Movable barrier operator having force and position learning capability

• US 6,528,961 B1
• Filed: 05/15/2000
• Issued: 03/04/2003
• Est. Priority Date: 06/06/1995
• Status: Expired due to Fees

• Current Assignee: The Chamberlain Group, Inc. (The Chamberlain Group LLC)
• Original Assignee: The Chamberlain Group, Inc. (The Chamberlain Group LLC)
• Inventors: Fitzgibbon, James J., Farris, Bradley, Moravec, John V.
• Primary Examiner(s): Nappi, Robert E.
• Assistant Examiner(s): Duda, Rina I.
• Application Number:
  US09/571,435
• Time in Patent Office: 1,023 Days
• Field of Search: 368/280-286, 368/445-456
• US Class Current: 318/283
• CPC Class Codes: E05F 15/00 Power-operated mechanisms for wings motor-operated accessories in locks for completing closing or initiating opening of a wing E05B17/00
• CPC Class Codes: E05F 15/41 Detection by monitoring transmitted force or torque E05F15/48 takes precedence; Safety couplings with activation dependent upon torque or force, e.g. slip couplings
• CPC Class Codes: E05F 15/668 for overhead wings
• CPC Class Codes: E05F 2015/436 the beam being parallel to the wing edge
• CPC Class Codes: E05Y 2400/315 Curve setting or adjusting
• CPC Class Codes: E05Y 2400/342 Pulse count value setting or correcting
• CPC Class Codes: E05Y 2400/554 sensing motor load
• CPC Class Codes: E05Y 2400/80 User interfaces
• CPC Class Codes: E05Y 2800/00 Details, accessories and auxiliary operations not otherwise provided for
• CPC Class Codes: E05Y 2800/414 against high or low temperatures
• CPC Class Codes: E05Y 2800/75 intermediate
• CPC Class Codes: E05Y 2900/106 for garages
• CPC Class Codes: G05B 19/42 Recording and playback systems, i.e. in which the programme is recorded from a cycle of operations, e.g. the cycle of operations being manually controlled, after which this record is played back on the same machine
• CPC Class Codes: G05B 2219/35472 Mode selection
• CPC Class Codes: G05B 2219/36457 During teaching, force set point is automatically adapted to circumstances
• CPC Class Codes: G05B 2219/36463 Manual switch to drive motor to wanted position, store, memorize position
• CPC Class Codes: G05B 2219/36464 Position, teach, store extreme, full open, closed positions
• CPC Class Codes: G05B 2219/36489 Position and force
• CPC Class Codes: G05B 2219/37429 Temperature of motor
• CPC Class Codes: G05B 2219/42281 If estimated temperature rise of motor is too high, inhibit motor
• CPC Class Codes: G05B 2219/42311 : Store working torque profiles as function of time, position, compare with real torque
• CPC Class Codes: G05B 2219/45242 : Door, panel, window operation, opening, closing
• CPC Class Codes: H02H 3/006 : Calibration or setting of parameters
• CPC Class Codes: H02H 7/0851 : for motors actuating a movable member between two end positions, e.g. detecting an end position or obstruction by overload signal
• CPC Class Codes: H02H 7/0852 : directly responsive to abnormal temperature by using a temperature sensor in a control circuit H02H7/0833

Abstract

A movable barrier operator includes a wall control switch module having a learn switch thereon. The switch module is connectable to a control unit positioned in a head of a garage movable barrier operator. The head unit also contains an electric motor which is connected to a transmission for opening and closing a movable barrier such as a garage door. The switch module includes a plurality of switches coupled to capacitors which, when closed, have varying charge and discharge times to enable which switch has been closed. The control unit includes an automatic force incrementing system for adjusting the maximal opening and closing force to be placed upon the movable barrier during a learn operation. Likewise, end of travel limits can also be set during a learn operation upon installation of the unit. The movable barrier operator also includes an ambient temperature sensor which is used to derive a motor temperature signal, which motor temperature signal is measured and is used to inhibit motor operation when further motor operation exceeds or is about to exceed set point temperature limits.

