CABLE SLACK DETECTOR

Abstract: An apparatus (100) that detects the occurrence of slack in a cable and that compensates for detected slack includes body parts (102, 106) that are movable relative to each other between fully extended and fully retracted positions. A bias device (112) biases the body parts toward the fully retracted position. However, normal tension conditions in the monitored cable overcome the bias and extend the body parts to their fully extended position. If the cable becomes slack, the body parts retract to take up the slack. If the cable slack is of such an extent that the body parts move to a predetermined relative position, the apparatus generates a signal warning of extreme slack conditions by a switch device (140, 142). The apparatus is also a cable slack control for a door operator (20, 22).

Description: CABLE SLACK DETECTOR .76758-51887 gACKgRQVWP Of THE JBT^ffTIW The present invention relates to an apparatus that detects the occurrence of slack in a cable, and compensates for detected slack by adding preloaded tension in the cable. The apparatus further generates a warning signal when the slack in the cable exceeds a certain extent More particularly, the detection and compensation apparatus in accordance with the present invention detects and compensates for slack in the door cable when a door operator lifts and lowers a door by selectively winding and unwinding such cable. The present invention also relates to a door motor drive control system that is equipped with such a cable slack detection and compensation device. A common, conventional commercial door operator system includes a shaft known as a "jack shaft", a drum mounted on the jack shaft, a cable windable on such drum, and a motor drive for turning the shaft and the drum to selectively wind and unwind the cable. The cable is connected to the door so that the motor lifts the door to open die door by rotating the drum in one direction, and lowers the door by rotating the drum in the opposite direction to pay out the cable. In typical commercial door installations, the door is "balanced" through the cable and paying out the cable allows the door to be closed by gravity. Such a commercial door is lowered by gravity and die lowering speed of the door is controlled by die rate at which the cable is unwound from the drum. It is important that tension remains in the cable as the door is being lowered. As long as tension remains in me cable, the drum properly will pay out the cable without risk that coils of cable wound on die drum will release from the drum prematurely. Loss of tension in the cable will occur if the door encounters an obstruction, most often in the door opening, as the door is lowered. Obstruction detection is inherent in residential door operators, but is much more difficult to implement in commercial settings. The typical capacitor start motor powered commercial door operator does not sense when an obstruction impedes or prevents lowering of the door, and consequently die operator will continue to unwind die cable from the drum. Thus, if an obstruction is detected in some other way, such as visually by an operator and tiien die obstruction is removed, the door will fall suddenly because tiie cable has developed slack due to having been unwound partially or fully from the drum prior to me detection of die obstruction. This situation leads to obvious danger to people and property below the door, and the door itself, due to uncontrolled door acceleration. Even a small degree of slack potentially is dangerous because under slack conditions, windings of cable can leave the drain and thus lead to die same uncontrolled downward acceleration. Generally, in hoisting apparatus relying upon a cable for lifting a load, it is conventional to detect and provide alarm conditions when the cable is underloaded or overloaded. For example, U.S. Patent 2,636,953 relates to die use of a slack detection system safety switch. According to die inventor of U.S. Patent No. 2,636,953, as long as die monitored cable is under sufficient tension, a contracting-bias spring will be extended nd i cam follower will have ridden down an inclined cam surface. If slack develops in die monitored cable, the bias spring contracts and the cam follower moves up the incline cam surface to change the condition of a switch and thereby turn off the hoist motor. U.S. Patent No. 1,432,058 discloses an early door operator. This operator features a compensating beam that is balanced so that excessive strain will overcome spring force which tends to hold die beam in balance and tiius tilt the beam to trigger a switch that provides a signal stopping me motor. U.S. Patent No. 394,952 represents an early hoisting arrangement, apparently for an elevator. It protects against botii underload and overload on die cable by a contact bar tiiat, during normal conditions, is centered between overload and underload switch contacts. U.S. Patent No. 5,361,565 also discloses an elevating system tiiat accounts for overload and underload. It shows a winch assembly equipped widi an overload/underload protector. If underload occurs, a compression spring is relieved of pressure and expands to trip an underload limit switch. U.S. Patent 3,012,520, also relates to a garage door opener. Springs allow the opening and closing of die door until tiiere is a certain amount of predetermined opposing force preventing door movement. U.S. Patent Nos. 5,348,373; 5,461,826; 5,477,641; 2,225,003; 3,936,622; and 3,612,487 also have been noted in regard to detecting underload and/or overload. What is missing in the conventional arrangements such as those άissizss ε. above, is a safety device tiiat is capable of preloading additional tension in die cc-b.≤ A eliminate dangerous slack conditions therein. Pnen, if the device can not tension -he oc.