OVERHEAD DOOR TILT DETECTION PACKAGE AND METHOD

Abstract

The invention provides an overhead door tilt protection package comprising an enclosure secured to an overhead door, an electrical connection within the enclosure, electrical components within the enclosure including an electronic tilt detector continuously measuring the angle of door deviation between either a horizontal or a zero-set condition and a determined tilt angle of the bottom bar, producing a deviation signal, determining a stable deviation value from the deviation signal, and setting an electrical deviation condition upon the stable deviation signal reaching a predetermined level. The electrical components produce a visible door power on and door power off condition based upon tilt deviation.

The invention further provides a procedure for improving the operation and safety of overhead doors including measuring deviation of the bottom bar of a door from either horizontal or a pre-set zero condition in real time with an electronic inclinometer, restricting the deviation measurement to a single axis of deviation, averaging the real time signal, determining the average signal as below or above a preset limit and then setting a start/stop condition.

Claims

1. An overhead powered door tilt protection package comprising: (a) a water resistant enclosure adapted to be secured to an overhead door adjacent its bottom bar, (b) an electrical connection within the enclosure extending to the operating electrical power of an overhead door, (c) electrical components within the enclosure including an electronic tilt detector continuously: i. measuring the angle of door deviation between either a horizontal or a zero-set condition and a determined tilt angle of the bottom bar, ii. producing a deviation signal, iii. determining a stable deviation value from the deviation signal, and iv. setting an electrical deviation condition upon the stable deviation signal reaching a predetermined level, (d) the electrical components adapted to produce a visible door power on and door power off condition upon deviation condition reaching the predetermined level, (e) the electrical components adapted to interact with electrical power of the door and start or stop door operation respectively in association with the start or stop condition.

2. An overhead powered door tilt protection package as claimed in claim 1 wherein the stable deviation value is an average of the real time deviation signal.

3. An overhead powered door tilt protection package as claimed in claim 2 wherein the angle of door deviation is measured about a single axis.

4. An overhead powered door tilt protection package as claimed in claim 3 wherein the single axis is perpendicular to the door and horizontal.

5. An overhead powered door tilt protection package as claimed in claim 3 wherein the water resistant enclosure is adapted to be secured to the face of an overhead door.

6. An overhead powered door tilt protection package as claimed in claim 5 wherein the inclinometer is restrained to provide only a deviation signal in relation to a single axis of deviation.

7. An overhead powered door tilt protection package as claimed in claim 2 wherein the inclinometer is restrained to provide a deviation signal in respect of only one axis perpendicular to the plane of the door.

8. An overhead powered door tilt protection package as claimed in claim 7 wherein deviation angle of door deviation lies in the plane of the door when open.

9. An overhead powered door tilt protection package as claimed in claim 6 including a reset switch to restore operation to the door despite the start or stop condition.

10. An overhead door package comprising a roll up doorway adapted to be raised and lowered between guide rails from a fully lowered position closing a doorway to an opened position away from the doorway with the door components retained above the doorway when opened, the improvement comprising the tilt detector of claim 1.

11. The invention further provides a tilt package which presents a go and no-go, on and off or proceed and stop condition visible to the door operator and a reset condition for manual and or powered use.

12. A procedure for improving the operation and safety of overhead powered doors including measuring deviation of the bottom bar of an overhead door from either horizontal or a pre-set zero condition in real time with an electronic inclinometer, restricting the deviation measurement to a single axis of deviation, averaging the real time signal, determining whether the average signal is below or above a preset limit, and, then setting a start/stop condition within the power operations of the overhead door in accordance with the above/below determination.

13. A procedure for improving the operation and safety of overhead powered doors as claimed in claims 12 including a procedure where the start/stop condition may be reset by an operator for manual or powered operations despite the start/stop condition.

Description

DRAWINGS

[0028] FIG. 1 is an overall vertical elevation view of the tilt detector of the invention in an installed condition.

[0029] FIG. 2 is a pictorial view of a typical roll up door indicating the areas of concern, particularly where small deviations may occur over long periods of use.

