Method and apparatus for mounting a barrier operator

An apparatus and a method for quick mounting of a barrier operator on a ground surface is disclosed. The apparatus includes a mounting frame positioned on the ground and mounting structure extending into the ground surface. Concrete may then be poured into the mounting frame to form an operator support on which the barrier operator is mounted. The mounting structure may be a mounting post received in an excavated portion of the ground, and the mounting post and excavated portion may then be filled with concrete. The concrete in the frame, mounting post, and mounting frame may communicate as to form a unitary mass with the mounting frame and mounting post. The mounting structure may be mounting rods secured directly with the ground. The mounting rods have a spiral flute for driving into and securing with the ground.

FIELD OF THE INVENTION

The invention relates to mounting a barrier operator and, in particular, to mounting a barrier operator on a ground surface.

BACKGROUND OF THE INVENTION

Currently, a number of different systems for opening, closing, or otherwise changing the position of a movable barrier are known. Of these, some are mounted on a wall or a ceiling for moving a door or gate. Other systems, or barrier operators, may be mounted on or at a ground surface for moving the barrier.

When mounting a barrier operator on a ground surface, a support structure is provided for securing and supporting the operator. The operator typically has an arm, a chain, or some other device coupling the operator to the barrier, such as a swinging gate. The operator moves the arm, for instance, to apply a force to the large, often metal barrier that spans across a driveway or paved entrance. As every action has an equal and opposite reaction, the force applied by the operator to pull or push the gate will also be experienced by the operator itself. Accordingly, it is important that the structure to which the operator is mounted be soundly installed with the ground, and that the operator itself is soundly installed to the support structure.

The support structure to which the operator is mounted is commonly referred to as a pad and is formed of poured concrete. To install the support structure, a ground area is excavated to a depth, typically at least a foot and often thirty inches or more. This depth will vary based on local soil conditions and other factors such as the frost line depth for the region or locale. In particular, local building codes are consulted for determining the proper minimum depth.

The excavated area is then surrounded by a form rising above the ground level. Concrete is then poured into the excavated area and into the form so that a height of the pad formed is typically at least three inches above the ground level. As the operator is mounted on a top surface of the concrete pad, the pad height provides clearance above the ground so that shifting soil, standing or flowing water, or snow does not as easily enter or cover a bottom portion of the operator. In this manner, the anchoring members, such as bolts, that hold the operator in place on the pad do not continually reside in a moist environment which would otherwise lead to corrosion and, ultimately, failure.

The concrete pad receives the barrier operator on the top surface, typically secured thereto by bolts. The bolts may be pre-set in the poured concrete prior to curing, or bolt holes may be drilled later for receiving the expansion bolts.

In any event, the concrete pad must cure prior to mounting of the operator. Prior to curing, the concrete pad is not capable of supporting the operator. Therefore, if bolts are pre-set, a template must be used to suspend and position the bolts. Alternatively, a template must also be used to drill the bolt or anchor holes for mounting the operator at a later time.

The entire installation process requires an extended period of time and more than one visit to the installation site. At a first instance, the excavation, the building of the form, and the pouring of the concrete may occur on a single day. However, once the concrete has been poured, a period of time must be waited for the curing process. Depending on temperatures and other factors, this curing time can be several days. An installer must return to the site at a later date and perform the steps for installing the operator itself onto the pad.

The provision of the concrete pad, as described, presents additional problems. The entire size of the pad can be, for example, in the order of 36″ in height, 24″ long, and 28″ wide. Such a volume has a significant materials cost and requires an equally significant amount of labor to mix and pour.

Because of the pad size, the concrete is susceptible to failure itself. A block of such as size should be agitated as it is poured to ensure large gas pockets are not formed. Additionally, proper curing may be compromised by soil or weather conditions, and improper curing may result in the pad cracking.

Accordingly, there has been a need for improvements in mounting barrier operators on a ground surface.

SUMMARY

A movable barrier operator mount is disclosed herein for securing and mounting a movable barrier operator with ground. The operator includes a device for coupling the operator with a movable barrier for opening and closing the movable barrier, and the operator includes a motor and a drive system for actuating the coupling device. The operator further includes structure for securing with structure on the operator mount.

