Abstract:
An operable fenestration operating system for a structure including a window or skylight having a frame, an operable sash and presenting a resistance force opposing opening and closing of the sash. A motorized operator is coupled with the frame and the sash to selectively open and close the sash. The invention includes an operator control unit communicatively connected to the motorized operator. The operator control unit includes a processor, a sensor for sensing the magnitude of the resistance force, a pulse width modulation circuit for supplying electrical power to the motorized operator. The processor varies the torque output of the motorized operator using the pulse width modulation circuit in response to the sensed parameter.

Description:
CLAIM TO PRIORITY  
       [0001]     This application claims priority to U.S. Provisional Application Ser. No. 60/552,777 entitled “Improved Integrated Power Window And Skylight Operating Systems” filed Mar. 12, 2004. That Provisional Application is incorporated herein in its entirety by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to power window and skylight operating systems.  
       BACKGROUND OF THE INVENTION  
       [0003]     Motorized window and skylight operator systems have existed in the market for a number of years. In general, these motorized window and skylight operator systems include a motorized operator and an operator control unit. Optionally, these systems may have at least a system control unit. Examples of such operator systems are shown, for example, in U.S. Pat. Nos. 4,136,578; 4,241,541; 4,253,276; 4,266,371; 4,305,228; 4,346,372; 4,497,135; 4,521,993; 4,617,758; 4,823,508; 4,840,075; 4,843,703; 4,845,830; 4,894,902; 4,937,976; 4,938,086; 4,945,678; 5,054,239; 5,152,103; 5,199,216; 5,313,737; 5,493,813; and 5,813,171, all of which are fully incorporated herein by reference.  
         [0004]     The above-mentioned references disclose various operator control unit and system control units for mechanically opening and closing windows and skylights. A problem with prior motorized operator systems, however, is that they have typically been difficult to install. Operable fenestration units such as skylights and windows are made in many sizes and configurations, and accordingly, a motorized operator must generally be adjusted for the particular parameters of the individual unit to which it is fit. This involves, for example, determining and setting operator limits corresponding to the fully open and closed positions of the unit. If these limits are not properly determined and set, the operator may continue to run and apply force to the skylight or window after it has reached the full physical limit of its travel, thereby causing damage to the operator, hardware, or unit.  
         [0005]     Another installation problem arises in adapting the operator to locally available electrical power. Alternating current power systems within residences and commercial buildings in the United States generally operate at 120 volts and 60 Hz. In other parts of the world, however, 240 volt systems are common, as are 50 Hz frequencies. With prior art power operator systems, it is accordingly necessary to ensure that the proper voltage and frequency is supplied by the building electrical power system to avoid damage to the operator motor and circuitry.  
         [0006]     Moreover, in installations where wireless remote control operation is desired, prior art systems have generally provided that control by means of infrared signals. Such signals, however, generally enable only “line-of-sight” communication between the transmitting and receiving devices. As a result, the operator system may not be easily usable with windows or skylights having drapes, blinds, or curtains, or where walls or other obstructions intervene between the transmitter and receiver.  
         [0007]     In these days of rising energy prices it is common for great care to be taken in the use of thermostatic control systems for controlling air conditioning. Little development has been directed toward the use of more passive ventilation options under thermostatic control. It would be desirable if a thermostatic control sensed the local temperature where people actually are rather than the temperature at whatever fixed location the thermostatic control happens to be located.  
         [0008]     What is still needed in the industry is an easily installable power operator system for windows and skylights that addresses the problems presented by prior art devices.  
       SUMMARY OF THE INVENTION  
       [0009]     The present invention addresses the need of the industry for an easily installable power operator system for windows and skylights. The present invention also assists in energy savings by permitting a home owner or building operator to take advantage of passive cooling controlled by automation. In addition, the present invention senses the temperature at the location of a remote control that can follow the occupants of the structure wherever they might be so that a desired temperature can be achieved where the people actually are located.  
