Electronic lock with misalignment scoring system

An electronic lock with a lock assembly that includes a bolt movable between an extended position and a retracted position. The electronic lock includes a motor configured to drive the bolt between the extended position and the retracted position. A controller is provided that is configured to control actuation of the motor to selectively move the bolt between the extended position and the retracted position. The electronic lock includes a user interface configured to output information about the electronic lock. A misalignment scoring means is provided for detecting interference to movement of the bolt between the extended position and the retracted position and determining a lock misalignment score based on the detected interference. The user interface identifies the lock misalignment score.

TECHNICAL FIELD

The present disclosure relates generally to electronic locks; in particular, this disclosure relates to an electronic lock with a misalignment scoring system. In some aspects, this disclosure provides a method of testing for misalignment issues in a lock's installation.

BACKGROUND

Electronic locks are well known. Some electronic locks operate in conjunction with an access control system, such as a home automation or home security system, while others operate in a stand-alone manner. Many electronic locks, such as electronic deadbolts, include a bolt that is driven by a motor between a retracted (unlocked) position and an extended (locked) position.

One of the challenges with electronic locks is misalignment of the lock face with respect to the door. If there is interference with movement of the bolt due to poor installation, environmental factors, building settling, etc., operation of the lock is negatively impacted. This problem often presents itself as an early low battery indication after installation. The early loss of battery life is caused by the increased load on the motor to overcome the side load from the door to drive the bolt between locked/unlocked positions. In some cases, the misalignment may completely prevent the motor from driving the bolt, which can be particularly problematic if the user is attempting to remotely operate the lock.

DETAILED DESCRIPTION OF THE DRAWINGS

In illustrative embodiments, an electronic lock is provided with a misalignment scoring system that indicates a level of interference experienced by the bolt as it moves between its extended and retracted positions. The misalignment score provides direct feedback during lock installation or when a user activates the misalignment test. The score enables the user or installer to take action to improve the lock's performance, which could extend the battery life and improve operation of the lock.

FIG. 1is a front view of a door, which could be an interior or exterior door. In this example, the door100has a lockset102with a handle104and an electronic deadbolt106. The electronic deadbolt106is shown solely for purposes of example and this disclosure applies equally to other types of electronic locks with a bolt. A door jamb108is adjacent the door100. The door100is shown solely for purposes of example and this disclosure applies equally to other types of doors that utilize a deadbolt.

Referring toFIG. 2, the electronic deadbolt106includes an exterior assembly200and an interior assembly202. The electronic deadbolt106includes a bolt204that is selectively extended/retracted to lock/unlock the door100with a motor300(FIGS. 3 and 4), depending on whether the user has locked/unlocked the electronic deadbolt106. Examples of electronic deadbolts with motors that move a bolt between extended and retracted positions are described in U.S. Pat. No. 9,024,759 filed Mar. 14, 2014 for a “Wireless Lockset with Integrated Antenna, Touch Activation, and Light Communication Method” and U.S. Application Publication No. 2014/0250956 filed Feb. 25, 2014 for an “Electronic Deadbolt,” both of which are hereby incorporated by reference.

As shown, the bolt204is in the extended position in which the bolt204extends through a strike plate208into a side bore206in the door jamb108. If the bolt204is misaligned, interference from the door jamb108and/or strike plate208as the bolt204moves between its extended and retracted positions could negatively impact performance of the electronic deadbolt106. In addition to misalignment of the bolt204due to the door jamb108and/or strike plate208, if the side bore206is not of constant width there can be an increasing sideload as the bolt204extends into the side bore206. For example, the interference could require increased torque from the motor300to overcome the side load of the door jamb108and/or strike plate208, which would reduce battery life. If the interference from the door jamb108and/or strike plate208is sufficiently bad, this could completely prevent the motor300from driving the bolt204. As discussed below, the electronic deadbolt106includes a misalignment scoring system that rates the level of interference with a lock misalignment score. By using the lock misalignment score during installation (or later when desired), a misalignment can be rectified and performance of the electronic deadbolt106, including battery life, can be improved.