The operator mount secures with the ground such that the operator may be secured directly to the operator mount immediately upon installation. In this manner, the issues attendant with allowing setting material such as concrete to cure prior to installation of the operator are relieved. That is, an installer may perform all of the steps necessary for securing the operator with the ground in a single visit.

Toward this end, the operator mount includes a frame positionable flush with a top surface of the ground and having the structure for securing with and supporting the operator located with the frame. The frame defines a volume or form that is filled with the setting material, and the securing structure of the operator mount is positioned above or otherwise clear of the volume. Thus, the securing structure supports the operator above the ground, and a clearance is provided for attaching securements or securing elements to the operator mount and the operator. As such, the state of the setting material (cured or un-cured) bears no impact on the ability of the securing structure to be joined with the operator.

The securing structure of the operator mount is provided by mount plates. The mount plates preferably have pre-located features, such as pre-drilled holes, for securing with the operator. As such, the needs for a template and/or for drilling into an operator pad, as is the case for the prior art, is eliminated.

In one form, the operator mount includes depending structure fixedly secured with the frame. A portion of the ground is excavated for receiving the depending structure. The depending structure includes a cavity, and the excavated ground portion is provided with a clearance around the depending structure. Both the clearance and the cavity are filled with setting material. The setting material in these spaces may communicate with the volume of the frame such that the setting material forms a unitary structure in the cured state. The operator mount may also include mounting structure, such as stakes, with are driven directly into the ground in a linear fashion. The operator mount provides sufficient support and rigidity to permit the operator to be mounted therein, prior to curing of the setting material. Further, the operator may be installed without waiting a time period for the cure, so that an installer may perform all work in a single visit.

The excavated ground portion is significantly reduced in comparison to an excavated ground portion required to form the operator pads of the prior art. Accordingly, the amount of work and time required to excavate the ground portion is also significantly reduced, as are the materials cost of the setting material and the risk of failure of a large block of concrete, for instance.

In another form, the setting material is placed only in the frame. The operator mount is provided with mounting structure received directly into the ground. The mounting structure may be the stakes, noted above, or is preferably rotationally driven members such as mounting rods. The mounting rods may include a spiral-fluted or threaded-screw-like portion such that the mounting rods are self-tapping to obtain purchase directly with the ground or earth. A relatively slow rotation of the mounting rods, with downward pressure, drives the mounting rods and fluting into the ground without churning or plowing the ground.

DESCRIPTION

Referring initially toFIG. 1, a barrier operator10having a housing12is shown secured to an operator mount14which is, in turn, secured with an area or volume of ground16. A support wall20is provided for supporting a movable barrier22such as a gate. The barrier22is depicted as swingably secured to the support wall20, though the support wall20alternatively may be a fence post or the like, or the barrier22may be moved in a linear direction. The operator10is operably coupled via an operator arm24to the barrier22for moving the barrier22to and between open and closed positions relative to a frame wall26. Typically, the ground16is simply earth, dirt, clay, or other ground materials having a top surface28proximate the support wall20.

The operator mount14is used for forming an operator support30, and the operator mount14and support30together secure and support the barrier operator10. As will be described herein, the operator mount14is a quick-mount such that the support30can be formed and the operator10mounted thereon in a minimal amount of time.

With reference toFIG. 2, the operator10is shown with the housing12removed to expose the operator internal components. The arm24is shown connecting to a drive system32for directing movement of the arm24and, consequently, movement of the barrier22. A control box34is also shown, as is a motor36or the like for providing power to the drive system32and arm24. Each of the arm24, drive system32, control box34, and motor36are secured to an operator frame40.

As best viewed inFIG. 3, the operator frame40secures with the operator mount14and with the internal components of the operator10, as well as the housing12. The frame40includes an upstanding body42with various structures, such as braces44, for securing the components thereto. The frame40also includes side brackets48secured to the body42, and secured with base plates50. To secure the operator10with the operator mount14, the base plates50are secured to the operator mount14with securements or fasteners such as with bolts52, as will be described in greater detail below.