         [0010]     In a preferred embodiment of the invention, a power operator and control system includes means for automatically determining the physical travel limits of a particular window or skylight on which the system is installed and automatically varying the motor torque to prevent damage to the system, hardware, window, or skylight.  
         [0011]     In further preferred embodiments of the invention, the operator and control system includes a DC regulated power supply along with means enabling direct application of AC power at any common voltage or frequency. It is thereby unnecessary to ensure that AC power of any specific voltage or frequency is available at the site where the operator system is to be installed, greatly enhancing ease of installation.  
         [0012]     Also, other preferred embodiments of the invention may include a wireless remote control system for the operator wherein the signal used for communication is at radio frequency (RF). This enables the remote control system to be used in applications where line-of-sight positioning of transmitter and receiver is not possible, thereby greatly increasing the flexibility of installation and operation of the system.  
         [0013]     In another embodiment of the invention, the remote control includes a temperature sensor and a processor. The system is capable of controlling the opening and closing of at least one skylight located in an upper portion of a structure and at least one window located in a lower portion of the structure. The window is preferably located on a shady or cooler side of the structure. Thus the remote control senses a temperature at its location and, if that temperature is higher than a preset value, opens the window and the skylight to facilitate passive movement of warm air out through the skylight and cooler air in through the window by convention. The remote control located thermostat may also eliminate the need for a hard wired thermostat, thereby reducing system installation time and cost. Further, the remote control may be made to simultaneously operate any number and combination of windows and skylights as may be desired.  
         [0014]     Other features and advantages of the invention will be apparent from the following description of the preferred embodiments thereof, and from the claims.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0015]      FIG. 1  is a perspective view of an embodiment of a motorized window and skylight operating system according to the invention;  
         [0016]      FIG. 2  is a perspective view of another embodiment of a motorized window and skylight operating system according to the invention;  
         [0017]      FIG. 3  is a perspective view of a first embodiment of an operator control unit with wall switch control;  
         [0018]      FIG. 4  is a perspective view of a second embodiment of an operator control unit with wall switch control;  
         [0019]      FIG. 5  is a perspective view of yet another embodiment of the operator control unit with wall switch control;  
         [0020]      FIG. 6  is a partial perspective view of a motorized operator system according to the present invention coupled with a window;  
         [0021]      FIG. 7  is a perspective view of the operator control unit and motorized operator having a chain drive; and  
         [0022]      FIG. 8  is block diagram of a portion of several components of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0023]      FIGS. 1 and 8  depict a motorized window and skylight operator system  10  according to the present invention. The motorized window and skylight operator system  10  generally includes a motorized operator  12  and an operator control unit  14 . Optionally, the system  10  may include a remote control unit  16  for wirelessly controlling the system from a remote location. In the depicted embodiment, the motorized operator  12  generally includes an operator cover  18 , an upper portion  20  having a motor  22 , and a lower portion  24  having a chain drive  26 . Other drives may also be used as will be recognized by those skilled on the art. The upper portion  20  may be coupled with the lower portion  24  by fasteners  28  such as screws. The operation and further details of the motorized operator  12  are disclosed in U.S. Pat. Nos. 4,521,993 and 4,945,678, both previously incorporated herein by reference.  
         [0024]     In the context of this application the term fenestration is to be construed to include but not be limited to openable windows and openable skylights.  
         [0025]     The operator control unit  14  may be controlled by any suitable means including wireless remote control  30 , automatic sensing units  31 , or a wired switch  32  which may be conveniently mounted in a wall switch panel  34 . The operator control unit  14  enables opening, closing or stopping movement of the window or skylight connected with the motorized operator at any intermediate point between the fully open and fully closed position of the window or skylight.  
         [0026]     Automatic sensing units  31  may include sensors for sensing incremental movement of the window, the presence of a substance (e.g., carbon dioxide and water), or physical conditions (e.g., temperature and relative humidity) in an area. These sensing units may also include means for transmitting control signals to the operator control unit if particular movements occur or conditions arise. Moreover, the sensing units may be located either adjacent or remote from the operator control unit to effect automatic opening or closing a window upon the occurrence of preselected conditions at the sensor.  