FIGS. 3 and 4are block diagrams showing certain electrical components of an example electronic deadbolt106.FIG. 3shows an illustrative embodiment of a stand-alone configuration, whileFIG. 4is an example embodiment of a networked configuration. In the embodiments shown, the electronic deadbolt106includes a motor300for driving the bolt204between its extended and retracted positions. As shown, a controller302controls actuation of the motor300to drive the bolt204. For example, the controller302could actuate the motor300to drive the bolt204to the retracted position responsive to a user entering a proper authentication code. Likewise, the controller302could actuate the motor300to drive the bolt204to the extended position responsive to receiving a command from a user to lock the electronic deadbolt106. The controller302may be embodied as any type of processor capable of performing the functions described herein. For example, the controller302may be embodied as a single or multi-core processor(s), digital signal processor, microcontroller, or other processor or processing/controlling circuit.

As shown, the electronic deadbolt106includes a misalignment scoring system304with a misalignment detection unit306and a misalignment scoring unit308. Upon entering into a misalignment testing mode, the misalignment scoring system304is configured to determine a lock misalignment score that is based, at least in part, on a level of interference to movement of the bolt204between its extended and retracted positions. The term “lock misalignment score” is broadly intended to encompass any rating of interference with movement of the bolt between its extended (locked) and retracted (unlocked) positions, including but not limited to interference caused by installation issues and/or internal issues with the electronic deadbolt that interfere with movement of the bolt. For example, the interference could be caused by the door jamb and/or strike plate due to installation issues and/or interference internal to the electronic lock that interferes with movement of the bolt even if the alignment with the door is good. The lock misalignment score could be, but is not necessarily, a numerical value. For example, the lock misalignment score could be “low,” “medium,” or “high.” By way of other non-numeric examples, the lock misalignment score could be a graphical representation, audible indication and/or haptic feedback that indicate a level of interference. In some embodiments, the lock misalignment score could be tied to lock functionality. For example, a score of “1” could signify one month of battery life, while a score of “12” could signify twelve months of battery life.

The misalignment detection unit306is configured to detect a level of interference in bolt movement between its extended and retracted positions. There are several means by which a level of interference in bolt movement could be detected. For example, the misalignment detection unit could measure at least one physical characteristic of the motor while driving the bolt between the extended position and the retracted position. In some embodiments, the misalignment detection unit306could include an electrical sensor to detect a current, voltage, and/or power drawn by the motor300in driving the bolt204between its extended/retracted positions. In other embodiments, the misalignment detection unit306could include a torque sensor to detect an amount of torque exerted by the motor300to drive the bolt204between its extended/retracted positions.

The misalignment scoring unit308is configured to take the data measured by the misalignment detection unit306and determine a lock misalignment score. For example, a current, voltage, power and/or torque measurement made by the misalignment detection unit306could be compared with a baseline measurement, which would represent no interference, and the lock misalignment score could increase as the current, voltage, power and/or torque needed by the motor300to drive the bolt204increased from the baseline measurement. There are numerous ways of establishing a baseline measurement. In some embodiments, the baseline measurement could be established during installation by actuating the bolt204between its extended and retracted positions with the door open. Embodiments are also contemplated in which the baseline measurement could be established during production of the electronic deadbolt106during factory calibration of the lock and stored in memory. By way of another example, the baseline measurement could be established during an initial handing process of the electronic deadbolt106when the lock is first installed. In some cases, the baseline measurement could be a programmed constant that was established through empirical measurements. In some embodiments, the comparison with the baseline measurement could be made on absolute measurements. For example, a peak current, voltage, power and/or torque level could be compared with that of the baseline measurement to determine a lock misalignment score. By way of another example, a rate of change of the current, voltage, power and/or torque measurement could be used to determine a level of interference. For example, there may be different current, voltage, power and/or torque levels during the operation of the motor through various phases of driving the bolt (e.g., starting motor, driving bolt, stopping motor, etc.). The measurements during various phases of the motor's operation could be compared with the baseline to determine the lock misalignment score.

As mentioned above,FIG. 3shows an embodiment of a stand-alone electronic deadbolt106with a user interface310on the electronic deadbolt106.FIG. 4shows an example embodiment in which at least a portion of the user interface310is off-loaded from the electronic deadbolt106onto a separate device. In the example shown, the electronic deadbolt106includes a communication unit400that communicates with a computing device402, which provides at least a portion of the user interface310. The communication unit400may be configured to use any one or more communication technology (e.g., wired or wireless communications) and associated protocols (e.g., Ethernet, Bluetooth®, Wi-Fi®, WiMAX, Zigbee®, Z-Wave®, etc.) to effect such communication. The computing device402may be embodied as, without limitation, a computer, a workstation, a server computer, a laptop computer, a notebook computer, a tablet computer, a smartphone, a mobile computing device, a desktop computer, a distributed computing system, a multiprocessor system, a consumer electronic device, a smart appliance, and/or any other computing device capable of providing a user interface. By way of an example, the user interface310could include an app on a mobile device through which a user could interact with the electronic deadbolt106. Although the example inFIG. 4shows the user interface310entirely off-loaded to the separate computing device as an example, a portion of the user interface310could still reside on the electronic deadbolt106and only a portion on the computing device402.