Referring now toFIGS. 4 and 5, the operator mount14for forming the support30is depicted. To install the operator mount14, the ground16is excavated to form a post hole58, as shown inFIG. 1. The operator mount14is then placed over, and mounting structure in the form of a mounting post60is positioned within, the post hole58. The post hole58is sized to be larger than the mount post60, as will be described below. It should be noted that the operator mount14may be provided with a plurality of mounting posts60, though only one is depicted and described herein.

The operator mount14is then forced downward such that a mount frame62is positioned flush with the top surface28of the ground16. The mount frame62is generally rectangular having four sides64a,64b,64c, and64d. Typically, opposed sides64a,64cand64b,64dwould be of equal lengths as to form a rectangle the size of the desired support30. Additionally, the sides64have a height66(FIG. 5) providing a clearance above the ground surface28for the operator10. By way of example, the frame sides64are twenty-four inches long and, and the height66is two inches. However, the shape of the frame62may be of any desired size, shape, and height. The sides64have a bottom edge68against which the ground surface28abuts when the operator mount14is installed with the ground16.

It should be noted that the operator mount14is preferably mounted on the ground to be generally horizontally level. The rotating arm24, for instance, operates best when moving in a plane oriented in the direction of movement of the barrier22. Towards this end, it may be beneficial to level the ground top surface28prior to installing the operator mount14. This may be accomplished either by filling an uneven portion of the ground16, or by an amount of excavation to reduce higher points, or both. In some forms, the operator mount14may be sunk a slight amount into the ground16, and an amount of excavation of the ground16may promote such. In any event, the top surface28refers to the surface of the ground16against which the operator mount14is positioned.

The operator mount14includes mounting stakes74for securing the operator mount14with the ground16. As shown, individual mounting stakes74are positioned at and wrap a short amount over each corner76of the frame62and extend downwardly. Though not shown, a portion of each stake74may extend inside a volume110defined by the sides64. Each stake74is formed of generally two flat portions78aligned with and closely positioned against respective sides64of the frame62. Each flat78tapers inwardly towards a distal end80of the stake74so as to form a point82. In this manner, the point82allows the stakes74to be driven into the ground16to secure the operator mount14flush with the top surface28.

As stated above, the operator mount14is used to form the support30. With particularly reference toFIG. 5, the operator mount14is positioned against the top ground surface28with the mounting post60located within the post hole58formed in the ground16, and the stakes74driven into the ground16. As will be discussed below, the mounting post60is secured with mount brackets120which are, in turn, secured with the frame62. The post hole58is generally larger and longer than the mounting post60such that an amount of space is initially provided surrounding the mounting post60within the post hole58. In an exemplary form, the mounting post60extends twenty-four inches into the post hole58.

Once the operator mount14is positioned flush with the top surface28, setting material such as concrete88is poured to combine with the operator mount14to form the support30. The mounting post60is generally a hollow tubular member defining an interior cavity90. As such, concrete88is poured into the cavity90and into the post hole58around the mounting post60. The cavity90is, for example, six inches square. It is also preferred that the cavity90be open at a mounting post bottom91, as shown inFIG. 5, such that concrete88in the post hole58may communicate and solidify with the concrete88within the cavity90through the mounting post bottom91.

A lower end of the mounting post92includes a number of fixtures93for improving the securement between the mounting post60and the post hole58. It is preferred that the lower end of mounting post92is generally square having four sides94. Each side94of the lower end of the mounting post92includes a cylindrical spur96extending orthogonally from its respective side94. The spur96is hollow to define a cavity or passage100in communication with the interior cavity90of the mounting post60and with the post hole58. As the concrete88is filled into the post hole58and mounting post cavity90, the concrete88will also flow into and, preferably, through the spur96such that the concrete88within and without the mounting post60cures as a unitary structure. In the present form, the spurs96are six inches long, and the passage100has a diameter of one inch.

To form a solid support for the operator10, the concrete88within the mounting post60and post hole58is secured with the mount frame62and with the top ground surface28. As can be seen inFIG. 4, the frame sides64bound the volume110so that the mounting frame62serves as form for concrete88poured therein. The mounting post60has an upper edge112positioned below a top edge114of the frame sides64such that the mounting post cavity90is in communication with the volume110. Additionally, the post hole58is in communication with the volume110. (SeeFIG. 5). Advantageously, concrete88poured into the volume110is then able to cure and solidify with concrete88located within the mounting post cavity90, and with the concrete88located within the post hole58. As noted above, the concrete88within the mounting post60cures and solidifies with the concrete88in the post hole58through the spurs96. In this manner, the mounting post60and operator mount14, in general, are soundly secured with the concrete88and the post hole58. Due to this securement, as well as the mass of the concrete88and the stakes74driven into the ground16, the operator mount14forms the support30for the operator10. Moreover, this combination provides a solid support30for sound connection and securement with the operator10prior to setting or curing of the concrete.