         [0027]     Some non-limiting examples of these sensing units include sensors for monitoring temperature, heat, carbon dioxide, rain, fire, smoke, and moisture sensors. In one example, a heat or smoke detector is used to detect the presence of fire and smoke and to signal opening or closing the window or skylight as desired to control smoke ventilation. In another example, a thermostat is used to effect automatic opening or closing a window or a skylight when a predetermined temperature is reached at the thermostat. This allows the use of passive cooling under a thermostatically controlled system.  
         [0028]     Moreover, a rain sensor may be used to effect automatic opening or closing a window or a skylight upon the detection of rain. The rain sensor may have gold plated contacts and/or alternating current (AC) sensing. Gold plated contacts reduce corrosion of rain sensors by rain, particularly rain with acidic contamination. Alternating current sensing may provide a more reliable method of detecting rain than direct current sensing as is used in many prior art sensing systems.  
         [0029]     If desired, the system may be controlled with any suitable wireless remote control  30  including apparatus using infra-red (IR), radio frequency (RF), sound, microwave, electrical, or magnetic signals. In one preferred embodiment, a handheld unit  36  includes an RF transmitter to send commands to a receiver in the operator control unit.  
         [0030]     RF signaling eliminates the need for “line of sight” proximity of the system transmitter and receiver as in prior IR signaling systems. Further, RF signaling eliminates the problem of interference by direct sunlight encountered with IR systems. Third, the RF systems work in multi-directional orientation so as to avoid the need to point the transmitter directly to the receiver. The RF transmitter may use a “rolling code” system as is known in the art to help safe guard against frequency capture. The transmitter communicates the key code, information on the command type (such as open, close, window, and blind), and the unit code (such as 1-9 and “all”). This enables the remote to control an infinite number of motors, grouped into 1 of 9 different unit codes or groups, and control them individually or all at once. The communication may be made in a “burst” or “packet” transmission which contains all the information on the command. Moreover, the “packet” information may be sent twice to ensure accuracy and eliminate false signals. Although any suitable frequency or modulation method may be used, in one currently preferred embodiment the transmission frequency is 433 MHz AM.  
         [0031]     Each operator control unit  14  can be connected with and control multiple motorized operators  12 , enabling simultaneous control of multiple windows and/or skylights. For example, a thermostat connected with a single operator control unit  14  may open and close several windows and skylights simultaneously to maintain a more comfortable interior temperature and take advantage of the “chimney cooling effect” to reduce energy consumption. Taking advantage of passive, convective cooling can realize substantial energy savings.  
         [0032]     In some embodiments, the operator control unit  14  may include a DC regulated power supply that converts AC power supplied at any common voltage and frequency to a constant and regulated DC output, thereby improving operator motor  22  performance by reducing speed and torque fluctuations caused by fluctuations in the AC power supply. The power supply enables direct application of varying worldwide power inputs to avoid the requirement for separate transformers and power supplies or re-wiring of transformers to compensate for changing voltage requirements.  
         [0033]     In some embodiments, the operator control unit  14  includes means for controlling the torque of motorized operator  12  through software control of output current to motorized operator  12 . The torque controlling means adjusts to provide the necessary torque to drive the system and allows current settings to be set to specific parameters for different operator systems  10  through software control determined by appropriate switch settings on a control board. This allows the creation of a custom profile for each operator system. The torque controlling means allows the operator torque to increase and decrease at different stages of operation to avoid damage to motorized operator  12  and to the controlled windows or skylights.  
         [0034]     The operator control unit  14  may include means for resetting the system with a wall switch panel  34  controlled by a remote control  30 ; means for changing switch settings on the control board; and means for powering down and back up. The means provide various flexible options to reset the system and to control the system easily.  