In some embodiments, the lock misalignment score is intended to be a consumer or installer facing feature that can be used during installation (or at a later date) to rectify a misalignment. Embodiments are also contemplated in which the lock misalignment score could be communicated to a backend service (e.g., through the communication unit400) where other usage and performance logs are collected to trigger a service call or as a resource to customer support staff. The user interface310conveys the lock misalignment score to the user. The manner by which the user interface310interacts with (or outputs information to) the user could be visual, audible, and/or haptic. In an embodiment in which the lock misalignment score is conveyed visually, for example, the user interface310could include LEDs in which a certain number (e.g., 3 out of 5) are illuminated to convey the score. In an example in which the electronic deadbolt106includes a keypad, the score could be conveyed by illuminating certain keys on the keypad. In a further example in which the electronic deadbolt106or the computing device402includes a display, the score could be shown on the display. In an embodiment in which the score is conveyed in an audible manner, the user interface310could include a speaker in which a sound conveys the score, such as by a number of beeps, a volume level, a frequency and/or a digitized voice. In an embodiment in which the score is conveyed in a haptic manner, the score could be conveyed based on a vibration pattern, intensity, etc. One skilled in the art should appreciate that many types of user interfaces could be used to convey the lock misalignment score and this disclosure is not intended to be limited to any specific example provided above. In some embodiments, the user interface310could be used for other functions related to the lock misalignment score. For example, the user interface310could include an interface element for a user to select to enter into a misalignment testing mode. For example, the user interface310could be a switch on the electronic deadbolt106for initiating the misalignment testing mode. In some cases, such as when the user interface310includes a display, a graphical user interface element, such as a button, could be used to enter into the misalignment testing mode. For example, the user interface310could include a menu from which a user could select a “misalignment test.” Likewise, the user interface310could be used to prompt the user during the misalignment testing, such as to open/close the door and/or indicate that the door has been opened/closed.

FIG. 5illustrates a method the electronic deadbolt106could execute during use to determine a lock misalignment score. The method begins with block500in which the controller302determines whether a misalignment testing mode has been activated. As mentioned above, the misalignment test could be activated using an element of the user interface310, such as a switch or button, for the user to actuate for the electronic deadbolt106to enter into the misalignment testing mode. If the misalignment test has been activated, the method advances to block502in which the user is prompted to open the door100. The method advances to block504in which a determination is made whether the door100has been opened. For example, a user may actuate an interface element, such as a switch or button, on the user interface310to indicate that the door has been opened. In some embodiments, a sensor could be used to determine whether the door100has been opened. If the door100has been opened, the method advances to block506in which the controller302actuates the motor300to drive the bolt204between its extended and retracted positions with the door100open. While the bolt204is being moved between its extended and retracted positions, the misalignment detection unit306, in block508, detects interference with the bolt204, which allows a baseline level of interference with the bolt to be established. Subsequently, at block510, the user is prompted to close the door100through the user interface310. Although this example describes an initial interference test with the door100open and then closed, this could be performed vice versa with the door100initially closed and then open. The method advances to block512in which a determination is made whether the door has been closed. If the door100has been closed, the method advances to block514in which the controller302actuates the motor300to drive the bolt204between its extended and retracted positions with the door100closed. While the bolt204is being moved between its extended and retracted positions, the misalignment detection unit306, in block516, detects interference with the bolt204. The method advances to block518in which the misalignment scoring unit308determines a lock misalignment score based on the interference measurements. This score is presented to the user on the user interface310, at block520, which provides direct feedback for the user/installer to tweak alignment of the bolt204with respect to the door jamb108depending on the lock misalignment score.

