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[0001]    The present application claims priority to U.S. Provisional Application of St. John et al., Ser. No. 60/230,433, the entirety of which is hereby incorporated into the present application by reference.  
         [0002]    The present application also claims priority as a continuation-in-part to U.S. application of Kowalczyk et al., Ser. No. 09/631,106 and U.S. application of Kowalczyk et al., Ser. No. 09/635,401, each of which in turn claim priority to U.S. Provisional Application of Kowalczyk, Ser. No. 60/148,100. The entirety of each of these applications is hereby incorporated into the present application by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0003]    The present invention relates to power door assemblies and, more particularly, to a retrofit power door assembly for installation on a manual swing door assembly.  
         BACKGROUND AND SUMMARY OF THE INVENTION  
         [0004]    Power operated door assemblies have been retrofit onto manual swing door assemblies and used to open and/or close an associated swinging door panel. Previously, power operated door assemblies have utilized electric motors to move the door between the closed and open positions. These designs are generally bulky and many require extensive modification to existing door frames and/or panels to allow the assembly to be used therewith. Furthermore, to produce the required torque necessary to open or close a standard door, these assemblies utilize a relatively powerful motor and drive system, which normally have used either an expensive high torque motor or a bulky high reduction ratio transmission.  
           [0005]    Other designs include pneumatic and hydraulic actuators to produce movement of the door. Some of these designs are advantageous over the previous electric motor designs, because the actuators can be made compact and relatively lightweight. However, the hydraulic pump or pneumatic compressor must be located remotely from the door in these designs. Therefore, the respective assemblies are relatively space-consumptive. Furthermore, as with the previous assemblies utilizing electric motors, the hydraulic and pneumatic operated door operating assemblies are very expensive.  
           [0006]    Consequently, there exists a need in the art to provide a cost-efficient self-contained compact door operating system that may be easily retrofit to existing manual swing door assemblies.  
           [0007]    It is an object of the present invention to meet the above-described need. To achieve this object, the present invention provides a retrofit power-operated door operating system for installation on a manual swing door assembly. The door assembly comprises a frame mounted to a building wall and a swinging door panel manually movable in a swinging manner with respect to the door frame between opened and closed positions thereof by manual force. The retrofit door operating system comprises a door panel mounting structure constructed and arranged to be mounted to the door panel and a wall mounting structure constructed and arranged to be mounted to the building wall. The retrofit door operating system further comprises a linkage structure connected between the door panel mounting structure and the wall mounting structure.  
           [0008]    An axial operator of the retrofit door operating system comprises an operator output member rotatable about an operator axis that extends generally vertically when the system is installed on the swing door assembly. The operator output member and the linkage structure are constructed and arranged such that, when the system is installed on the swing door assembly, rotation of the operator output member drives the linkage structure to move the wall and door panel mounting structures relative to one another to affect powered swinging movement of the door panel between the open and closed position thereof. The axial operator further comprises an electric motor connectable to an electric power supply. The motor has a motor output member rotatable about the operator axis and is constructed and arranged to rotate the motor output member about the operator axis. A planet gear reduction transmission is connected between the motor output member and the operator output member. The reduction transmission rotates the operator output member at a lower rotational speed than a rotational speed at which the motor rotates the motor output member and applies a higher torque to the operator output member than a torque which the motor applies to the motor output member.  
           [0009]    The reduction transmission comprises an orbit gear arranged generally coaxially with respect to the operator axis and a planet gear carrier positioned radially inwardly of the orbit gear and arranged for rotation about the operator axis. The planet gear carrier has a mounting portion offset generally radially from the output axis. The reduction transmission further comprises a planet gear rotatably mounted to the mounting portion of the planet gear carrier such that the planet gear rotates about a planet gear axis that extends through the mounting portion generally parallel to the operator axis. The planet gear is operatively connected to the motor output member and engaged with a radially inwardly facing interior surface of the orbit gear such that rotation of the motor output member rotates the planet gear relative to the planet gear carrier about the planet gear axis, which in turn causes the planet gear to roll along the interior surface of the orbit gear in a generally circumferential direction with respect to the operator axis. The planet gear carrier is thereby rotated about the output axis at a lower rotational speed and at a higher torque than the rotational speed and torque at which the motor rotates the motor output member. The planet gear carrier is operatively connected to the operator output member such that rotation of the planet gear carrier as a result of the planet gear being rotated by the motor output member as aforesaid rotates the operator output member to affect the relative movement between the frame and door panel mounting structures.  
           [0010]    The retrofit power operated door operating system also comprises an input device operable to generate a door movement signal and a controller communicated to the motor of the axial operator. The controller is operable responsive to receiving the door movement signal to control operation of the motor so as to selectively cause the motor to rotate the motor output member and thereby rotate the operator output member to affect the powered swinging movement of the door panel between the opened and closed positions thereof.  
           [0011]    With retrofit door operating systems, it would also be desirable to provide the system with an override that enables the door panel to be moved freely under manual power. Although in most retrofit door operating systems the door panel can be moved under manual power against the resistance of the operator (i.e., backdriving of the electric motor), jamming of internal components, such as the breakage of a gear tooth and subsequent lodging thereof in the gear train, can “freeze” the operator, thus preventing the ability to move the door panel either manually or under power.  