≤ sufficiently, the device should signal that the cable still remains slack. This protects against slack conditions in a door operator by equipping the operator to stop the motor immediately from further unwinding the cable when such a slack condition warning signal is received. SUMMARY OF THE INVENTION The present invention is a slack cable detection and compensation apparatus ideally suited for commercial door operators, and a door operating system including such a detection and compensation device. The detection and compensation apparatus in accordance with die present invention is mountable to the door and connectable to the door cable. A preferred detection and compensation apparatus has two relatively movable (slidable) body parts with a stop mechanism for stopping tiieir relative movement at a fully extended (normal) position. The body parts are biased together toward a fully retracted position by a tension spring. The preferred detection and compensation apparatus further includes a position sensor that indicates the relative position of the two body parts. The two body parts are moveable to and from a first position in which die detection and compensation apparatus fully is extended by die tension in d e door cable. If there is some degree of slack in the cable, the apparatus will contract from this fully-extended position to a second, intermediate position, in which die apparatus neither is fully extended nor fully retracted. In die preferred form, die apparatus has a substantial range of relative movement or travel by die two body parts between tiieir fully-extended position and their second or intermediate position. This allows the apparatus to absorb small track pertubations • without tripping. This form of the apparatus retracts along this travel range from its fully- extended position to remove slack from the cable. If, however, the extent of slack developed in die cable exceeds the extent to which the apparatus retracts from the fully-extended position to die intermediate position, the apparatus will continue to retract to its fully-retracted position. As the apparatus continues to retract from die intermediate position to its fully- retracted position, the position responsive device thereof generates a warning signal indicating that die device is not capable of removing all of the slack detected in the cable. In an alternative form, the travel range from the fully extended portion to the intermediate portion is reduced. This provides for earlier generation of die warning signal. This form of the apparatus can have an appreciable travel range between the intermediate position and die fully retracted position in accordance widi die objective of slack take up. In the preferred, exemplary detection and compensation apparatus disclosed in detail in he following, the position sensor is embodied by a device such as a switch circuit. In such an arrangement, a cam follower and a push-button switch of the switch circuit on one of die body parts are actuated when the cam follower engages with a cam surface provided on the other of die body parts. When d e apparatus is in its fully extended condition, the cam surface and the cam follower physically are separated and tiius d e switch is in its unactuated condition. When the two body parts reach rheir intermediate position, die cam follower and the cam surface come into contact. As die apparatus further retracts, the cam surface causes the cam follower to activate die switch and generate the appropriate warning signal. In tins way, die detection and compensation apparatus in accordance with die present invention first attempts to compensate for slack in the door cable, and then, if die extent of slack exceeds die tensioning capabilities of the apparatus, the apparatus causes generation of a warning signal to indicate die continuing slack condition in the door cable. Thus, under normal operation conditions, the tension in die door cable overcomes the spring force of the tension spring to maintain the body parts in their fully extended condition. However, when the operator cable becomes very slack, the bias spring urges the parts together, which thus activates die position sensor to signal a slack condition to die door operator. Door operation stops in this condition to prevent further unwinding of the cable from the drum. This in turn prevents or at least limits door "free fall". A door motor drive control system in accordance widi die present invention also includes an inhibiting device to selectively inhibit d e signal from the slack detection and compensation apparatus. It is contemplated that the inhibiting device responds to when die door essentially is oriented horizontally to generate an inhibit signal. This occurs when the door is fully raised. When die door is horizontal, die inhibiting device generates the inhibit signal to ensure that the slack detection and compensation apparatus will not inadvertently shut off die motor when die cable is expected to become slack temporarily as die door first is being lowered. Summarized, a cable slack condition detection and compensation apparatus, in accord with the present invention, for connecting a cable to an object for Ufting and lowering of the object, comprises: a first body part having a portion cormectable to the cable; a second body part having a portion connectable to the object; means for connecting said first body part and said second body part for movement of said body parts relative to each otiier, said body parts being relatively movable to and from a position in which said apparatus is fully extended, and a position in which said apparatus is fully retracted, said fully extended position and said fully retracted position and positions tiierebetween defining a range of movement of said body parts; biasing means for biasing said body parts in a direction from said fully extended position toward said fully retracted position, whereby said biasing means moves said body parts from said fully extended position towards said fully retracted position along said movement range in response to a presence of slack in the cable; and means responsive to said relative positions of said body parts for indicating when said biasing means retracts said body parts from said fully extended position to a predetermined position along said movement range, a portion of said movement range from said fully extended position to said predetermined position providing slack compensation prior to indicating by said responsive means. A cable