Claims

1. A movable barrier operator comprising:

an electric motor;

a switch operatively coupled to the electric motor for commanding the electric motor to move;

an input for commanding a learn mode state;

a transmission for connection to a movable barrier to be moved;

means for storing a force set point; and

means responsive to the learn mode state for changing the force set point while a limit of travel for the movable barrier is being established and when the force needed to move the barrier is greater than the force set point.

2. A movable barrier operator according to claim 1, further comprising a plurality of force set points as a function of position of the barrier.

3. A movable barrier operator according to claim 1, further comprising:

means for detecting a position of the movable barrier;

means for correcting the detected position according to the movable barrier position; and

means responsive to the corrected detected position for detecting the force applied to the movable barrier and for changing the force set point when the force needed to move the barrier is greater than the force set point.

4. A movable barrier operator according to claim 3, wherein the means for detecting a position of the movable barrier includes means for measuring the amount the motor has turned during movement of the barrier.

5. A movable barrier operator according to claim 1, further comprising:

memory for storing a counter value representative of an amount the movable barrier has traveled; and

a barrier motion registering means for incrementing and decrementing the counter value in response to barrier motion in a forward direction and a reverse direction, respectively.

6. A movable barrier operator according to claim 2 wherein the plurality of force set points comprises a plurality of force set points for travel in an open direction and a plurality of force set points for travel in a close direction.

7. A movable barrier operator according to claim 1 wherein the means for changing the force set point comprises closure of the move command switch for a period of time.

8. A movable barrier operator comprising:

an electric motor;

an input for commanding a learn mode;

a transmission connected to the electric motor to be driven thereby and for connection to a movable barrier to be moved;

a controller responsive to the commanded learn mode for detecting the force applied to the movable barrier and for changing the force set point while a limit of travel for the movable barrier is being established and when the force needed to move the barrier is greater than the force set point.

9. A movable barrier operator according to claim 8, further comprising:

memory for storing a counter value indicative of the absolute position of the barrier with respect to a barrier frame and for storing a force set point;

a position indicator for changing the counter value in the memory in response to barrier motion; and

a pass point signal generator for producing a pass point signal indicative of the barrier moving past a location fixed with respect to the barrier frame, wherein a preselected value of the counter value in the memory is stored in response to the pass point signal.

10. A movable barrier operator according to claim 8, further comprising a plurality of force set points as a function of position of the barrier.

11. A movable barrier operator according to claim 9 wherein the plurality of force set points comprises force set points for travel in an open direction and a plurality of force set points for travel in a close direction.

12. A movable barrier operator according to claim 8 wherein the input comprises a switch and changing the force set point comprises closure of the switch for a period of time.

13. A method for automatically setting the force set points of a movable barrier operator which moves a barrier within a frame, comprising the steps of:

initiating a learn mode of an operator;

selecting an open force set point for driving a barrier to a desired open limit;

driving the barrier to a desired open limit;

detecting the force applied to the barrier;

changing the open force set point when the force needed to move the barrier is greater than the selected open force set point;

providing the ability to change the open force set point while the open limit is being established;

storing the open force set point value in a memory of said operator;

selecting a down force set point for driving the barrier to a desired down limit;

driving the barrier down to a generally closed position;

detecting the force applied to the barrier;

changing the down force set point when the force needed to move the barrier is greater than the selected down force set point; and

providing the ability to change the down force set point while the down limit is being established;

storing the down force set point value in the memory of said operator.

14. The method of claim 13 wherein the step of changing the force set point comprises closing a switch for a period of time.

15. The method of claim 13, further comprising:

detecting and storing an array of open force set points and down force set points as a function of position of the door within the frame.

16. A movable barrier operator having automatic force learning capabilities comprising:

a motor for driving an output shaft;

a transmission connected to the output shaft to be driven thereby and to a movable barrier to be moved;

a memory for storing a force set point;

a controller for generating a move signal to enable the transmission to move the barrier, wherein the controller detects the force applied to the movable barrier and is capable of changing the force set point while a limit of travel for the movable barrier is being established and when the force needed to move the barrier is greater than the force set point.