           [0012]    It is therefore another object of the present invention to provide a retrofit door system with an override feature that allows the door panel to be moved freely under manual power. To achieve this object, the present invention provides a retrofit power-operated door operating system for installation on a manual swing door assembly comprising a frame mounted to a building wall and a swinging door panel manually movable in a swinging manner with respect to the door frame between opened and closed positions thereof by manual force. The retrofit door operating system comprises a door panel mounting structure constructed and arranged to be mounted to the door panel and a wall mounting structure constructed and arranged to be mounted to the building wall. A linkage structure is connected between the door panel mounting structure and the wall mounting structure. A retrofit power-operated door operator is operatively connected to the linkage structure such that, when the system is installed on the swing door assembly, the operator drives the linkage structure to affect powered swinging movement of the door panel between the open and closed positions thereof.  
           [0013]    Additionally, the retrofit door operating system comprises a manually operable clutch movable between an engaged position wherein the clutch enables the operative connection between the operator and the linkage such that operation of the operator under power affects the powered swinging movement of the door panel and a disengaged position wherein the clutch disables the operative connection between the operator and the linkage structure to permit manual swinging movement of the door panel. The clutch has a manually engagable release member constructed and arranged to be manually moved in a releasing manner. The clutch is constructed and arranged such that manual movement of the release member in the releasing manner moves clutch from the engaged position thereof to disengaged positions thereof.  
           [0014]    The retrofit door operating system further comprises an input device operable to generate a door movement signal and a controller communicated to the operator. The controller is operable responsive to receiving the door movement signal to control operation of the operator so as to selectively cause the operator to drive the linkage structure as aforesaid to affect the powered swinging movement of the door panel between the opened and closed positions thereof.  
           [0015]    Other objects, features and advantages of the present invention will become apparent from the following detailed description, the accompanying drawings and the appended claims. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is an elevated front view of a manual swing door assembly with a retrofit power operated door operating system of the present invention installed thereon;  
         [0017]    [0017]FIG. 2 is an exploded view of the retrofit power operated door operating system shown in FIG. 1;  
         [0018]    [0018]FIG. 3 is a sectional view of the axial operator taken along line  3 - 3  in FIG. 2;  
         [0019]    [0019]FIG. 4 is a perspective view of the electric motor showing the rotatable motor output member detached from the motor driveshaft;  
         [0020]    [0020]FIG. 5 is a perspective view of the electric motor showing the annular member detached from the motor driveshaft;  
         [0021]    [0021]FIG. 6 is an exploded view of the reduction transmission of the axial operator;  
         [0022]    [0022]FIG. 7 is a sectional view of the reduction transmission;  
         [0023]    [0023]FIG. 8 is a perspective view showing an upper surface of the first clutch member;  
         [0024]    [0024]FIG. 9 is a perspective view showing the lower surface of the first clutch member;  
         [0025]    [0025]FIG. 10 is a perspective view showing the upper surface of the second clutch member;  
         [0026]    [0026]FIG. 11 is a top plan view of the wall mounting structure;  
         [0027]    [0027]FIG. 12 is a sectional view of the wall mounting structure taken along line  12 - 12  in FIG. 11;  
         [0028]    [0028]FIG. 13 is a perspective view of the clutch showing the first clutch member engaged with the second clutch member;  
         [0029]    [0029]FIG. 14 is a perspective view of the clutch showing the first clutch member disengaged from the second clutch member;  
         [0030]    [0030]FIG. 15 is a side plan view of the handle structure;  
         [0031]    [0031]FIG. 16 is a perspective view of the retrofit power operated door operating assembly installed on a door showing the assembly and door in a closed position;  
         [0032]    [0032]FIG. 17 is a perspective view of the retrofit power operated door operating assembly installed on a door showing the assembly and door in an open position;  
         [0033]    [0033]FIG. 18 is an exploded view of the electric strike;  
         [0034]    [0034]FIG. 19 is a top plan view of the retrofit power operated door operating assembly installed on a door showing the assembly and door in a closed position;  
         [0035]    [0035]FIG. 20 is a detailed elevated front view of the manual swing door assembly with the retrofit power operated door operating assembly installed thereon; and  
         [0036]    [0036]FIG. 21 is a perspective view of the remote transmitter. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0037]    FIGS.  1  shows a pre-existing manual swing door assembly  10  with a retrofit power-operated door operating system  500  installed thereon. The door assembly  10  comprises a door frame  12  mounted to a building wall  14  at a doorway opening and a swinging door panel  16  mounted to the frame  12  by hinges. Door panel  16  is manually movable in a swinging manner about a door moving axis DA (FIG. 1), with respect to the door frame  12 , between opened and closed positions.  
         [0038]    Shown in greater detail in FIG. 2, the retrofit door operating system  500  comprises a door panel mounting structure  502  mounted to the door panel  16  and a wall mounting structure  504  mounted to the building wall  14 . In the illustrated embodiment, the wall mounting structure  504  is mounted indirectly to the wall  14  by being mounted to the frame  12 . However, the wall mounting structure  504  may be mounted directly to the wall  14  without being mounted to the frame  12 . A linkage structure  600  is connected between the door panel and wall mounting structures  502 ,  504 . The retrofit power-operated door operating system  500  includes an axial operator  100  that operatively connects to the linkage structure  600  such that, when the system  500  is installed on the door assembly  10 , the operator drives the linkage structure to affect powered swinging movement of the door panel  16  between the open and closed positions thereof.  
         [0039]    The axial operator  100  includes an electric motor  102  that drives a rotatable operator output member  104 . A planet gear reduction transmission  200  is connected between the motor  102  and the output member  104 . The reduction transmission  200  is constructed and arranged to rotate the output member  104  at a lower rotational speed than a rotational speed at which the motor  102  rotates and to apply a higher torque to the output member  104  than a torque which the motor  102  applies to the reduction transmission  200 .  