slack control apparatus for a door operator having a jack shaft, drum means mounted on the jack shaft, a cable windable on die drum means, and drive means for turning me jack shaft, comprises: cable slack condition detection and compensation means for connecting me cable to die door, said detection and compensation means including means for adding tension to die cable to maintain die cable at a minimum tension, and means for providing a slack detection signal when said means for adding tension to the cable is incapable of tensioning the cable to said minimum tension; and drive control means for causing the drive means selectively to turn the jack shaft in a first direction to unwind die cable and lower a door, and a second direction to wind die cable and lift die door, said drive control means including means responsive to a slack detection signal from said compensation means for stopping die drive means. Alternatively, a cable slack condition detection and compensation apparatus for connecting a cable to an object for lifting and lowering of the object, comprises: a first body part having a portion cormectable to die cable and a first planar portion; a second body part having a portion connectable to the object and a second planar portion; means for connecting said first body part and said second body part for sliding movement of said body parts relative to each otiier along said planar portions thereof, said body parts being relatively movable to and from a position in which said apparatus is fully extended, and a position in which said apparatus is fully retracted, said fully extended position and said fully retracted position and positions tiherebetween defining a range of movement of said body parts; biasing means for biasing said body parts in a direction from said fully extended position toward said fully retracted position along said movement range in response to a presence of slack in die cable; and means responsive to said relative positions of said body parts for indicating when said biasing means moves said body parts from said fully extended position to a predetermined position along said movement range. Also a metiiod of detecting and compensating for slack in a cable used for lifting and lowering an object, comprises the steps of: providing an apparatus including two body portions connected to each other so that they are movable relative to each otiier to and from a first position in which said body portions are fully extended widi respect to each otiier, and a second position in which said body portions are fully retracted with respect ic each otiier, said first and second positions and positions tiierebetween defining a range of movement of said body portions, and means for generating a warning signal when said body portions retract from said first position toward said second position to a predetermined position; connecting one of said body portions to said cable and the otiier of said body portions to said object; biasing said body portions toward said second position agains. ϊer-sic in said cable, whereby when said cable becomes slack, said biasing means moves said body portions from said first position toward said second position in order to take up slack in said cable; sensing when said body portions retract from said first position to said predeteraiined position; and causing said generating means to generate said warning signal upon sensing that said body portions have retracted to said predetermined position. gwEr PESΏ ΓΠQN QF THE PBAWTTOS Further aspects and features of the present invention will be even more apparent from the following detailed description and drawings, and me appended claims. In the drawings: Fig. 1 is a perspective view of a preferred embodiment of a cable slack detection and compensation apparatus in accordance with die present invention; Fig. 2 is a plan view of one side of die apparatus of Fig. 1, witii phantom lines showing the intermediate position of die body parts and the resulting position of the position sensor; Fig. 3 is a plan view similar to Fig. 2, of the opposite side of die apparatus of Figs. 1 and 2; Fig. 4 is a downwardly-looking view of die apparatus as shown in Fig. 1; Fig. 5 is an upwardly-looking view of the apparatus as shown in Fig. 1 ; Fig. 6 is a front view of the apparatus as shown in Fig. 1; Fig. 7 is a rear view of the apparatus as shown in Fig. 1; Fig. 8 is a view similar to Fig. 2, with the fully-extended position o A.s apparatus being shown in phantom; Fig. 9 is a view, similar to Fig. 3, that like Fig. 8, shows die fully-extended position of die apparatus in phantom; Fig. 10 is a perspective view of a conventional door assembly and conventional door operator equipment for raising and lowering the door; Fig. 11 is a perspective view showing an alternative embodiment of the slack detection and compensation apparatus of die present invention as mounted to the door and operatively connected to me door cable; Fig. 12 is a block diagram of a door motor drive control system in accordance with the present invention; Fig. 13 is a plan view of one side of die embodiment of Figure 11; and Fig. 14 is a plan view of die other side of the embodiment of Figure 11. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS For reference, we first show an example of a conventional door assembly 10. Door assembly 10 is of the commercial type which benefits greatly from installation of a cable slack condition detection and compensation apparatus in accordance with the present invention to make operation of door assembly much safer. From Figure 10, die major elements of commercial door assembly 10 are seen. Door 12 includes multiple panels 14 hinged togetiier to permit movement along the door track 16. The door operating system for lifting and lowering door 12 includes a jack shaft 20 that spans the widti of the door. Upon jack shaft 20 is mounted a cable drum 22 for winding and paying out a cable 24 to lift and lower door 12. A drive motor assembly 26 rotates drum 22 to wind or unwind cable 24 . Door 12 is balanced so tiiat it will close under its own weight when the drive motor unwinds die cable 24 from drum 22. While door assembly 10 