As noted above, the operator frame40secures with the operator mount14. The base plates50of the operator frame40are secured with mount brackets120fixed to the operator mount14. More specifically, the mount brackets120have a generally horizontal mount plate122and a generally vertical fixing plate124so that the mount brackets120form an L-shape. The fixing plates124are fixedly secured, such as by welding, with an upper portion126of the mounting post sides94, and may also be secured with the frame sides64. The mount brackets120are positioned such that the mount plates122are positioned above the top edges114of the frame sides64. This allows a short clearance127between a bottom side128of the mount plates122and the volume110of the mount frame62filled with concrete88. The clearance127allows connectors, such as the bolts52, to be secured on the mount plate bottom sides128. The mount plates122secure with the base plates50, such as with the bolts52.

The described construction of the mount frame62and mount brackets120inhibit the ability of flowing or standing water, snow, or debris to come into contact with the securements such as the bolts52. The frame62and mount brackets120provide the described clearance such that the securements are positioned a distance above any water, for instance. Additionally, the frame62acts as a barrier for material such as water, precipitation, soil, or debris to pass under the securements.

It should be noted that the mount brackets120do not interfere with the communication of concrete88between the mounting post cavity90and the volume110. As best seen inFIG. 5, the fixing plates124have a bottom edge130which is positioned above the ground surface28and above the bottom edge68of the sides64. Accordingly, the concrete88is free to flow or be forced around and below the fixing plates124.

In a preferred form, the mount frame62is provided with additional structure for rigidity and for enclosing the concrete88within the volume110. As can be seen inFIG. 5, the mount frame sides64are provided with crosspieces136along the bottom edges68. The crosspieces136resist deformation of the mount frame62due to shear stress, provide a more rigid structure, and are positioned below a portion of the concrete88located in the volume110.

Preferably, the crosspieces136are formed integral with the sides64to form an L-shape. By way of example, the mount frame62may be formed of a single elongated piece of steel with three90degree notches forming a right triangle cut into one edge at the position of three of the corners. The piece of steel may then be folded along a longitudinal line intersecting each apex of the three triangles so that the steel piece forms the L-shape. The piece of steel may then be folded along a lateral line bisecting each triangle so that a rectangle is formed from the steel piece, and the longitudinal ends of the steel abut and may be joined such as by welding. The edges of the triangles also abut in this configuration, and may be welded if desired.

It is preferred that the height of the operator mount30not decrease over time. Were the operator support30to settle, a number of problems may occur, such as mis-alignment of the arm24and barrier22at their, or increased susceptibility of the securements such as bolts52to moisture. The above-described prior art operator pads have a significant weight due to the volume of concrete which can depress the supporting ground or earth below the pads. The present operator support30formed by the operator mount14provides sufficient support and rigidity required for the operator10while having a much lower weight than the prior art operator pads. Therefore, settling by the operator support30is less likely than for the prior art pads. Additionally, the construction of the frame62such that the frame62filled with concrete88is positioned above and against the ground surface28provides an area of support by the ground roughly equal to that of the prior art pads. Consequently, the weight or force per area on the ground by the operator support30is reduced, in comparison to the prior art pads, without a sacrifice of the support and securing provided to the operator10itself.

As is readily apparent, other constructions for the mount frame62are available. For instance, the mount frame62may be biodegradable, and the stakes74wrapping over the corners76of the mount frame62may extend in a greater distance so that they cooperate with the volume110. In this example, the mount frame62may serve as a form for the concrete88poured into the volume110and may, at some later time, degrade so that the stakes74, mounting post60, and mount brackets120fixed to the operator10remain secured with or embedded in the concrete88.