         [0040]    The retrofit door operating system  500  further includes an input device  506  for generating a door movement signal, described further hereinbelow, and a controller  508  communicated to the motor  102 .  
         [0041]    The construction of the axial operator  100  may be best understood from FIGS. 2 and 3. The axial operator  30  includes the reversible electric motor  102 , the rotatable operator output member  104  and the reduction transmission  200  mounted in torque-transmitting relation between the motor  102  and the operator output member  104 . The motor  102  and the reduction transmission  200  are housed within a cylindrical casing or housing  106 .  
         [0042]    [0042]FIG. 3 shows a cross-sectional view of the assembled axial operator  100 . The operator output member  104  extends outwardly from the reduction transmission  200  and rotates about an operator axis OA (FIG. 2). It can be appreciated from FIG. 1, for example, that when the axial operator  100  is mounted on the door assembly  10 , the operator output member  104  (and the operator axis OA defined by the member  104 ) extends generally vertically and generally parallel to the door moving axis DA.  
         [0043]    The operator output member  104  is operatively connected to the linkage structure  600  such that rotating the operator output member  104  under power moves or swings the door panel  16  between its open and closed positions. With respect to the swinging door panel  16 , the operator output member  104  is operatively connected with the linkage structure  600  such that rotation of the operator output member  104  in a first rotational direction moves the door panel  16  towards and into its fully open position and such that rotation of the operator output member  104  in a second rotational direction opposite the first rotational direction moves the door panel  16  towards and into its closed position.  
         [0044]    The reversible electric motor  102  shown is preferably a conventional D.C. motor  102 . The motor  102  has a rotatable motor output member  108  that is co-axial with the operator axis OA so that the motor output member  108  rotates about the operator axis OA when the motor  102  is energized. The motor  102  is communicated to a controller  508  (shown in FIG. 2). Electrical signals transmitted from the controller  508  control operation of the motor  102  in a manner that is well-known in the art.  
         [0045]    D.C. motors are widely commercially available and the construction and operation of such motors are well known. Hence, the details of the motor  102  are not considered in specific detail in the present application. Preferably, the motor  102  is of the type in which the direction of the rotation of the motor output member  108  can be reversed by reversing the direction of the current flowing to the motor  102 . The controller  508  is in electrical communication with the motor  102  through conventional electroconductive wires (not shown) and is used in a manner well known to those skilled in the art to control the motor  102  operation and to switch the direction of the motor current. Reference may be made to U.S. Provisional Application of Ranaudo; Ser. No. 60/266,454, the entirety of which is hereby incorporated into the present application by reference, for further details concerning the control system.  
         [0046]    The motor  102  is shown in isolation in FIGS. 4 and 5. The D.C. motor  102  is housed in a cylindrical casing  110 . A motor drive shaft  112  extends thorough front and rear wall portions  114 ,  116  of the casing  110  and is driven by an armature assembly  118  of well known construction (shown schematically inside the casing  110  in FIG. 3). The motor output member  108  is fixedly mounted to one end of the shaft  112 . The preferred motor output member  108  is a spur or pinion gear.  
         [0047]    An annular member  120  is fixedly mounted to an opposite end of the shaft  112  for rotation therewith. Individual portions of magnetic material are evenly spaced about the outer periphery of the annular member  120  and a metering device (not shown) is mounted adjacent the end of the motor casing  110 . The metering device is a Hall effect sensor, which generates and transmits a signal to the controller  508  each time a portion of magnetic material passes by the device during rotation of the member  120 . This signal is fed back to the controller  508  through conventional wires (not shown) to enable the controller  508  to monitor, for example, the angular speed of the motor shaft  112  and the angular position of the door panel  16  with respect to the door frame  12  based on the number and frequency of rotations of member  120 . The construction and use of Hall effect sensors is well known in the art and will not be considered in detail in the present application. The invention may be practiced without the use of the Hall effect sensor.  
         [0048]    The reduction transmission  200  is operatively connected in torque transmitting relation between the motor output member  108  and the operator output member  104 . The reduction transmission  200  is constructed and arranged such that the transmission  200  rotates the operator output member  104  at a lower rotational speed than a rotational speed at which the motor  102  rotates the motor output member  108  and applies a higher torque to the operator output member  104  than a torque which the motor  102  applies to the motor output member  108 .  
         [0049]    The construction of the reduction transmission  200  can be best appreciated from FIGS. 6 and 7 which show the reduction transmission  34  in isolation from the remaining components of the operator. The reduction transmission  200  includes a generally cylindrical outer housing  202 , the interior of which is splined to provide a set of axially extending gear teeth  64  defining a ring or orbit gear. Annular front and rear covers,  66  and  68 , respectively, are secured to respective ends of the outer housing  202  with threaded fasteners  210  to close the front and rear ends of the housing  202 . The covers  206 ,  208  each have a central opening  212 ,  214 , respectively, to provide access to the interior of the reduction transmission  200 .  
         [0050]    Three planet gear carriers  216 ,  218 ,  220  are disposed inside the housing  202  and rotate about the operator axis OA. Each planet gear carrier  216 ,  218 ,  220  has a set of mounting portions in the form of planet gear mounting pins extending rearwardly therefrom. The three sets of mounting pins are designated  222 ,  224 ,  226 , respectively. Each mounting pin of each set  222 ,  224 ,  226  extends generally in an axial direction from its respective planet gear carrier  216 ,  218 ,  220  so that each pin is generally parallel to the operator axis OA of the axial operator  100 . Preferably, there are three pins in each set  222 ,  224 ,  226  and the pins of each set are circumferentially spaced evenly about the operator axis OA of the axial operator  100 .  