[0030] FIGS. 3 and 4 are pictorial views of partially damaged doors.

[0031] FIG. 5 is a pictorial view of the green/red tilt event display.

[0032] FIG. 6 is a preferred circuit diagram identified as to function.

[0033] FIG. 7A is an elevation view showing a typical installation in a before condition.

[0034] FIG. 7B is an elevation view showing a typical installation in an after condition.

THE PREFERRED EMBODIMENT

[0035] The preferred embodiment of the invention as shown in FIG. 01 comprises a tilt detection package 1 arranged to be secured to the face 2 of a roll up door, preferably adjacent the lower extremity of the door as by fasteners 3. The tilt package 1 preferably includes a weather and site specific protective cover 4 for individual tilt detection components 5 which are preferably secured to a separate circuit board 6. The components 5 includes a programmable electronic inclinometer 8 capable of measuring degrees of tilt from a reference angle, such as the horizontal, in small time and value increments. Preferably the increments are 2 degrees from horizontal or less, preferably much less, and the inclinometer has no operative inertial mass. Electronic inclinometers 8 suitable for the preferred embodiment have almost no mechanical weight or inertia and are almost immune to vibrations and many abrupt changes in motion of the base and provide a real time value for the inclination reading.

[0036] The inclinometer 8 preferably includes a 0-set or level-set switching capacity which is operable at a range of small angles from the reference angle (horizontal).

[0037] Most preferably inclinometer 8, alone or in conjunction with components 5, includes a programmable tilt angle limit switch, and averaging function and a learning function. The tilt angle limit switch provides for the on/off operational condition of the door mechanism. The learning function is programmed using common programming techniques to adapt to initial (upon installation) motions of the package 1 and, over time, preferably, to adapt to increasingly random and violent motions of the package as the door ages in use to provide a steady-state-type inclination signal representative of the operational average tilt of the door panel 2.

[0038] Circuit board 7 is fixed to package 1 and cover 4 as by fasteners 9 for a permanent and stable relationship providing x-y axes of rotation in the plane of the door panel face 2. Electrical lines are connected between the tilt package 1 and the electrical circuit powering the door as by expansible coiled or other wire or wiring fixed to the door where either the switch condition will operate a high power switch in the door power circuit or the on/off power will be switched directly within the tilt package 1.

[0039] The programming will preferably restrict the inclinometer results to a stable representation of the tilt angle 10 of the package 1 and, thus, door panel 2 about the z-axis perpendicular to the door panel face 2 and eliminate inclination or motion results about the x or y axes.

[0040] Once 0-set, the inclinometer 8 and the components 5 are powered as by electrical circuit connection provided as at 10 as to present a visible green/red operational condition from the board 6 through the cover 4 into the relevant workplace as shown in FIG. 5.

[0041] The green condition indicated on the display is readily visible to an operator or passer by as being measured average door tilt less than a small defined angle, preferably, 2, 5 or 10 degrees from horizontal. The red condition indicated on as measured average door tilt of more than the small defined angle, namely a relevant a door tilt event.

[0042] The red/green display, by the tilt event, is electrically connected to door power systems so as to present an operational (green) condition where power to the door up/down switch circuitry is provided and an inoperative condition (red)where said power is prevented from reaching the up-down circuitry.

[0043] A door-up/door-down operator switch is provided within operational eyesight of said display and is only operable to electrically control the up/down powered condition of the powering motor when said display is in the green condition. In a tilt event condition, the door and its driving motor are permanently disconnected from electrical power and up/down switching is inoperative.

[0044] The tilt assembly includes structure to provide for a non-zero tolerance to the horizontal level of the installation and a reset operative to reset the 0-tilt condition in accordance with the actual operational conditions at the time of reset. Thus, upon installation with the door or grill assembly factory-fresh the reset will set the 0 deflection condition and provide a green display condition. Upon a tilt event, damaging or not, being cleared the reset will set a new baseline condition as green which accommodates the then-present condition of the door which may be a 0 angle or horizontal condition or some other baseline angle condition present at the time and required for door operations whether such operations are temporary or permanent

[0045] A manual up/down system of the well-known type is preferably included. The manual up/down, often a chain hoist, is not interconnected with the tilt package so that the door may be moved manually under low loading conditions to relieve against minor jamming/tilt events or unusual tilt conditions. Once a tilt event has been alleviated and door returned to horizontal or other operable condition the tilt package will automatically return to the green-go condition and up/down switching may provide for powered door movement.

