction discs, wherein the operator arm may be an adjacent part to at least one friction disc, and a spring for biasing the friction discs and the operator arm towards each other for transfer of rotation of the output shaft to the operator arm through static friction, through all of which the output shaft passes.

18. A door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position, the door operator comprising:

a motor including a drive shaft rotatable in a first direction adapted to open the door and in a second direction adapted to close the door;

an operator arm assembly including;

an output shaft operatively coupled to the drive shaft; and

a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, wherein the operator arm is adapted to have a closed position coincident with the closed position of the door and a fully open position coincident with the fully open position of the door;

an electro-magnetic door position sensor for sensing the position of the operator arm;

a first magnet that rotates about the axis of the output shaft as the output shaft turns wherein the first magnet demarcates the closed position of the operator arm; and

a controller in communication with the motor and the door position sensor.

19. The door operator of claim 18, further comprising a second magnet that rotates about the axis of the output shaft as the output shaft turns and is angularly spaced from the first magnet relative to the axis of the output shaft, wherein the second magnet demarcates the fully open position of the operator arm.

20. The door operator of claim 19, wherein the first and second magnets are disposed on the operator arm.

21. The door operator of claim 19, wherein the operator arm defines an annular channel that encircles the output shaft, and the first and second magnets are disposed in the channel.

22. The door operator of claim 19, further comprising a magnet holding member mounted to the output shaft that rotates about the axis of the output shaft as the operator arm moves and on which the first and second magnets are disposed.

23. A door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position, the door operator comprising:

a motor including a drive shaft rotatable in a first direction adapted to open the door and in a second direction adapted to close the door;

an operator arm assembly including;

an output shaft operatively coupled to the drive shaft; and

a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, wherein the operator arm is adapted to have a closed position coincident with the closed position of the door and a fully open position coincident with the fully open position of the door;

a support member for directly or indirectly supporting the motor and that is adapted to be mounted to a door frame or structure proximate to the door frame; and

a level mounted to the support member.

24. The door operator of claim 23, wherein the support member defines a recess in which the at least a portion of the level is received.

25. A door assembly, comprising:

a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position; and

a door operator comprising;

a motor including a drive shaft rotatable in a first direction to open the door and in a second direction to close the door;

an operator arm assembly including;

an output shaft operatively coupled to the drive shaft;

a rotatable operator arm defining an opening through which the output shaft passes, the operator arm operatively connected to the door; and

a clutch assembly mounted to the output shaft and conditionally operatively engageable with the operator arm, the clutch assembly including at least one friction disc on each side of the operator arm and parts adjacent to the friction discs, wherein the operator arm may be an adjacent part to at least one friction disc, and a spring for biasing the friction discs and the operator arm towards each other for transfer of rotation of the output shaft to the operator arm through static friction, through all of which the output shaft passes;

a door position sensor for sensing the position of the operator arm; and

a controller in communication with the motor and the sensor,

wherein when the door is manually pushed open from the closed position, parts adjacent to the friction discs slide against the friction discs, the door position sensor indicates to the controller that the door is not closed, the controller signals to the motor to rotate the drive shaft in the direction that closes the door, and the motor rotates the drive shaft in such direction.

26. The door assembly of claim 25, wherein the door position sensor is also for sensing the position of the door as fully open, and wherein when the controller receives a signal initiating powered opening of the door, the controller signals to the motor to rotate the drive shaft in the direction that opens the door, and the motor rotates the drive shaft in the direction that opens the door until the sensor indicates to the controller that the door is fully open, at which time the controller sends a signal to the motor that stops rotation of the drive shaft in the direction that opens the door.

27. A method of using a door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position, the door operator including a motor including a drive shaft, an output shaft operatively coupled to the drive shaft, a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, a clutch assembly mounted to the output shaft and including at least one friction disc on each side of the operator arm and parts adjacent to the friction discs, wherein the operator arm may be an adjacent part to at least one friction disc, a sensor for sensing the position of the operator arm, and a controller in communication with the motor and the sensor, the method comprising:

manually pushing the door from a closed position towards the fully open position; and

overcoming the force of static friction between parts adjacent to the friction discs and the friction discs to initiate movement of the door, operatively disengaging the operator arm from the output shaft.

28. The method of claim 27, further comprising overcoming the force of sliding friction between parts adjacent to the friction discs and the friction discs to continue movement of the door without rotating the output shaft in the direction of rotation of the operator arm.

29. A method of making a door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and an open position, comprising:

providing a motor including a drive shaft;

providing an operator arm assembly including;

an output shaft operatively coupled to the drive shaft;

a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, wherein the operator arm is adapted to have a closed position coincident with the closed position of the door and a fully open position coincident with the fully open position of the door; and

a clutch assembly mounted to the output shaft and conditionally operatively engageable with the operator arm, wherein when a force is manually applied to move the operator arm towards the fully open position the output shaft and operator arm are not operatively engaged, and when no manual force is applied the output shaft and the operator arm are operatively engaged;

providing a door position sensor for sensing the position of the operator arm;

providing a controller in communication with the motor and the sensor; and

assembling the motor, operator arm assembly, and the controller.