         [0051]    Three sets of three planet gears, generally designated  228 ,  230 ,  232 , are rotatably mounted on the sets of planet gear mounting pins  222 ,  224 ,  226 , respectively (such that one gear is mounted on each pin). Although the illustrated embodiment shows three carriers each carrying three planet gears, the number of carriers, the number of gears carried by any individual carrier and the diameters of the gears and carriers may be varied to achieve the desired reduction ratio. In the illustrated embodiment, the speed reduction ratio achieved is approximately 42.6:1 from the input of the reduction transmission  200  to the output of the reduction transmission  200 . The ratio may be increased for applications in door assemblies having door panels of greater weight which require more torque to move between open and closed positions. Conversely, the ratio may be decreased for door assemblies with lighter door panels, which require less torque to affect opening and closing movement.  
         [0052]    Each planet gear carrier  216 ,  218 ,  220  has a carrier output member  234 ,  236 ,  238 . The carrier output members  236 ,  238  of the rear and central carriers  218 ,  220  are provided by pinion gears integrally formed on the forward face of the respective carrier. The output member  234  on the forward carrier  216  is a splined bore having a series of axially extending, gear engaging teeth.  
         [0053]    When the transmission  200  is assembled, the planet gears of each gear set  228 ,  230 ,  232  are intermeshed with the teeth  204  of the housing  202 . When the operator  100  is assembled, the drive shaft  112  of the motor  102  extends through the opening  214  in the rear cover  208  and the axially extending teeth of the motor output member  108  are intermeshed with the teeth of the planet gears of set  232 . Rotation of the motor output member  108  rotates the planet gears of set  232  about their respective axes (formed by the mounting pins  226 ) which causes the gear set  232  to travel circumferentially (i.e., revolve) about the operator axis (axis OA) in intermeshed relation with the teeth  204  of the housing  202 . The circumferential travel of the planet gears of set  232  about the transmission axis causes the rear carrier  220  to rotate about the operator axis OA at a rate that is slower than the rate at which the motor output member  108  rotates about the axis OA.  
         [0054]    The planets gears of the gear set  230  are intermeshed with both the output member  238  integrally formed on the rear carrier  220  and with the teeth  204  on the interior of the housing  202 . Rotation of planet gear carrier  220  causes the planet gears of the gear set  230  to rotate about their respective axes (provided by mounting pins  224 ), which in turn causes the planet gears of the gear set  230  to travel circumferentially with respect to the operator axis OA in intermeshed relation with the teeth of the housing  202  (i.e., the orbit gear). This circumferential travel of the gears of gear set  230  rotates the central carrier  218  about the operator axis OA at a rate that is slower than the rotational rate at which the rear planet gear carrier  220  rotates about the axis OA.  
         [0055]    In like manner, the planet gears of the gear set  228  are in intermeshed relation both with the teeth of the output member  236  of the central carrier  218  and with the interior teeth  204  of the housing  202  such that rotation of central planet gear carrier  218  rotates the planet gears of the gear set  228  about their respective axes (provided by the mounting pins  222 ), which in turn causes the planet gears of the gear set  228  to travel circumferentially with respect to the operator axis OA in intermeshed relation with the teeth  204  on the interior of the housing  202 . As with carriers  218  and  220 , this circumferential travel of the gear set  228  rotates the forward gear carrier  216  about the operator axis OA at a rate that is slower than the rotational rate at which the central planet gear carrier  218  rotates about the axis OA.  
         [0056]    The reduction transmission  200  may be constructed without the use of intermeshed teeth. Instead, the various gears may be frictionally engaged with one another without the use of teeth. Metal washers  240  are provided to prevent frictional wear of the planet gear sets.  
         [0057]    The operator output member  104  extends through the opening  212  in the front cover  206  and is received within the splined bore that defines the output member  234  of the forward carrier  216 . The intermeshing of the teeth on a rearward end portion  122  of the operator output member  104  with the teeth of the output member  234  prevents angular displacement of the operator output member  104  with respect to the carrier  216  during power operated door movement so that the operator output member  104  and forward carrier  216  rotate about the operator axis OA as a single unit. As will become apparent, rotation of the operator output member  104  imparts torque to the linkage structure  600  to affect door panel movement. It can be appreciated that the output member  234  of the forward carrier  216  may be considered to function as the output of the reduction transmission  200 .  
         [0058]    Because each successive planet gear set  232 ,  230 ,  228  rotates more slowly than the previous output member ( 108 ,  238 ,  236 , respectively) which drives the same, the rotational speed of the operator output member  104  at the output of the reduction transmission  200  is significantly lower than the rotational speed of the motor output member  108  secured to the shaft  112  of the motor  102 . As a result, the torque at the output of the reduction transmission  200  is greater than the effective torque of the motor  102 . The decease of the rate of rotation and increase in torsional force provided by the reduction transmission  200  allows high speed/low torque motors (which are less expensive and smaller than low speed/high torque motors) to be used to drive movement of doors having weights which the motor  102  alone could not effectively drive.  