FIG. 6illustrates a method the electronic deadbolt106could execute during use to determine a lock misalignment score in conjunction with a door handing process. The method begins with block600in which the controller302determines whether a door handing process has been activated, which could be user-selected, such as a button on user interface310, or could occur automatically upon power-up, such as when a user inserts batteries into the electronic deadbolt106. A door handling process determines whether the electronic deadbolt106has been mounted to the left side or right side of the door, which affects a direction of movement for the bolt204between its locked and unlocked positions. If the door handing process has been activated, the method advances to block602in which a determination is made whether the door100has been opened. If the door100has been opened, the method advances to block604in which the controller302actuates the door handing process, which moves the bolt204between its extended and retracted positions with the door100open. While the bolt204is being moved between its extended and retracted positions, the misalignment detection unit306, in block606, detects interference with the bolt204, which allows a baseline level of interference with the bolt to be established. Subsequently, at block608, the bolt204is moved to the retracted position. The user is then, at block610, prompted to close the door100through the user interface310. The method advances to block612in which a determination is made whether the door has been closed. If the door100has been closed, the method advances to block614in which the controller302actuates the motor300to drive the bolt204between its extended and retracted positions with the door100closed. While the bolt204is being moved between its extended and retracted positions, the misalignment detection unit306, in block616, detects interference with the bolt204. The method advances to block618in which the misalignment scoring unit308determines a lock misalignment score based on the interference measurements. This score is presented to the user on the user interface310, at block620, which provides direct feedback for the user/installer to tweak alignment of the bolt204with respect to the door jamb108depending on the lock misalignment score.

FIG. 7illustrates a method the electronic deadbolt106could execute during use to determine if a lock misalignment score is outside an acceptable range. For example, the electronic deadbolt106could determine a lock misalignment score each time the bolt204moves between its retracted/extended positions (or periodically as the bolt204moves) and send an error message notification if the score is outside an acceptable range. In this example, the method begins with block700in which the controller302receives a request to actuate the bolt204. Upon receiving such a request, the method advances to block702in which the misalignment detection unit306detects interference with the bolt204as it is actuated between its extended and retracted positions. Subsequently, at block704, the misalignment scoring unit308determines a lock misalignment score based on the interference measurements. The method advances to block706in which a determination is made whether the lock misalignment score is outside an acceptable range. If the score is within an acceptable range, the method loops back to block700. If the misalignment score is outside an acceptable range, the method advances to block708in which a notification is sent regarding the lock misalignment score. For example, a notification could be communicated to the user, such as through a mobile app associated with the electronic deadbolt106, through a backend service (e.g., through the communication unit400) where other usage and performance logs are collected to trigger a service call, through a blinking light or audible beep and/or other local error message.

EXAMPLES

Example 1 is an electronic lock with a lock assembly including a bolt movable between an extended position and a retracted position. The lock includes a motor configured to drive the bolt between the extended position and the retracted position. A controller is provided that is configured to control actuation of the motor to selectively move the bolt between the extended position and the retracted position. A user interface is provided configured to output information about the electronic lock. The lock includes misalignment scoring means for detecting interference to movement of the bolt between the extended position and the retracted position and determining a lock misalignment score based on the detected interference. The user interface identifies the lock misalignment score.

In Example 2, the subject matter of Example 1 is further configured in which the misalignment scoring means measures at least one physical characteristic of the motor while driving the bolt between the extended position and the retracted position.

In Example 3, the subject matter of Example 2 is further configured in which the at least one physical characteristic includes a measurement of an absolute voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position.

In Example 4, the subject matter of Example 2 is further configured so that the at least one physical characteristic includes a measurement of a rate of change in voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position.

In Example 5, the subject matter of Example 2 is further configured in which the at least one physical characteristic includes a measurement of a torque exerted by the motor while driving the bolt between the extended position and the retracted position.

In Example 6, the subject matter of Example 1 is further configured in which the misalignment scoring means compares a baseline interference measurement with a current interference measurement to determine the lock misalignment score.

In Example 7, the subject matter of Example 6 is further configured in which the baseline interference measurement is established by: (1) an interference measurement taken while a door onto which the locking assembly being installed is open; (2) an interference measurement taken during calibration of the electronic lock; (3) an interference measurement taken during a handing process of the electronic lock; and/or (4) storing a predetermined value in a memory of the electronic lock.

In Example 8, the subject matter of Example 7 is further configured in which the current interference measurement is based on an interference measurement taken while a door onto which the locking assembly is installed is closed.