30. The method of claim 29, wherein the clutch assembly comprises at least one friction disc on each side of the operator arm and parts adjacent to the friction discs, through all of which the output shaft passes, wherein the operator arm may be an adjacent part to at least one friction disc.

31. The method of claim 29, further comprising:

providing a support member for directly or indirectly supporting the motor and that is adapted to be mounted to a door frame or structure proximate to the door frame; and

mounting a level to the support member.

32. The method of claim 29, wherein the door position sensor is an electro-magnetic sensor and further comprising:

mounting a magnet holding member that rotates around the output shaft axis to the output shaft; and

disposing a first magnet on the magnet holding member to actuate the sensor when the operator arm is in the closed position.

33. The method of claim 32, further comprising disposing a second magnet on the magnet holding member to actuate the sensor when the operator arm is in the fully open position.

34. The method of claim 32, wherein the operator arm is the magnet holding member.

35. A method of installing a door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and an open position, the door operator including a support member, a motor mounted directly or indirectly to the support member and including a drive shaft, an output shaft operatively coupled to the drive shaft, a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, a clutch assembly mounted to the output shaft and including at least one friction disc on each side of the operator arm and parts adjacent to the friction discs, through all of which the output shaft passes, wherein the operator arm may be an adjacent part to at least one friction disc, a spring to bias the friction discs and the operator arm together, and a retaining nut to apply adjustable force to the spring, a sensor for sensing the position of the operator arm and door, and a controller mounted to the support member and in communication with the motor and the sensor, the method comprising:

mounting the support member to a door frame or building structure proximate to the door frame;

operatively connecting the operator arm to the door; and

tightening the retaining nut to a torque that applies pressure to the friction discs and operator arm sufficient to maintain operative engagement of the friction discs and adjacent parts when the door is powered by the motor, the applied torque allowing static friction between the friction discs and at least two adjacent parts to be overcome when the operator arm is moved towards the open position manually, operatively disengaging the friction discs and at least two adjacent parts.

36. The method of claim 35, wherein the sensor is an electro-magnetic sensor, and further comprising disposing a first magnet on a member that rotates around the axis of the output shaft, wherein when the door is in the closed position the first magnet actuates the sensor.

37. The method of claim 36, further comprising disposing a second magnet on the member that rotates around the axis of the output shaft, wherein when the door is in the fully open position the second magnet actuates the sensor.

38. The method of claim 35, wherein mounting the support member to a door frame or building structure proximate to the door frame includes:

placing the support member of the door operator in contact with a door frame or building structure proximate to the door frame for mounting to the door frame or building structure proximate to the door frame; and

adjusting the alignment of the support member such that the integral level indicates that the integral level is level.

39. The method of claim 38, wherein the integral level is level when the integral level indicates that the level is horizontal.

40. The method of claim 38, wherein the integral level is level when the integral level indicates that the level is vertical.

41. A method of installing a door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and an open position, the door operator including a support member, a motor mounted directly or indirectly to the support member and including a drive shaft, an output shaft operatively coupled to the drive shaft, a rotatable operator arm defining an opening through which the output shaft passes and adapted to be operatively connected to the door, an electro-magnetic door position sensor for sensing the position of the operator arm, and a controller mounted to the support member and in communication with the motor and the sensor, the method comprising:

mounting the support member to a door frame or building structure proximate to the door frame;

operatively connecting the operator arm to the door; and

disposing a first magnet on a member that rotates around the axis of the output shaft, wherein when the door is in the closed position the first magnet actuates the sensor.

42. The method of claim 41, further comprising disposing a second magnet on the member that rotates around the axis of the output shaft, the second magnet angularly spaced from the first magnet relative to the central axis of the output shaft, wherein when the door is in the fully open position the second magnet actuates the sensor.

43. The door operator of claim 42, wherein the first and second magnets are disposed on the operator arm.

44. The door operator of claim 43, wherein the operator arm defines an annular channel that encircles the output shaft, and the first and second magnets are disposed in the channel.

45. A method of installing a door operator for selectively operating a door positioned within a door frame and hinged along one edge to the door frame for movement between a closed position and a fully open position, the door operator including a motor and a support member for directly or indirectly supporting a motor, the support member having an integral level mounted thereto, the method comprising:

placing the support member of the door operator in contact with a door frame or building structure proximate to the door frame for mounting to the door frame or building structure proximate to the door frame;

adjusting the alignment of the support member such that the integral level indicates that the integral level is level; and

mounting the support member to the door frame or building structure proximate to the door frame.

46. The method of claim 45, wherein the integral level is level when the integral level indicates that the level is horizontal.

47. The method of claim 45, wherein the integral level is level when the integral level indicates that the level is vertical.