         [0059]    As is considered in greater detail below, a controlling system (including the controller  508  and the Hall effect sensor) communicated to the motor  102  of the axial operator  100  is operable to selectively control operation of the motor  102  so as to rotate the operator output member  104  in either the first or the second output rotational direction thereof to thereby move the door panel  16  toward and into either the open position thereof or the closed position thereof, respectively.  
         [0060]    The reduction transmission  200  is secured to the motor  102  by a pair of axially extending threaded fasteners (not shown) that extend through the length of the motor casing  110  and that are received within threaded bores (not shown) formed in the rear cover  208  of the reduction transmission  200 . The manner in which threaded fasteners are used to secure the reduction transmission  200  to the motor  102  is shown in each of U.S. patent application of Kowalczyk, et al., Ser. Nos. 09/631,106, 09/635,401, 09/497,729 and 09/497,730 which patent applications are hereby incorporated into the present application in its entirety for all material disclosed therein, including for exemplary constructions of the axial operator.  
         [0061]    The reduction transmission  200  and the motor  102  (secured together by fasteners as described) are mounted within the cylindrical casing  106  by threaded fasteners that extend through the bottom of the cylindrical casing  106  and threadedly engage the casing  110  on the motor  102 . The cylindrical outer casing  106  is a protective metal sleeve preferably formed either by extrusion or a roll-forming and seam-welding operation. Apertures (not shown) are formed in the outer casing  106  for passage of electrically conducting wires from the motor  102  to a source of power and from the Hall effect sensor to the controller  508 .  
         [0062]    It can be understood that because the axial operator  100  is relatively small and provides a relatively high reduction ratio (42.6:1 in the exemplary axial operator  100 , as previously noted) in a compact package, the axial operator  100  can be easily installed in a door assembly in a wide variety of door assembly locations and orientations in operative association with the linkage structure  600 .  
         [0063]    Shown in FIG. 2, the door panel mounting structure  502  includes an axial operator-mounting bracket  510 . The mounting bracket  510  is secured to door panel  16  proximate the upper hinge-side corner thereof with a plurality of threaded fasteners  512  inserted through apertures on a vertically arranged door attachment plate  514 . An outwardly extending operator attachment plate  516  extends horizontally from the door attachment plate  514 . An output member-receiving opening  517  formed through the operator attachment plate  516  allows the operator  100  to be secured thereto, with the operator abutting a downwardly facing surface of attachment plate  514  and the operator output member  104  extending vertically through the opening  517  beyond an upwardly facing surface  518 . A plurality of threaded fasteners  520  pass through associated vertically extending openings within operator attachment plate  516  and engage within associated threaded recesses  522  within casing  106 .  
         [0064]    Referring to FIG. 2, it may be preferable for the retrofit door operating system  500  to include a manually operable clutch assembly  700 . Clutch assembly  700  serves to operably couple operator output member  104  and linkage structure  600 . Specifically, the clutch  700  is movable between (a) an engaged position wherein the clutch enables the operative connection between the operator  100  and the linkage structure  600  such that operation of the operator  100  under power affects the powered swinging movement of the door panel  16 , and (b) a disengaged position wherein the clutch  700  disables the operative connection between the operator  100  and the linkage structure  600  to permit manual swinging movement of the door panel  16 .  
         [0065]    Clutch assembly  700  includes a first clutch member  702  and a second clutch member  704 . First clutch member  702  is fixedly attached to an end of an arm  601  of the linkage structure  600 . As shown in FIGS. 2 and 8, a laterally extending groove  706  serves to accept the end of the arm  601  of the linkage structure  600  therein. Shown in FIG. 2, a retaining element  708  is secured to first clutch member  702  in overlaying relation to the associated end of the arm  601  thereby retaining the associated end of the arm  601  within groove  706 . The retaining element  708  is secured to an upwardly facing side of the first clutch member  702  by a plurality of threaded fasteners  710 . As shown in FIG. 2, it may be necessary for one or more of the threaded fasteners  710  to pass through bores in the arm portion  601  to properly securely attach the retaining element  708  to the first clutch member  702 .  
         [0066]    As shown in FIG. 9, a downwardly facing side of first clutch member  702  includes a pair of diametrically spaced downwardly extending lug elements  714 . During normal operation of the retrofit door operating system  500 , the lugs  714  are disposed within a laterally extending groove  716  provided on an upper side of the second clutch member  704 . It is also contemplated that first and second clutch members  702 ,  704  may comprise opposing clutch friction disks. In a case utilizing such friction clutch disks, during normal operation, the opposing disks will be in frictional engagement.  
         [0067]    As stated previously, operator output member  104  extends vertically past an upwardly facing surface  518  of operator attachment plate  516 . Second clutch member  704  is mounted on the operator output member  104 , such that second clutch member  704  is non-rotatable with respect to output member  104 , but is capable of limited axial movement with respect to output member  104 . Specifically, the second clutch member  704  has a central opening  718  which is received over the upper free end  524  of operator output member  104 . The opening  718  and the end  524  of the operator output member have corresponding non-circular shapes that prevent relative rotational movement therebetween yet allow limited relative axial movement. A compression spring  720  is disposed in surrounding relation about an axially extending portion  722  of second clutch member  704 . A first end of the compression spring  720  engages a radially outwardly extending annular flange  724  provided by second clutch member  704 . A second end of compression spring  720  engages the upwardly facing surface  518  of the operator attachment plate  516 . The spring  720  biases the second clutch member  704  into coupled engagement with the first clutch member  702 , thus biasing the clutch  700  into its engaged position.  
         [0068]    Although the clutch  700  in the illustrated embodiment is preferred, the clutch may have any construction or design and the illustrated example thereof is not intended to be limiting.  