As can be seen inFIG. 5, a boundary150of the post hole58is well within the extent of the frame sides64. Accordingly, much less work and time are required to excavate the post hole58in comparison to the prior art support pad, discussed above. In addition, the amount of concrete88used is significantly reduced with the operator mount14. As the entire mass of concrete88is much smaller than the prior art support pads, there is less work in pouring and reaming the concrete, and less risk of improper curing.

Due to the construction of the support30using the operator mount14, the operator10may be installed immediately without needing the concrete88to be cured. The position of the operator mount14with the ground16, and being secured there by the stakes74, provides sufficient support for the operator10to be immediately secured thereon. Furthermore, the support30formed by the operator mount14and concrete88provide sufficient support and securement to the operator10that operation of the operator10to move the barrier22, as described above, may immediately be full service, though this may depend on environmental factors such as soil conditions. Alternatively, the operator10may be secured to the support30by connecting the operator frame40to the mount plates122of the operator mount14, while leaving the arm24, for instance, disconnected from the barrier22. In this manner, a user may simply and easily connect the arm24to the barrier22after a reasonable amount of time (for curing of the concrete88) without the need for a return trip by an installer.

Referring now toFIG. 6, an alternative embodiment for a quick-mounting operator mount200for forming an operator support30is depicted having alternative structure for securing the operator mount200with the ground16. As can be seen, the mounting post60of the previous embodiment has been omitted, though it may be included.

The operator mount200includes mounting structure in the form of mounting rods220for securing with the ground16, either in place of or in addition to the mounting post60and stakes74. As can be seen, the operator mount200is provided with mount brackets202for securing with the operator frame40, the mount brackets202being similar or identical to the above-described mount brackets120. The mount operator200further includes a mount frame204having sides206generally constructed as described above for sides64, and crosspieces210which may be constructed in the manner of the crosspieces136. The mount brackets202secure to the sides206.

The crosspieces210differ from the above-described crosspieces136so that the crosspieces210allow the mounting rods220to secure the mount frame204with the ground16. The crosspieces210include bores or slots212extending therethrough, and the mounting rods220are received into and through the slots212. The slots212are open on an inner side222of the crosspieces to allow the mounting rods220to be received therein.

The mounting rods220are designed to seat securely in the ground16. Each mounting rod220has a body224having a lower terminal end230with a sharp tip232for driving into the ground16without a need for excavation or a pilot hole. Positioned a short distance above the tip232is a screw-like element234that is relatively large in comparison to the mounting rod body224with relatively thin spiral fluting236for being rotationally driven into the ground16. Under slow rotation, the element234will self-tap into the ground16while the thin fluting avoids significant plowing or churning of the ground16so that the ground16retains a significant amount of its packed density and integrity. The mounting rods220are provided with a length238such that the fluting236reaches a depth sufficient for securing the mount frame204with the ground16. Preferably, the fluting236makes at least one full turn around the mounting rod body224. Each mounting rod220further has an enlarged head240of sufficient size so that the head240does not pass through the slots212. The head240is preferably formed as to mate with a wrench, pliers or the like, though it may be provided with a recess for a driver such as a flat-head driver, Phillips head driver, or hexagonal key driver.

The operator mount200is simple to install to form the operator support30. The mounting rods220are positioned within the slots212with the head240above the crosspieces210. The mount frame204is then positioned generally in a desired location for the operator10to be located. Each mounting rod220is then driven into the ground16until the mount frame204is flush with the top ground surface28and the mounting rod head240is tightly positioned against its crosspiece210around the slot212. As will be appreciated, a washer (not shown) of various types may be provided between the head240and the crosspiece210to enhance the securement therebetween. As the mounting rods220are not typically susceptible to heave due to frost conditions, the need for the mounting post60and for concrete being poured into an excavated post hole58, as in the previous embodiment, may be eliminated.

Once the operator mount200is secured with the ground16, the operator support30may be formed. As with the previous embodiment operator mount14, the frame204defines a volume250which is then filled with concrete. The mounting rods220may include additional structure (not shown) extending above the head240so that the rods220extend into the volume250and into the concrete received by the volume250. In the event the frame204is biodegradable, such additional structure on the mounting rod220would allow it to remain secure with the concrete in the volume250once the frame204no longer remains or maintains its structural integrity.