17. A movable barrier operator according to claim 16, further comprising:

a detector for sensing when the barrier moves past a reference pass point and for generating a pass point signal representative thereof, the reference point being effective for enabling the controller to normalize the position of the barrier; and

a position indicator, responsive to the pass point signal, for generating a signal indicating the relative position of the barrier with respect to the pass point.

18. A movable barrier operator comprising:

a motor for driving an output shaft;

a transmission connected to the output shaft to be driven thereby and for connection to a movable barrier to be moved with respect to a barrier frame;

a memory for storing a force set point; and

a controller, responsive to a barrier position signal, operable in a learn mode, for detecting a force applied to the movable barrier and capable of changing the force set point while a limit of travel for the movable barrier is being established and when the force needed to move the barrier is greater than the force set point.

19. A movable barrier operator according to claim 18, further comprising:

an ambient temperature detector positioned near the electric motor; and

a controller, responsive to the commanded learn mode and to the ambient temperature detector, for detecting the force applied to the movable barrier and for changing the force set point when the force needed to move the barrier is greater than the force set point and for applying a temperature offset based on the detected ambient temperature to the force set point.

20. A movable barrier operator having automatic force setting capabilities, the operator comprising:

a motor coupled to a movable barrier to be moved;

a force detector for detecting a force applied to the movable barrier;

memory for storing a force set point; and

a controller operatively coupled to the motor for commanding the motor to move and, during a learn mode, for changing a first force set point to another force set point while a limit of travel for the movable barrier is being established.

21. A movable barrier operator according to claim 20, further comprising:

an input for indicating to the controller that the force set point should be adjusted while the limit of travel for the movable barrier is being established.

22. A movable barrier operator according to claim 20, further comprising:

a position detector for detecting a quantitative indication of position of the movable barrier so that the controller can detect the force applied to the movable barrier and adjust the force as needed.

23. A movable barrier operator according to claim 22, further comprising:

an input for identifying an actual position of the movable barrier so that the controller can compare the actual position to the quantitative indication of position and correct the quantitative indication of position to accurately reflect the actual position of the movable barrier if the comparison indicates that a correction is needed.

24. A movable barrier operator according to claim 22, wherein the position detector comprises:

a motor rotation sensor for measuring the amount the motor turns during movement of the movable barrier.

25. A movable barrier operator according to claim 20, further comprising:

a temperature detector coupled to the controller so that the force set point can be adjusted according to temperature.

26. A movable barrier operator according to claim 25, wherein the controller comprises:

a controlling unit capable of increasing the force set point in response to a decrease in temperature detected by the temperature detector.

27. A method of selecting force settings for a movable barrier operator, the method comprising:

entering a learn mode within which a force setting for a movable barrier operator can be selected;

activating an actuation switch causing the movable barrier operator to move a movable barrier at a first force setting from one of an open and closed position to the other of said open and closed position;

detecting whether a change in force setting has been requested during the movement of the movable barrier; and

changing the force setting from the first force setting to another force setting when a change in force setting has been requested.

28. A method according to claim 27, wherein detecting whether a change in force setting has been requested comprises:

detecting whether a user input has been activated for a period of time during the movement of the movable barrier thereby indicating that the force setting should be increased from the first force setting to another force setting.

29. A method according to claim 27, wherein the method further comprises:

detecting a quantitative indication of position of the movable barrier so that the controller can detect the force applied to the movable barrier and adjust the force as needed.

30. A method according to claim 29, wherein the method further comprises:

identifying the actual position of the movable barrier via an input;

comparing the actual position to the quantitative indication of position; and

correcting the quantitative indication of position to accurately reflect the actual position of the movable barrier if the comparison identifies that a correction is needed.

31. A method according to claim 27, wherein the method further comprises:

changing the force setting in response to a change in temperature detected by a temperature detector.

32. A method according to claim 31, wherein changing the force setting comprises:

increasing the force set point in response to a decrease in temperature detected by the temperature detector.