[0046] A tilt by-pass switch is also included in some installations for careful usage of powered door movement by skilled operators where necessary, such as with heavy industrial doors or emergency situations.

[0047] FIG. 02 is a pictorial view of the tilt detector 24 as installed to an industrial roll up door 20. Door 20 includes panels 22 intersecured to each other and retained by door side rails 21 for up down door movement by door bottom 23 in relation to door roll 25 secured to the building. In many cases particular problem areas occur as at 26 and 27 in relation to twisted end locks and bent guides which, if uncorrected, will fatally damage door 20.

[0048] FIG. 03 is a pictorial view of the tilt detector installation shown in FIG. 02 with the door up/down action impeded for illustration purposes by a bar 33. Door 30 is retained in position with side rails 31 and operated for up/down movement of bottom edge 32. Upon an average departure of the tilt detector 35 from the 0-set or horizontal condition, as at 36, of 2, 5 or 10 degrees, as set, preferably 2 degrees, the red/green condition will be set to red from green and power will be disconnected from drive motors, thus stopping the door on a just-in-time basis.

[0049] FIG. 04 is a further pictorial view of the tilt detector installation of FIG. 02 wherein door 30 bottom edge 32 has encountered bar obstacle 33 and driven door bottom 32 off angle for a tilt condition stoppage of powered operation. Permanent and possibly fatal damage to the door 30 is shown in FIG. 04 is imminent as shown by bunching and buckling as at 36 in FIG. 04. Further operation of door 30 could tear door panels completely free of side rails 31 and the door 30 itself.

[0050] FIG. 05 is a plan view of the red/green condition indicator as seen by the operator while in use with one light green and the other red. A red condition prevents electrically driven operation of the upper door roll 25.

[0051] FIG. 06 is a circuit diagram for the preferred embodiment of the electrical components 5 as driving the red/green indicators of FIG. 05.

[0052] In FIG. 06 the labeled components are as follows:

[0053] B1—Bridge Rectifier

[0054] U1—Programmable Microcontroller

[0055] U2—Precision Solid-State Inclinometer

[0056] U3—12V Switching Power Regulator

[0057] IC1—3.3 VDC Voltage Regulator

[0058] LED1—Power Indicator

[0059] LED2—Status Indicator K1—Double-Pole Wire Terminal

[0060] JP1—Programming Header Connector

[0061] C1—C8—Power Supply Filtering Capacitors

[0062] D1—Protection Diode

[0063] D2—Inductive Kickback Protection Diode

[0064] D3—Power Supply Feedback Diode

[0065] L1—Power Supply Inductor

[0066] R1, R4—Current Limiting Resistors

[0067] R2, R3—Voltage Divider Resistors

[0068] T1—Relay Coil Switching Transistor

[0069] FIG. 07 shows a typical full installation of the tilt detector and door combination of the invention in both normal condition and in a tilt event. Roll-up door 70 is includes centrally mounted detector 71 in a substantially open condition with bottom bar 73 just above the fully closed position. Door 70 is restrained between side rails 74 with end-locks and guides to close the opening below upper element 75. Typically, the electrical connections to main power, as at junction box 72, are provided by the installer to connect detector 71 to operating power for the door. Upon a pathway restriction being encountered bottom bar 73 is slowed down or completely restrained against further downward or upward motion as the case may be and continues such motion until bottom bar 73 acquires a tilt angle 76 in relation to horizontal or the 0-set angle at which point principal power is disconnected from the drive motor, the tilt condition is set to red and the door stops its driven motion.

[0070] The scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations, and/or additions to the present subject matter as would be readily apparent to a person skilled in the art.