is ,„„ Λ^ WO 99/08956 depicted wid only one drum 22 and cable 24, it is common practice that a like drum and cable would be provided on die opposite end of jack shaft 20 (die right-hand side of door 12 in Figure 10). Control over the drive motor assembly 26 will be discussed further in detail in the following. With reference now to Figure 11, for illustrative purposes, we show the placement and mounting of a preferred form of a cable slack condition detection and compensation apparatus 100'. Figure 11 corresponds to die left, lower most corner of die door assembly 10 of Figure 10. As such, it is appreciated tiiat Figure 11 shows apparatus 100' mounted to the left-hand, lower most portion of die door 12, for connection with die door cable 24 . It should be kept in mind diat if assembly 10 included a right-side drum 22 and cable 24, anotiier such apparatus 100' would be mounted to die right-hand, lower most portion of the door. As will be described in detail, apparatus 100' so connected to door cable 24, acts to take up slack in the door cable if slack develops in the cable, and if die slack exceeds a certain extent, die apparatus generates a signal to prevent die drive motor assembly 26 from lowering door 12. The embodiment of Figure 11 will be discussed in more detail infra. Figures 1 through 9 are different views of a preferred implementation of a cable slack condition detection and compensation apparatus 100 in accordance with the present invention. To introduce details of die inventive device, it is convenient, initially, to refer to Figures 1 dirough 3. There, detection and compensation apparatus 100 is seen to include a first body part 102 that has a U-shaped portion 104 adapting die apparatus for connection with a door cable such as seen in Figure 11. A second body part 106 rests on die first or cable-connecting body part 102 and the second or mounting body part 106 are secured togetiier by a connecting assembly generally identified by reference numeral 110 . Body parts 102 and 106 and die connecting structure 110 are arranged so that the body parts are slidable relative to each other against die bias imparted by a coil spring 112 . Cable-connecting body part 102 primarily is a flat member with two raised portions and an elongate slot. As mentioned previously, one of the raised portions is die U- shaped portion 104 for connection to die door cable. At its opposite end, connecting part 102, has a stop 114 which like U-shaped portion 104 integrally is formed widi d e connecting part. Connecting part 102 further includes a first protrusion 116 which supports a position sensor 118. A second protrusion, generally opposite die supporting protrusion 116 , provides a first arm 120 for connecting bias spring 112 . Also, in the preferred form of slack condition detection and compensation apparatus 100 as shown in Figures 1 through 9, an elongate slot 122 extends longitudinally substantially along die length of the flat area of cable connecting part 102. In preferred apparatus 100, the mounting part or member 106 is substantially completely flat. It has two bores (not shown) which each receive a bolt-and-nut 124 for coupling body parts 102 and 106 so that they slide with respect to one anodier along the length of slot 122 . Mounting part 106 provides die second arm 126 , opposing the first arm 120 of the connecting part 102, for attachment of spring 112 . At its upper portion mounting body part 106 has an upstanding shoulder 128 that faces stop 114 in opposition to control die extent of relative movement of the two sliding body parts. The edge 130 which defines shoulder 128 leads to a horizontal section 132 of a cam surface generally referred to as surface 134. At a forward-most portion of mounting part 106 (die left-most portion in Figures 1 and 2), horizontal cam surface section 132 intersects widi an inclined section 138 which slopes upwardly, rearwardly from a vertical forward .edge 136 of die mounting part to connect with die horizontal section. Position sensor 118 includes a sensor switch assembly 140 mounted to d e upstanding protrusion 116 of connection part 102 . Sensor switch 140 is conventional and preferably is of a sealed type such as model DCIC-D4RB by Cherry Corporation. When slack condition detection and compensation apparatus 100 is in its fully retracted position shown in Figures 1-3, a cam following switch arm 142 rides on die horizontal section 132 of cam surface 134 so that the switch arm thereof continually actuates push-button switch 144. Activation of push-button switch 144 switches a circuit to place it in an ON or ALARM state and provide a signal indicative of the relative position of body parts 102 and 106. On die other hand, when body parts 102 and 106 are in their fully-extended relative positions as shown in Figures 8 and 9, cam follower 142 and die cam surface 134 are isolated from each other whereby follower arm 142 lowers due to gravity, leaving switch assembly 140 in its normal open or OFF condition with no pressure applied to push-button 144 . Those of ordinary skill in the art will appreciate that otiier position sensing arrangements could be used in place of switch assembly 140 in connection widi cam surface 134. For instance, an optical device with a transmitter mounted to one of the body parts and a receiver mounted to the other likewise could detect the relative position of die body parts. Alternatively, a magnetic sensing arrangement with a sensing device on one body part and a sensed device on die otiier could be employed. Otiier such position sensing devices, as would be apparent to tiiose of ordinary skill, likewise could be substituted. Figures 4 dirough 7 provide top and bottom, and front and rear views of detection and compensation apparatus 100 in detail. These drawings, taken witii Figures 1 through 3, 8, and 9, tiius clearly show the positions of each of the elements making up the preferred apparatus 100. Normally, significant tension will be present in die door cable. Cable tension is attributed to the weight of the door. The tension present in the door cable overcomes die contracting bias of spring 112 and tiius causes apparatus 100 to extend