         [0035]     In further embodiments, the operator control unit  14  includes other components or routines, such as main control loop, initialize window routine, read line voltage and adjusts for changes routine, drive motor routine, timer interrupt service routine, and read inputs and determine a goal positions routine, as described in U.S. Pat. Nos. 4,933,613; 5,004,961; 5,285,137; 5,355,059; and 5,449,987, all of which are fully incorporated herein by reference.  
         [0036]      FIG. 2  depicts a motorized window and skylight operating system according to the present invention. The system generally includes a motorized operator  12  with a chain drive or gear drive, a remote control  30 , and an operator control unit  14 . The chain drive motorized operator  12  is generally used with heavy skylights, while the gear drive is generally used for windows and lighter weight skylights.  
         [0037]      FIGS. 3-5  depict three embodiments of the operator control unit  14  suitable for the motorized window and skylight operating systems according to the invention. In the depicted embodiments, the operator control unit  14  is wired to a wall switch panel  34 . The wall switch panel  34  may include a membrane switch  38  which makes wall switch panel  34  easy to clean and unobtrusive. A cut groove  40  may be incorporated around the membrane switch to allow for placing and cutting of wall paper over the face of the entire wall switch panel  34 . This cut groove  40  also serves as a paint barrier to prevent paint from getting on the membrane switch when the face of the wall switch panel is being painted. An optional bi-color light emitting diode (LED)  42  may be incorporated on the wall switch panel  34  for providing feedback to the installer or user on the operating status and fault codes of the motor  22  or control board.  
         [0038]      FIG. 6  depicts the motorized operator system  10  of the present invention engaged with a window  44  having a rotary crank type manual operator mechanism  46  as is commonly known in the art. The motorized operator  12  couples to rotatable shaft  48  of the window operator mechanism  46  using a spline adaptor  50  as depicted. The motorized operator  12  is attached to the frame of the window  44  with a bracket  52 .  
         [0039]     In some embodiments, the operator control unit  14  itself may be installed in a wall with the operator control unit  14  recessed substantially inside the wall such that the only visible feature is a low profile wall switch panel  34  that matches a standard size (4.5″×4.5″) 2-gang electrical box face plate. In other embodiments, the system may incorporate easy break-off flanges  54  that allows common operator control unit  14  to be installed in both new construction projects and in remodeling projects.  
         [0040]     The operator control unit  14  may be installed in 0, 90, 180 and 270 degree orientations while the mating wall switch panel  34  can remain in the normal viewing angle. This provides the end user more installation options. This may be accomplished through the use of two sets of mounting holes  52  in the box  58  to mount the wall switch panel  34  and the use and placement of two knock-outs  60  for high-voltage input wiring. The two sets of mounting holes  52  are then oriented orthogonal to each other.  
         [0041]     In some embodiments, common screws or nails are used to mount operator control unit  14  into the wall. High-voltage AC input wiring can be routed into the box  58  on two opposite sides via removable knock-outs  60  to provide for ease of assembly. In some embodiments, a strain relief bushing of push-in design may be provided to allow Romex style nonmetallic sheathed wiring to be pushed into box  58  without the need to assemble and tighten any fasteners to provide clamping force. The wiring access hole left when knock outs  60  are removed may be designed to accept standard ½″Romex or conduit fittings to meet the strain relief requirement.  
         [0042]     A terminal block  62  including an easy snap-on feature may be provided to allow easy and secure hook-up of supply wiring and to fasten the terminal block  62  to the electronic box  58  sidewalls without requiring any additional fasteners.  
         [0043]     In some embodiments, motor  22  in the motorized operator  12  is a high reduction gear motor with an interchangeable drive bushing which fits onto the crank shaft  48  of manual window or skylight operators  46 . A 24 volt DC motor  22  is used to power motorized operator  12 .  
         [0044]     Motor  22  is controlled digitally through a pulse width modulation (PWM) control circuit. The control circuit monitors current drawn at the motor to sense the position of the window or the skylight. When the window or the skylight reaches a pre-determined stall position in either open or closed orientations, the motor current spikes to the stall current limit allowed by the control. This serves to protect the motor  22  from over current burn-out and establishes an end point location for the control program.  