Example 9 is an electronic lock with a lock assembly including a bolt movable between an extended position and a retracted position and a motor configured to drive the bolt between these positions. A controller is provided that is configured to control actuation of the motor to selectively move the bolt between the extended position and the retracted position. The controller is configured to enter into a misalignment testing mode. A user interface is provided that is configured to output information about the electronic lock. The electronic lock includes a misalignment scoring system configured to determine a lock misalignment score responsive to the controller entering into the misalignment testing mode. The misalignment scoring system determines the lock misalignment score based on interference to movement of the bolt between the extended position and the retracted position. The user interface includes a user-selectable element configured to switch the controller to the misalignment testing mode.

In Example 10, the subject matter of Example 9 is further configured such that the misalignment scoring system includes a misalignment detection unit configured to detect interference to movement of the bolt between the extended position and the retracted position.

In Example 11, the subject matter of Example 10 is further configured such that the misalignment detection unit includes at least one electrical sensor for detecting voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position.

In Example 12, the subject matter of Example 11 is further configured such that the misalignment scoring system determines the lock misalignment score based, at least in part, on (1) a measurement of a rate of change in voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position; and/or (2) an absolute voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position.

In Example 13, the subject matter of Example 10 is further configured such that the misalignment detection unit includes at least one torque sensor configured to detect a torque exerted by the motor to drive the bolt between the extended position and the retracted position.

In Example 14, the subject matter of Example 13 is further configured such that the misalignment scoring system determines the lock misalignment score based, at least in part, on a measurement of a torque exerted by the motor while driving the bolt between the extended position and the retracted position.

In Example 15, the subject matter of Example 9 is further configured such that the lock misalignment score is a numeric value.

In Example 16, the subject matter of Example 9 is further configured such that the lock misalignment score is a non-numeric value.

In Example 17, the subject matter of Example 9 is further configured such that the lock misalignment score represents an estimated life expectancy of a power source associated with the electronic lock.

In Example 18, the subject matter of Example 9 is further configured such that the user interface is configured to identify the lock misalignment score in a visual, audible, and/or haptic manner.

In Example 19, the subject matter of Example 9 is further configured such that the user interface includes a user-selectable element configured to represent a door position associated with the lock assembly.

In Example 20, the subject matter of Example 9 is further configured such that the misalignment scoring system is configured to determine a lock misalignment score responsive to the controller actuating the motor.

Example 21 provides a method of testing for misalignment issues in a lock's installation. The method includes providing an electronic lock with a motor configured to drive a bolt between an extended position and a retracted position. A lock misalignment score is determined with at least one processor based on interference to movement of the bolt moving between the extended position and the retracted position. The lock misalignment score is communicated with at least one processor to a user interface associated with the electronic lock.

In Example 22, the subject matter of Example 21 further including measuring interference to movement of the bolt between the extended position and the retracted position while a door associated with the electronic lock is in both an open and a closed position.

In Example 23, the subject matter of Example 22 further includes prompting on the user interface to move a door associated with the electronic lock to an open and/or a closed position.

In Example 24, the subject matter of Example 23 further includes actuating the bolt between the extended position and the retracted position responsive to detecting that a door associated with the electronic lock has been moved to an open and/or a closed position.

In Example 25, the subject matter of Example 24 is further configured such that detecting that the door associated with the electronic lock is open or closed is based on actuation of a user-selectable element on the user interface.

In Example 26, the subject matter of Example 21 further includes entering, with at least one processor, into a misalignment testing mode that initiates determination of the lock misalignment score responsive to actuation of a user-selectable element of the user interface.

In Example 27, the subject matter of Example 21 is further configured such that determining a lock misalignment score includes measuring at least one physical characteristic of the motor while driving the bolt between the extended position and the retracted position.

In Example 28, the subject matter of Example 27 is further configured such that measuring at least one physical characteristic of the motor includes: (1) a measurement of a rate of change in voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position; (2) a measurement of an absolute voltage, current, and/or power drawn by the motor while driving the bolt between the extended position and the retracted position; and/or (3) a measurement of a torque exerted by the motor while driving the bolt between the extended position and the retracted position.

Although the present disclosure has been described with reference to particular means, materials and embodiments, from the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the present disclosure and various changes and modifications may be made to adapt the various uses and characteristics without departing from the spirit and scope of the present invention as set forth in the following claims