to its fully-extended position shown in phantom in Figures 8 and 9. In tiiis position, shoulder 128 and stop 114 are in contact while cam follower 142 and cam surface 134 are separated completely. In tiiis condition, position sensor 118 controls a circuit to indicate at die apparatus 100 detects that tension properly is present within the cable. If slack develops in die cable, apparatus 100 begins to retract under die bias of spring 112. This acts to tension the cable to a minimum tension imparted to die cable by bias spring 112. Before it causes generatation of an ALARM signal, apparatus 100 has the capacity to take up slack in the cable to die extent that it retracts from its fuily-extendeα position as shown in phantom in Figures 8 and 9 to an intermediate position at which zzz follower 142 just contacts and begins to ride up inclined cam surface section 133. The intermediate position of body parts 102 and 106 where cam follower 142 just begins to engage inclined cam surface 138 is shown in phantom in Figure 2. As the cam fcllcv/or 142 rides up cam surface section 138, die cam follower soon reaches an actuating position at which die follower arm contacts and actuates push-button switch 144 . In this condition, switch assembly 140 causes generation of the warning or ALARM signal indicating that apparatus 100 is incapable of compensating for the degree of slack present in the door cable. Bias spring 112, meanwhile, will continue to retract body parts 102 and 106 to their fully closed or retracted position. Those of ordinary skill in die art now will appreciate tiiat, in addition to alternative position sensors, otiier alternative elements are useful in a slack detection and compensation apparatus in accordance widi die invention. Preferred apparatus 100 (and 100') has generally flat body parts to facilitate sliding movement relative to each other. However, otiier arrangements of relatively movable parts can be implemented provided tiiey are coimected in a way to provide diem with a range of motion for die take up of slack before reaching a final position at which they are incapable of taking up further slack. Moreover, different connecting arrangements for different body parts, to provide for die slack take up range of motion, now will be apparent to those of ordinary skill in the art. For instance, a track assembly could be substituted for connecting arrangement 110. Further still, we contemplate that the body parts could be connected at one end by a connective assembly (such as a journal or a hinge) and by a biasing device so tiiat die body parts form an angle be w≤en them mat can be changed depending upon whether there is slack in die cable. Figure 12 shows a cable slack compensation and control system 200 also iπ accordance with d e present invention. System 200 includes a slack condition detection and compensation apparatus in accord with the invention, which apparatus has been idsntified by reference numeral 202 in Figure 12. Slack detector and compensator 202 provides an input to a door drive control circuit 204. Sensor switch 140 is considered part of door drive control circuit 204 because the condition of its switch 144 informs the door drive control circuit as to the tension conditions in the door cable 24 (Figures 10 and 11). When die cable 24 is under normal tension, or at least under die minimum tension tiiat is imparted thereto by detection and compensation apparatus 202, the door drive control circuit 204 will operate the motor M in accordance witii commands to open or close die door as input from user control switch panel 206. Control system 200 also includes an inhibit circuit 208 for selectively inhibiting response by the door control circuit to a slack warning signal from the slack detection and compensation apparatus 202. Inhibiting circuit 208 is present to prevent the door drive control circuit 200 from stopping die motor when slack temporarily is expected to be present in e cable. This occurs when die door first is being lowered from its fully open position. At tiiis time, slack commonly is present in the door cable, and during this time, a slack warning signal from detector/compensator 202 must be inhibited in order to prevent the drive circuit 204 from turning off die motor M . It is contemplated that preferred door control system 200 incorporates a conventional tilt sensor (not shown) mounted near the bottom of die door as an element of the inhibiting circuit 208. Including such a tilt sensor, inhibiting circuit 208 provides a signal whenever the door is nearly horizontal, corresponding to when the door is in its substantially fully open position. As the door moves toward closing, the inhibit signal from circuit 208 terminates whereupon door drive control circuit 204 again becomes completely responsive to a slack warning signal from slack detection and compensation apparatus 202 . At this time, we return to Figure 11, and also consider Figures 13 and 14. These figures show d e alternative arrangement for slack detection and compensation apparatus 100'. Apparatus 100' features two relatively sliding body parts 102' and 106'. However, in apparatus 100', die relative travel distance between the body parts 102' and 106' has been reduced, and die switch assembly 140' tiiereof is arranged for actuation to occur earlier tiian tiiat of apparatus 100. From Figure 11, it first is apparent that the orientation of the bias spring- holding arms 120' and 126' is modified so that tiiey are perpendicular to die planes of body parts 102' and 106'. This arrangement for the spring-holding arms 120' and 126' further spaces the bias spring 112' away from die door 12 and the door track 16. The primary difference of apparatus 100' over tiiat of apparatus 100 is the reduction in travel length between die fully extended position of body parts 102' and 106' and tiieir intermediate position at which the cam follower 142' of the switch assembly 140' comes into contact with die cam surface 134'. Figures 13 and 14 omit die bias spring 112' in order to more clearly illustrate the relatively close proximity between the cam follower roller 142' and die cam surface 134' which, in the embodiment