         [0069]    Preferably, the clutch  700  incorporates a releasable locking mechanism (not shown) that automatically locks the clutch  700  in its disengaged position until the user releases the locking mechanism to allow the clutch to be returned to the engaged position thereof. For example, a spring biased pawl could be provided to engage the handle structure  732  or the second clutch member  704  to maintain the second clutch member  704  out of engagement with the first clutch member  702 . The advantage of providing such a locking mechanism is that it makes the clutch mechanism easier to use. Specifically, the user does not have to maintain the clutch  700  in its disengaged position with one hand while opening the door panel  16  with the other because the locking mechanism functions to maintain the clutch  700  in its disengaged position.  
         [0070]    In the illustrated embodiment, the arm portion  601  of the linkage structure  600  is substantially flat and elongated in configuration. This design provides adequate lateral stiffness, needed to transfer torque from the operator output member  104  to the wall mounting structure  504  and maintains a low profile for the linkage structure  600 . As stated above, one end of the arm  601  is non-rotatably mounted to the first clutch member  702 . An opposite end of the linkage structure  600  includes a pivotal connection member  726  that defines a linkage pivotal axis LA. Pivotal connection member  726  has an axially extending portion  728  that threadedly engages a threaded opening  730  in linkage structure  600 . Another portion of the pivotal connection member  726  is operatively connected to another arm portion  530  of the linkage structure.  
         [0071]    Wall mounting structure  504  is fixedly secured to the building wall  14 . Preferably, the wall mounting structure  504  is attached to the door frame  12 , but in alternative designs it may be directly mounted to the wall  14 . In the illustrated embodiment, the wall mounting structure  504  is a frame mounting bracket that includes a substantially flat frame attaching member  526  that is attached along an upper edge of the inner periphery of the door frame  12 . The attaching member  526  extends laterally with respect to door frame  12  and is fixedly secured thereto with a plurality of threaded fasteners  528 . A portion of the frame attaching member  526  is deformed to provide a lateral slide channel  528  that slidably receives the arm portion  530  of the linkage structure  600  therein. In the illustrated embodiment, the arm portion  530  acts as a slide member that slides rectilinearly within the slide channel  528 . Shown in FIGS. 11 and 12, wall mounting structure  504  may be formed from a single piece of metallic sheet material. The slide channel  528  may be formed by bending the metallic sheet into the desired configuration, such as that shown in FIG. 12, to form the channel  528  within which slide member  530  may be disposed.  
         [0072]    The slide member  530  may include a polymer insert member  532  to which pivotal connection member  726  is connected. Insert member  532  serves as a cushion to reduce jarring movement of the door panel  16  as axial operator  100  opens or closes door panel  16 . It is also contemplated that insert member  532  may be formed of a metallic material, or that the pivotal connection member  726  may be connected directly to slide member  530 . Preferably an E-clip or a C-clip, shown at  732  in FIG. 2, is fastened to an uppermost end of pivotal member  726  to retain the pivotal member  726  in connection with the slide member  530 .  
         [0073]    A pair of end caps  534  prevent the slide member  530  from sliding out of slide channel  528  and provide the wall mounting structure  504  with an enhanced aesthetic appearance.  
         [0074]    It is preferable that slide channel  528  is sufficient in length such that slide member  530  has sufficient travel to allow door panel  16  to be fully opened and fully closed. Furthermore, it is preferable that a portion of the frame attaching member  526  that attaches to the frame  12  be of the same length as the portion defining the slide channel  528  to provide sufficient support to the channel  528 .  
         [0075]    Although the illustrated example of a linkage structure  600  is preferred because it is economical and functions to effect the requisite transferal of force from the operator  100  in a compact design, it should be understood that the linkage structure  600  may be any arrangement capable of linking the operator  100  to the door panel  16  in such a manner that operation of the operator  100  affects movement of the door panel  16 .  
         [0076]    The door mounting structure  502  also includes a controller-mounting bracket  550 , shown in FIG. 2. Mounting bracket  550  is attached to door panel  16  by a plurality of threaded fasteners  552 . Mounting bracket  550  is further connected to operator-mounting bracket  510  by a pair of threaded fasteners  554 . Mounting bracket  550  is situated underneath mounting bracket  510  and is disposed between door panel  16  and axial operator  100 . Controller  508  is mounted to an outwardly facing surface of the mounting bracket  550 . Mounting bracket  550  further includes a outwardly extending portion  556  protruding from a bottom portion thereof and below the operator  100 .  
         [0077]    A manually engagable release member allows the clutch  700  to be disengaged in an emergency situation when it is desirable to manually bypass the axial operator  100  to allow the door panel  16  to be manually opened or closed. The manually engagable release member includes a handle structure  732  that has a pair of interconnecting members  734 . Interconnecting members  734  are disposed on opposite sides of operator  100  and extend downwardly from the second clutch member  704  to a position below operator  100  and also below portion  556  of bracket  550 . Each interconnecting member  734  includes a second clutch member-engaging portion  736  that engage the second clutch member  704 . It is preferable to form second clutch member-engaging portions  736  by bending upper ends of associated interconnecting members  734  to a horizontally extending, confronting arrangement, shown in FIGS. 13 and 14. Interconnecting members  734  pass through respective vertically extending openings  558  in the outwardly extending portion  556 . The vertically extending openings  558  provide horizontal support to the interconnecting members  734  and serve as guides for vertical movement of the interconnecting members  734 .  
