Abstract:
This invention relates generally to a garage door opener. The garage door opener has a user interface and a motor operatively connected to the garage door, at least one sensor, and an integrated motor control circuit. The integrated motor control circuit has a motor control microprocessor and a memory. The memory contains previous operation data. The motor control microprocessor receives data from the user interface, the memory and the sensors to control the motor.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    This invention relates generally to garage door openers. More particularly, this invention relates to a soft start motor for a garage door opener. 
         [0002]    Various types of automatic garage door openers have existed for many years. Conventional automatic garage door openers are electromechanical devices which raise and lower a garage door to unblock and block a garage door opening in response to actuating signals. The signals are electrical signals transmitted by closure of a push-button switch through electrical wires or by radio frequency from a battery-operated, remote controlled actuating unit. In either case the electrical signals initiate movement of the garage door from the opposite condition in which it resides. That is, if the garage door is open, the actuating signal closes it. Alternatively, when the garage door is closed, the actuating signal will open the garage door. Once movement has been initiated, the system is deactuated when the garage door movement trips a limit switch as the garage door approaches its open or closed position. 
         [0003]    Conventional drive systems typically include either a very long worm drive or a very long drive through a chain loop tensioned between a pair of sprockets. The chain is connected to the garage door. A typical worm drive shaft is at least about eight feet in length, while the sprockets in a chain loop drive are likewise separated by a distance of at least eight feet. 
         [0004]    When a conventional motor is activated, an instantaneously high current is usually generated. This high locked rotor torque creates high stresses on the mechanical linkages as the reverse direction play is slammed out. One of the main limiters to life of a garage door opener and its hardware is this impulse, which strikes the mechanical components of the door opener with large locked rotor torque to help break away door under frozen conditions. This impulse is applied in all conditions whether needed or not. Such motor hard start further creates distracting noise. Therefore, there is a need for an improved garage door opener. 
       SUMMARY OF THE INVENTION 
       [0005]    As described herein, embodiments of the invention overcome one or more of the above or other disadvantages known in the art. 
         [0006]    In one aspect, the invention relates generally to a garage door opener. The garage door opener has a user interface and a motor operatively connected to the garage door, at least one sensor, and an integrated motor control circuit. The integrated motor control circuit has a motor control microprocessor and a memory. The memory contains previous operation data. The motor control microprocessor receives data from the user interface, the memory and the sensors to control the motor. 
         [0007]    In another aspect, a garage door opener is disclosed. The garage door opener has a user interface, an integrated motor control circuit at least one sensor, and a motor. The integrated motor control circuit has an alternating current to direct current converter, a motor control microprocessor, an inverter, and a memory. The memory contains previous operation data. The sensor provides current operation data to the motor control microprocessor. The motor is in communication with the motor control circuit and is operatively connected to the garage door. The motor control microprocessor receives data from the user interface, the memory and the sensors to control the motor. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The following figures illustrate examples of embodiments of the invention. In the drawings: 
           [0009]      FIG. 1  is a perspective view of a garage door opener. 
           [0010]      FIG. 2  is a schematic representation of an aspect of the invention integrated into the garage door opener of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0011]    While the apparatus herein is described in the context of a garage door opener, as set forth more fully below, it is contemplated that the described apparatus or method may find utility in other applications. The description herein below is therefore set forth only by way of illustration rather than limitation, and is not intended to limit the practice of the herein described methods and apparatus. 
         [0012]      FIG. 1  illustrates a garage door opener  114  as is known in the art. Garage door opener  114  is mounted on the ceiling  112  of a garage and with a garage door  110  movably mounted on rails  121  and  122 . A shaft  108  is rotatably mounted above the door  110  on the wall  107  and carries counter balance spring  123 . Cables and pulleys such as the pulleys  105  and  106  are attached to the shaft  108  and the cables are connected to the door so as to spring bias it to counter balance the weight of the door in a conventional manner. The garage door opener  114  is attached to the ceiling  112  by bracket arms  117  and  118  which have portions  119  and  120  through which openings are formed to attach the door operator to the ceiling  112 . 
         [0013]    The garage door operator has a main body portion  113  which may have a light  116 . The motor, gear train and various electrical components are contained in the body compartment  113 . A rail  128  extends from the body portion  113  and may be formed in a number of tubular sections which telescope together for support of a chain drive or other similar system or may be a treaded rod for a worm drive or similar system for opening and closing the garage door. A trolley  127  fits over the tubular rail  128  and has an arm  124  of generally L-shape which is attached to the trolley. The other end of the arm  124  is attached to a bracket  6  connected to the door  110  such that as the trolley  127  is moved relative to the rail  128 , the door can be opened and closed. 
         [0014]    According to an aspect of the invention, as shown in  FIG. 2 , the main body houses the controls and operating components of the system. Line power  250 , such as but not limited to 110V or 240V alternating current or AC, is supplied to the system and converted to a direct current or DC voltage in AC to DC converter  210 . DC bus  252  supplies the operating power to the integrated motor control circuit  201 . 
         [0015]    When a user actuates user interface  230  a signal is sent via bus  202  to the opener microprocessor control board  220  to direct the motor control microprocessor  204  on integrated motor control circuit  201  via bus  258 . User interface  230  may be a remote device such as a RF remote or button or switch, or may be a human machine interface, HMI, for user control and display of system information to the user. Motor control microprocessor  204  provides a start signal to inverter  208  via bus  262 . The start signal may be preprogrammed or when data is available the start signal may be provided from a memory profile  212  via bus  264 . 
         [0016]    Memory  212  contains data from previous operation of the garage door opener  114 . The data stored may include, but is not limited to, operating temperature of the motor, ambient temperature, rotor speed or torque. The use of the memory profile data permits the motor control microprocessor to adjust the start signal depending on the ambient conditions. The conditions may include, door hard start, such as where the door has iced to the floor  111 , operating torque, such as excess friction or during the vertical traverse as opposed to the horizontal traverse. The motor control microprocessor  204  may also utilize present operation parameters, such as the current draw of the inverter  208  via bus  254 , rotor speed  216  via bus  256 . These parameters are used to monitor garage door operation such as torque demand, sudden changes in torque demand and communicate this information back to the main control board to allow for condition diagnosis. 
         [0017]    The motor control microprocessor  204  of the variable speed motor  206  may determine trends in operating torques and self learn speed profiles based on the rotor revolutions to match each individual garage door application. This would allow each application to develop on its own a unique profile based upon recorded data during operation to match motor operation parameters to individual needs. Things like ramp up and down rates and torques could be self taught and optimized based on self learned parameters. 
         [0018]    The variable speed motor  206  may be a three phase motor or any other variable speed AC or DC motor. The information relayed from the motor control to the garage door opener main board could include torque, long and short term changes in torque demand for operation, and could be used for sensing broken springs, or maintenance requirements. This information may be used to assist service requirements or determine correct operation of the variable speed motor. Further, by utilizing feedback from the sensors, the torque of the motor may be incrementally increased during the start of the garage door opener until a predetermined operation speed of the motor is obtained. By incrementally increasing the torque during motor start excess noise and wear on mechanical parts will be prevented, increasing customer satisfaction and increasing reliability of the garage door opener. 
         [0019]    A visual signal, such as a flashing light emitting diode or LED, to relay health status or serial communication status. The visual signal may also be an auditable signal or a display on an HMI device. 
         [0020]    While the invention has been described in terms of a specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims in similar applications.