of apparatus 100', is provided by spring arm 120'. As thus seen from Figures 13 and 14, body parts 102' and 106' do not have a portion such as protrusion 116 and instead, switch assembly 140' is mounted on the door- mountable body part 106', on the side opposite to tiiat which slides against body part 102'. (Thus by omitting such protrusion, apparatus 100' has the advantage of decreased weight in tiiat preferred apparatus 100 and 100' each are contemplated as constructed from steel, or like metals.) Actually, as also seen, the underside surface of spring arm 120' provides die cam surface 134' for actuating the switch 140'. From Figures 13 and 14, it is seen that the follower roller 142a' is in relatively close proximity to the cam surface 134' even when apparatus 100' is in its fully extended position. As such, apparatus 100' has a lesser travel distance for taking up slack in the cable 24 prior to when die cam follower 142' and cam surface 134' will engage to trigger the switch 140' and thus cause generation of the alarm signal. Apparatus 100' thus provides an arrangement where die alarm signal is generated earlier if slack occurs in the cable 24. It also now is apparent to those of ordinary skill tiiat die travel range between die fully extended position, and die intermediate position at which the alarm signal is friggered, is dependent upon where switch assembly 140' is mounted on body part 106'. Changing die position at which switch 140' is mounted on part 106' results in a change of the pre-alarm compensation length. (If desired, die actuating position for causing the warning signal can be set to correspond to die fully retracted position of die body parts 102' and 106' (or 102, 106).) On die other hand, apparatus 100', as shown, has a longer travel range for slack take up after die alarm signal has been generated. Apparatus 100' also compensates for slack in the cable but generates the alarm signal when mere is a lesser extent of slack within the cable. Spring arm 120' also performs a third function in apparatus 100'. Because it is substantially perpendicular to die plane of its body part 103', spring arm 120' also is positioned to engage with die shoulder 128' of body part 106' to tiius act as the stop for apparatus 100'. Apparatus 100' further is seen to have a connecting arrangement 110' that has a pair of slots 122'. The fravel range permitted by slots 122' is somewhat less than that accorded by slot 122 and apparatus 100. Otherwise, tiiose of ordinary skill in die art will appreciate tiiat the single slot or the paired slot arrangement is applicable in either of embodiments 100 or 100'. In operation, the detection and compensation apparatus 100 (or 100') simply is mounted to die lower part of the door 12 by any conventional fastener as understood from Figure 11. Reference will be made to apparatus 100. The fastener extends dirough the mounting portion 108 of mounting part 106. The door cable attaches to the U-shaped portion 104 of cable-connecting portion 102. Thereafter, the apparatus 100 (or 100') is in place for monitoring tension within the door cable 24. Normally, tension in the door cable maintains apparatus 100 in the fully- extended condition as shown in phantom in Figs. 8 and 9. If slack begins to develop in die cable, the apparatus automatically begins to compensate by the contraction of spring 112 . As apparatus 100 retracts, forward edge 136 moves toward die cam follower 142 . If die degree of slack exceeds the range of motion permitted between die fully extended position of Figures 8 and 9 (in phantom) and the position where cam follower 142 just contacts inclining cam surface section 138, the cam follower moves up the incline section far enough to depress push-button and tiiereby generate a slack warning signal. Widi reference also to Figure 12, door drive control circuit 204 operates to drive die motor M to close d e door or open the door in response to user commands entered at the control switch panel 206 . However, when slack detection and compensation apparatus 202 applies a slack warning signal to door drive control circuit 204 , die drive control circuit automatically at least stops the motor M from further rotating the drum (e.g. drum 26 in Figure 10) in order to eliminate further pay out of die door cable (e.g. cable 24 in Figure 11). As also apparent to tiiose of ordinary skill in die art, door drive control circuit 204 could begin to wind die cable to take up slack within the cable. Further, drive control circuit 204 can be implemented to continue to wind die cable in order to raise e door and tiiereby enable removal of an obstruction, if the cause of the detected slack condition was the result of an obstruction. Further, inhibiting circuit 208 monitors the position of the door in order to inhibit drive control circuit 204 from improperly responding to a warning signal from slack detection and compensation apparatus 202 when the door is in a substantially horizontal position. As mentioned in die foregoing, tiiis selectively prevents slack detection and compensation apparatus 202 from interfering with routine lowering of the door from die fully- open position of die door where the door is oriented substantially horizontally. If it is desired to generate die detected slack or warning signal earlier than would be done by apparatus 100, alternative apparatus 100' can be substituted for apparatus 100 in control system 200. Apparatus 100' will generate the detection signal in the presence of a lesser extent of slack in the cable in order to signal the control system 200 earlier h&ϊ -hs cable is becoming slack. Apparatus 100' however, continues to compensate for slack ever. after it begins to generate the detection signal due to increased travel range between its actuating position and its fully retracted position. It is to be understood that there can be various changes and modifications to the preferred embodiments of the present invention disclosed herein, which changes and/or modifications may be made by of one of ordinary skill in the art. However, such would still result in an arrangement well within the scope of the invention as set forth in the claims.