         [0045]     The operator control unit  14  may include a digital processor  63  capable of running a control program. The control program may include an initialization routine to prevent the motorized operator  12  from reaching the full open end point of the hardware, since this type of stall load severely shortens the life of the hardware. The initialization routine first determines parameters related to the end points of the hardware (stall in open and close) and the time between open and closed positions. The end point parameters are stored in a non-volatile memory connected with the digital processor  63 . In one embodiment of the invention the program stops the fenestration at 75% of full open on the first command to “open.” Each successive “open” command opens the fenestration another 5% until the fully open position is reached. These stop points may be estimated in comparison with the motor  22  rotation count between full open and full closed stall conditions.  
         [0046]     The control program may also provide a safety or obstruction detection and avoidance feature. This feature enables the window or the skylight to sense the presence of an obstruction during all but the last 20% of the closed position, preferably the last 10%, more preferably the last 5%. This is accomplished by using a lower amperage cutoff point for the motor.  
         [0047]     Further safety may be provided through the use of a screen interlock. The screen interlock is a device fastened to the screen of the motorized window. The screen interlock interrupts the power to the drive motor  22  when the screen is removed from the window, thereby preventing the insertion of fingers of other body parts into the fenestration where they might be caught in the closing process. Thus the screen acts as a safety barrier.  
         [0048]     In some embodiments, the operator control unit  14  includes a six switch DIP on which the user sets specific operating parameters by placing various switches on or off. The positions of switches one and two are used to determine the type of motor to be controlled (motors for window, light skylight, or heavy skylight) or whether the unit is a leader or follower (for skylight synchronous operation). Switch three is used to set the operating direction of the window motor (clockwise vs. counterclockwise). Switch four is used to signal the control board that motorized blinds are connected to. Switches five and six are used to determine the number of locks (such as one, two and none) to drive on a motorized casement window or to tell the control board which synchronous motor positions are for skylight synchronous operation.  
         [0049]     In some embodiments, the control circuit monitors a number of input points and drives the motor accordingly. The first and primary input to the control circuit may be via a wall switch panel  34  connected directly to the control board. The second input may be via a radio frequency (RF) receiver, which is responsive to a remote control as previously described. The third input may be via a high priority input (HPI), which is a set of three pair control loops.  
         [0050]     The first loop of the HPI is the open and hold or smoke vent port. This port enables the direct connection of a pair of contacts to open the window or the skylight and lock out the wall switch panel  34  control in the case of fire detected by a fire or smoke sensor connected to the port. The second port of the HPI is the close and hold or security port. This second port enables the direct connection of a pair of contacts to close and lock out the vent when it is controlled by a home security system. The third HPI port works in conjunction with the security port by providing a positive (dry contact) feedback that the fenestration is in the fully closed position. The third port enables the fenestration to signal the security system that the fenestration is closed prior to arming the security system monitoring command.  
         [0051]     An additional input port may be built into the control circuit for connection to a rain sensor (not shown), which will close the window or the skylight upon sensing condensing moisture or raindrops on its contact surface.  
         [0052]     Further, the control circuit may provide an interface for 12 volt DC operated power blinds. The blinds connected to the interface may be controlled via a hand held remote control or through the wall switch panel.  
         [0053]      FIG. 7  depicts a perspective view of an operator control unit  14  engaging with a motorized operator  12  having a chain drive  26  for opening and closing windows and skylights. The motorized operator  12  is in a close proximity with and connected through a cable to operator control unit  14 . The motorized operator  12  includes a lower portion having a chain drive  26  and an upper portion having a DC motor  22 . The operator control unit  14  includes a control board (not shown). In some embodiments, the control board (not shown) enables asynchronous control of multiple skylights using a single system control unit, such as a remote control  30 , a membrane switch  38 , high priority inputs (HPI), or a rain sensor. A command signal from either the remote control  30 , the membrane switch  38 , the HPI, or the rain sensor to one primary skylight receiver board is communicated through hardwiring from a RS485 bus to a plurality of independent, secondary skylights downstream of the primary skylight. The secondary skylights execute the command with no feedback to the master. A bi-color light emitting diode (LED)  42 , visible through the unit cover, may be optionally incorporated on the control board (not shown). LED  42  provides feedback to the installer or the user on the operating status and fault codes of the motor or control board.  