         [0078]    The handle structure  732  may include a handle grip portion  738  to allow a user to manipulate the manually engagable release member. In the illustrated embodiment, the lower ends of the interconnecting members  734  are bent such that the lower ends contact one another and are connected to each other, preferably by rivets or spot welding. The handle grip portion  738 , formed preferably of polycarbonate material, is over-molded on the intersecting lower ends of the interconnecting members  734 , as shown in FIG. 15. With this arrangement, to move the clutch  700  to its disengaged position, the user applies a downwardly directed force on the handle grip portion  738  to thereby move the second clutch member  704  downwardly against the biasing of spring  720  and affect disengagement of the clutch  700 . In another embodiment of the handle structure  732 , shown in FIGS. 16 and 17, the lower ends of the interconnecting members  734  are bent to a horizontally confronting configuration. An arcuate handle grip portion  738 ′, formed preferably of polycarbonate material, is over-molded on the lower ends of the interconnecting members  734  of this embodiment. The specific configuration of the release member is not critical to the present invention and the invention may be practiced with a release member of any construction or configuration.  
         [0079]    The retrofit door operating system  500  may also include an electric strike  800  to facilitate locking and unlocking the door panel  16  with respect to the door frame  12 . The electric strike herein contemplated is the type disclosed in U.S. Pat. No. 3,861,727, which is hereby incorporated by reference into this patent application for the present invention.  
         [0080]    The electric strike  800  is operatively connected to the controller  508  so that the controller  508  can selectively activate or deactivate the electric strike  800  based on signal(s) received from the input device  506 . As shown in FIG. 18, the electric strike  800  includes a strike member  802  that is pivotally mounted within a casing  804 . A pivot pin  806  serves to connect the strike member  802  to the casing  804 . A solenoid  808  includes a plunger  810  and a return spring  812 . The solenoid  808  is mounted within the casing  804  by a bracket  814  that is fixedly attached to the casing by a plurality of threaded fasteners (not shown). The solenoid  808  is disposed within a central opening within the bracket  814  and is secured with a threaded nut  816 . A blocking member  818  is threadedly attached to one end of the plunger  810 . When the solenoid  808  is energized, the blocking member  818  is moved to a blocking position wherein it blocks strike member  802  from pivotal movement, effectively locking the bolt on the door panel  16  therein and preventing the door panel  16  from being opened. When the solenoid  808  is deenergized, the return spring  812  biases the plunger  810  in a direction such that blocking member  818  is moved to a releasing position wherein it is clear of strike member  802  and allows the strike member  802  to pivot inwardly into the casing  804 , effectively unlocking the bolt on the door panel  16  and allowing the door panel to be opened. A biasing spring  820  biases the strike member  802  with respect to the casing  804  such that the strike member  802  is urged toward a normal engaging position wherein the strike  802  retains the bolt on the door panel  16  therein. A strike plate  822  is mounted to the casing  804  with a pair of threaded fasteners  824  and cooperates with the strike member  802  to form the recess within which the door bolt is disposed when the door panel  16  is in a closed position. A face plate  826  is mounted to the door frame  12  with a pair of threaded fasteners  828  in covering relation to the casing  804 .  
         [0081]    As stated previously, the controller  508  is communicated to the motor  102  of the axial operator  100  to commence rotation of the motor and affect movement of door panel  16  upon the appropriate signal from the input device  506 . Further, the controller  508  is communicated to the electric strike  800  such that, upon the appropriate signal from the input device  506 , the controller may energize or deenergize the solenoid  808  to cause the door panel  16  to be locked or unlocked with respect to the door frame  12 .  
         [0082]    As shown in FIG. 1, the retrofit door operating system  500  is supplied with electrical power via an electrical power supply cord  570  extending between a wall-mounted electrical socket  18  and the controller  508 . It is contemplated that either the controller  508  or electrical power supply cord  570  may include a transformer to allow the AC current supplied by the wall-mounted electrical socket  18  to DC current, as used by the motor  102 . As shown in FIGS. 19 and 20, a flat flexible cable  572  connects the controller  508  to a connecting terminal  574 , which is mounted to the building wall  14  immediately adjacent the edge of the door frame  12 . The electrical power supply cord  570  connects to a first pair of positive and negative terminals  576 , which is communicated to controller  508  by two of the wires in the flat flexible cable  572 . A second pair of positive and negative terminals  578  communicates with the controller  508  by an additional two wires in the flexible cable  572 . An opposite end of electrical cord  580  is connected to the solenoid  808  of electric strike  800 . The configuration of the flexible cable  572  is such that the door panel  16  may be moved between the open and closed positions without interference from the flexible cable  572 . Specifically, all the wires in the flexible cable  572  are arranged in a planar, parallel array, which provides the cable with a low profile and compact arrangement that is difficult to obtain with cables that have circularly arranged wires.  