Claims: What is claimed is: 1- A cable slack condition detection and compensation apparatus for connecting a cable to an object for lifting and lowering of the object, said apparatus comprising: a first body part having a portion connectable to the cable; a second body part having a portion connectable to the object; means for connecting said first body part and said second body part for movement of said body parts relative to each other, said body parts being relatively movable to and from a position in which said apparatus is fully extended, and a position in which said apparatus is fully retracted, said fully extended position and said fully refracted position and positions therebetween defining a range of movement of said body parts; biasing means for biasing said body parts in a direction from said fully extended position toward said fully retracted position, whereby said biasing means moves said body parts from said fully extended position towards said fully retracted position along said movement range in response to a presence of slack in me cable; and means responsive to said relative positions of said body parts for indicating when said biasing means retracts said body parts from said fully extended position to a predetermined position along said movement range, a portion of said movement range from said fully extended position to said predetermined position providing slack compensation prior to indicating by said responsive means. 2. A cable slack condition detection and compensation apparatus as claimed in claim 1, wherein said responsive means includes electronic means and said responsive means performs said indicating by switching an electronic circuit. 3. A cable slack condition detection and compensation apparatus as claimed in claim 2, wherein, said elecfronic means includes an elecfronic switch; one of said body parts has a cam surface; and said detection and compensation apparatus includes a cam follower disposed between said switch and said cam surface for actuating said switch when said cam surface and said cam follower move relative to each other to an actuating position, said cam surface and said cam follower moving to said actuating position when said biasing means biases said body parts to said predetermined position. 4. A cable slack condition detection and compensation apparatus as claimed in claim 3, wherein said portion of said range of movement of said body parts between said fully extended position and said predetermined position exceeds a portion of said range of movement of said body parts between said predetermined position and said fully retracted position. 5. A cable slack condition detection and compensation apparatus as claimed in claim 3, wherein a portion of said range of movement of said body parts between said predetermined position and said fully retracted position exceeds said portion of said range of movement of said body parts between said fiilly extended position and said predetermined position. 6. A cable slack detection and compensation apparatus as claimed in claim 1, wherein one of said body parts has a slot extending longitudinally therein, and die other of said body parts has a member projecting into said slot for defining said relative movement with said slot, said slot and said member providing said connecting means; said body parts each have a flat portion, and said relative movement is relative sliding movement of said flat portions; and one of said body parts has a stop, and the other of said body parts has a shoulder facing in opposition to said stop, said stop and said shoulder cooperating to prevent extending movement beyond said fully extended position. 7. A cable slack detection and compensation apparatus as claimed in claim 6, wherein each of said body parts has a protruding arm, and said biasing means includes a spring with one end thereof connected to said protruding arm of one of said body parts and an opposite end tiiereof connected to said arm of the other body part; and one of said body parts includes a mounting portion for mounting said responsive means to determine die extent of each of said portions of said range of motion. 2-i 8. A cable slack control apparatus for a door operator having a jack shaft, drum means mounted on the jack shaft, a cable windable on the drum means, and drive means for turning the jack shaft, said apparatus comprising: cable slack condition detection and compensation means for connecting the cable to the door, said detection and compensation means including means for adding tension to the cable to maintain the cable at a minimum acceptable tension, and means for providing a slack detection signal when said means for adding tension to the cable is incapable of tensioning die cable to said minimum tension; and drive control means for causing the drive means selectively to turn the jack shaft in a first direction to unwind die cable and lower a door, and a second direction to wind die cable and lift die door, said drive control means including means responsive to a slack detection signal from said compensation means for stopping the drive means. 9. A cable slack control apparatus as claimed in claim 8, further comprising inhibiting means, responsive to a position of the door, for generating an inhibit signal for inhibiting response by said drive control means to a slack detection signal from said cable slack detection and compensation means. 10. A cable slack control apparatus as claimed in claim 8, wherein said means for adding tension includes a first body part, a second body part, means for connecting said first body part and said second body part for movement of said body parts relative to each other, said body parts being relatively movable to and from a position in which said apparatus is fully extended, and a position in which said apparatus is fully retracted, said fully extended position and said fully retracted position and positions therebetween defining a range of movement of said body parts, and biasing means for biasing said body parts in a direction from said fully extended position toward said fully retracted position along said movement range in response to a presence of slack in the cable. 11. A cable slack control apparatus as claimed in claim 10 wherein said body parts each have a flat portion, and said relative movement is sliding movement of said flat portions. 12. A cable slack control apparatus as claimed in claim 11, wherein one of said body parts has a slot extending longitudinally therein, and -he ώer of said body parts has a member projecting into said slot for providing said relativ≤ movement; one of said body parts has a stop for preventing said relative movement syz'A said fully extended position, and die otiier of said body parts has a shoulder facing in opposition to said stop; and each of said body portions has a protruding arm, and said biasing means includes a spring with one end tiiereof connected to said protruding arm of one of said body portions and an opposite end thereof connected to said arm of die otiier body portion. 