         [0054]     A wall switch panel  34  may be connected to the control board through a RJ45 cable and connector  43 , such as those depicted in  FIG. 5 , to provide additional control input options to the user. Optionally, a standard 110VAC single pole/double throw (momentary center “off”) switch (not shown) may be used to control the unit&#39;s opening, closing, or resetting without either a wall switch panel  34  or a remote control  30 . The control board may include a RS485 input to provide for home automation control system interface. The operator control unit  14  may include locating tabs on the base of the operator control unit  14  to align the box  58  to the operator control unit  14  during installation, thereby preventing misalignment and simplifying installation.  
         [0055]     In some skylight embodiments, snap features are provided to fix in place temporarily the cover  18  for the motorized operator  12  or the operator control unit  14  during installation until the more permanent mounting fasteners  28  such as screws can be installed. This prevents the cover  18  from “falling” from the unit and possibly being damaged or creating a safety hazard.  
         [0056]     The chain drive  26  in the motorized operator  12  includes a heavy lift chain  64  that is capable of lifting heavy skylight lids. The chain  64  is driven by a high reduction gear drive  68  coupled to a 24 volt DC motor  22 . Again, the motor  22  may be controlled digitally through a pulse width modulation control circuit. The digital control system may also include simultaneous monitoring of the motor  22  speed and rotations through a Hall effect pickup and a magnet attached directly to the motor  22  shaft. The control circuit monitors the current drawn at the motor  22  to sense skylight lid position.  
         [0057]     When the skylight lid reaches a pre-determined stall position in either open or closed orientation, the motor  22  current spikes to the stall current limit allowed by the control. This serves to protect the motor  22  from over current burnout and establishes the end point position for the control program. The control program then runs through an initialization routine to determine parameters related to the end points (stall in open and close) and the number of motor  22  rotations between open and closed positions. These parameters are stored in a non-volatile memory and used to control the skylights position depending upon the input commands given to the control circuit. The control program is designed to prevent the motorized operator  12  from reaching the full open end point of the hardware, since this type of stall load severely shortens the life of the hardware. In some embodiments, the unit may open to 90% of full open position on skylights. These stop points may be estimated in comparison with the motor  22  rotation count between full open and full closed stall conditions.  
         [0058]     Again, an additional input port may be built into the control circuit for connection to a rain sensor. The additional input port enables a signal to close the window or the skylight upon sensing condensing moisture or rain drops on its contact surface. Optionally, a wall switch panel  34  may be used to input commands to the operator control unit  14  connected through a RJ45 cable and a cable connector on each end of the cable  43 .  
         [0059]     To lift heavy skylights, multiple motors, either in one single motorized operator  12  or in a multiple motorized operators  12 , may be used together. The control circuit for these multiple motors  22  may include a two-way communication link via a pair of four wire connection ports. These ports enable the motors  22  to communicate the relative chain position and motor  22  revolution counts to insure that the skylight lids are moved by the motors  22  in unison. The motor  22  may also be controlled digitally through a pulse width modulation control circuit, which may also simultaneously monitor the motor  22  speed and rotations by using a Hall effect pickup and a magnet attached directly to the motor  22  shaft. Without feedback produced by the Hall effect pickup, the motors  22  could run at different speeds, and result in the chains running “out of time.” In some instances, misalignment of the chains by more than six millimeters total between the motors may result in damage to the skylight or even breakage of the glass.  
         [0060]     The present invention may be embodied in other specific forms without departing from the central attributes thereof, therefore, the illustrated embodiments should be considered in all respects as illustrative and not restrictive, reference being made to the appended claims rather than the foregoing description to indicate the scope of the invention.