13. A cable slack control apparatus as claimed in claim 10, wherein said means for providing a slack detection signal includes elecfronic switch means. 14. A cable slack control apparatus as claimed in claim 13, wherein one of said body parts has a cam surface; and said compensation apparatus includes a cam follower disposed between said switch means and said cam surface for actuating said switch means when said cam surface and said cam follower move relative to each other to an actuating position, said cam surface and said cam follower moving to said actuating position when said biasing means biases said body parts to a predetermined position intermediate said fully extended position and said fully retracted position. 15. A cable control apparatus as claimed in claim 14, wherein - porticr. ci " said range of movement of said body parts between said fully extended position and said predetermined position exceeds a portion of said range of movement of said bciy parts between said predetermined position and said fully retracted position. 16. A cable control apparatus as claimed in claim 14, wherein a portion of said range of movement of said body parts between said predetermined position and said fully retracted position exceeds a portion of said range of movement of said body parts between said fully extended position and said predetermined position. 17. A cable slack condition detection and compensation apparatus for connecting a cable to an object for lifting and lowering of the object, said apparatus comprising: a first body part having a portion connectable to the cable and a first planar portion; a second body part having a portion connectable to die object and a second planar portion; means for connecting said first body part and said second body part for sliding movement of said body parts relative to each other along said planar portions thereof, said body parts being relatively movable to and from a position in which said apparatus is fully extended, and a position in which said apparatus is fully retracted, said fully extended position and said fully retracted position and positions ώerebetweεn defining a range of movement of said body parts; biasing means for biasing said body parts in a direction from said fully extended position toward said fully retracted position along said movement range in response to a presence of slack in the cable; and means responsive to said relative positions of said body parts for indicating when said biasing means moves said body parts from said fiilly extended position to a predetermined position along said movement range. 18. A cable slack condition detection and compensation apparatus as claimed in claim 17, wherein said responsive means includes elecfronic means and said responsive means performs said indicating by switching an electronic circuit. 19. A cable slack condition detection and compensation apparatus as claimed in claim 18, wherein said responsive means includes first means on one of said body parts and second means on the other of said body parts, said second means switching said electronic circuit in response to a positional relationship between said first means and said second means. 20. A cable slack condition detection and compensation apparatus as claimed in claim 19, wherein, said first means is a cam surface; and said second means is an electronic switch including a cam follower, said cam surface actuating said switch when said cam surface and said cam follower move relative to each otiier to an actuating position, said cam surface and said cam follower moving to said actuating position when said biasing means biases said body parts to said predetermined position. 21. A cable slack condition detection and compensation apparatus as claimed in claim 20, wherein a portion of said range of movement of said body parts between said fully extended position and said predetermined position exceeds a portion of said range of movement of said body parts between said predetermined position and said fiilly retracted position. 22. A cable slack condition detection and compensation apparatus as claimed in claim 20, wherein a portion of said range of movement of said body parts between said predetermined position and said fiilly retracted position exceeds a portion of said range of movement of said body parts between said fully extended position and said predetermined position. 23. A cable slack detection and compensation apparatus as claimed in claim 17, wherein one of said body parts has a slot extending longitudinally therein, and die otiier of said body parts has a member projecting into said slot for defining said sliding movement with said slot, said slot and said member providing said connecting means; and one of said body parts has a stop, and die otiier of said body parts has a shoulder facing in opposition to said stop, said stop and said shoulder cooperating to prevent extending movement beyond said fully extended position. 50 24. A cable slack detection and compensation apparatus as claimed in claim 23, wherein each of said body parts has a protruding arm, and said biasing means includes a spring with one end thereof connected to said protruding arm of one of said body parts and an opposite end thereof connected to said arm of the other body part; and one of said body parts includes a mounting portion for mounting said responsive means to determine the extent of each of said portions of said range of motion. 25. A method of detecting and compensating for slack in a cable used for lifting and lowering an object, said metiiod comprising the steps of: providing an apparatus including two body portions connected to each otiier so that they are movable relative to each other to and from a first position in which said body portions are fully extended widi respect to each other, and a second position in which said body portions are fully retracted witii respect to each other, said first and second positions and positions therebetween defining a range of movement of said body portions, and means for generating a warning signal when said body portions retract from said first position toward said second position to a predetermined position; connecting one of said body portions to said cable and the otiier of said body portions to said object; biasing said body portions toward said second position against tension in said cable, whereby when said cable becomes slack, said biasing means moves said body portions from said first position toward said second position in order to take up slack in said cable; sensing when said body portions retract from said first position to said predetermined position; and causing said generating means to generate said warning signal upon sensing that said body portions have retracted to said predetermined position.

Inventors: BALLI ROBERT E, DELANEY CHARLES E, BALLI, ROBERT, E., DELANEY, CHARLES, E.
Applicants: GMI HOLDINGS INC, GMI HOLDINGS, INC.
Application year: 1998
Main classification: B66D1
IPC codes: B66D1, E05F15