         [0083]    The input device  506  may be in the form of a remote transmitter  582 , as shown in FIG. 21, that is adapted to be carried by a person. The remote transmitter  582  includes a manually actuated switch  584  that allows the user to send a door movement signal to a receiver  586 . The receiver  586  is adapted to assess the validity of the door movement signal (e.g., determine if the received signal is valid or appropriate). That is, the receiver  586  (or the controller  508 ) analyzes the door movement signal to determine whether it carries a code that matches a predetermined code provided to the receiver  586  (or controller  508 ). The controller  508  then carries out instructions prescribed by the door movement signal. For example, with the door  12  closed and the strike  800  in the locking position thereof, the user can use the transmitter  502  to transmit a valid door opening signal to the receiver  586 . Based on receiving this signal, the controller  508  then responsively deenergizes the strike  800  to release the door panel  16  and then begins the operation of the operator  100  to move the door panel  16  in the opening direction. Alternatively, the system could be configured such that the transmitter transmits a door unlocking signal separate from the door opening signal. In this configuration the user could first transmit the valid unlocking signal with the transmitter  582  (thus causing the controller  508  to deenergize the strike  800 ) and then transmit a subsequent valid door opening signal (thus causing the controller  508  to actuate the operator  100  for opening movement of the door panel  16 ). The door movement signal may also be a door closing signal that causes the controller  508  to actuate motor  102  to move the door panel  16  towards and into its closed position. Once closed, the controller then energizes the electric strike  800  to move the same into its locked position, effectively locking the door panel  16  with respect to door frame  12 . It is also contemplated that the remote transmitter may transmit separate door closing and unlocking signals, which would require a user to depress a switch for closing the door panel  16  and locking the electric strike  800 .  
         [0084]    It should be noted that the controller  508  functions to monitor the door panel position using feedback generated by the Hall effect sensor. The controller  508  uses this information to vary the speed of the motor (and hence the speed of door panel movement) during various phases of the door panel&#39;s range of movement. For example, as the door panel moves in the closing direction and is near the closed position, the controller  508  slows down the motor speed so that the last few inches of door panel travel are at a reduced speed. This helps to reduce the likelihood of objects being trapped between the door panel  16  and frame  12  during door closing. Also, the controller  508  may be programmed to monitor the motor speed via the Hall effect sensor in relation to the amount of power being delivered to the motor. By comparing this information, the controller  508  can determine whether the door panel  16  has encountered and obstruction and then responsively stop delivery of power to the motor (or reverse the motor entirely).  
         [0085]    It is contemplated that other types of input devices may also be possible. For instance, a wall-mounted key pad (not shown) may be utilized to produce the door movement signal(s). In this case, the wall-mounted key pad may be connected to the connecting terminal  574  by a separate electrical cord that serves to convey the door movement signal to the receiver  586 . To prevent unauthorized access, the user must enter a valid access code into the key pad prior to operating the system.  
         [0086]    A cover  588  attaches to the operator-mounting bracket  510  with a threaded fastener  590 . The cover  588  serves to surround and enclose the majority of the retrofit door operating system  500  to reduce dirt and dust contamination thereof and provide a more aesthetically pleasing appearance by concealing the internal components of the system. A horizontal slot  592  in the upper end of the cover  588  allows the arm portion  601  to pivotally move therein while the door panel  16  moves between the closed and open positions.  
         [0087]    Operation  
         [0088]    To install the system  500 , the wall mounting structure  504  is mounted to the upper inner edge of frame  12  as shown and the door panel mounting structure  502  is mounted to the door panel upper corner as shown with the linkage structure  600  extending therebetween. The linkage is preferably distributed to the end user pre-connected to the wall and door mounting structures  502 ,  504 ; but it may be separate, thus requiring the additional steps of attaching the linkage structure  600  to the wall and door mounting structures  502 ,  504 . The connecting terminal  574  is connected to the wall adjacent the frame  12  and the flat cable  572  is connected between the controller  508  and the terminal  574  as described above. The user routs out the portion of the door frame  12  where the existing strike is and mounts the electric strike  800  into the routed opening. Then, the low voltage wiring  580  is ran along the outer edge of the door frame  12  and connected at one end to the solenoid of the strike  800  and at the other end to the connecting terminal  574 . Preferably, a plurality of fasteners, such as staples, are used to secure the low voltage wiring  580  to the outer edge of the door frame  12 . The power supply cord  570  is then plugged into a live electric outlet to provide power to the system  500 .  
         [0089]    Upon receipt of the door movement signal that includes the instruction for the controller  508  to actuate the electric motor  102 , the rotatable motor output member  108  is rotated in the dictated direction. The rotatable operator output member  104  is also rotated, but at a speed lower than the speed of the motor output member  108  and a torque greater that the torque of the motor output member  108  as defined by the gear ratio of the reduction transmission  200 . The rotatable operator output member  104  in turn affects the rotation of first and second clutch members  702 ,  704  (assuming the clutch is in the engaged position). The operator  100  drives the linkage structure  600 , which in turn affects powered swinging movement of the door panel  16 .  
         [0090]    From the closed position towards the open position, the arm  601  of the pivoting linkage structure  600  pivots in a direction opposite to the direction the door panel  16  moves. For example, FIGS. 16 and 19 show the door panel  16  in a closed position. In this case, the door panel  16  pivots counter-clockwise from the closed position to the open position. Therefore, to effect movement of the door in the counter-clockwise direction, the operator  100  pivots the linkage structure  600  in a clockwise direction. It is noted that the arc  19 , in FIG. 19, represents the path the operator axis OA travels about the door axis DA as the door panel  16  moves between the closed position and the open position. The sliding nature of the connection between the wall mounting structure  504  and the sliding arm  530  of the linkage structure  600  allows the arm  530  to slide rectilinearly within slide channel  528  toward the hinge side of the door panel  16 , as the door panel is moved in the opening direction.  
         [0091]    From the open position towards the closed position, the door panel  16  moves clockwise towards the closed position. Therefore, the operator  100  pivots the arm  601  of the linkage structure  600  in a counter-clockwise direction to impart the clockwise movement of the door panel  16 . The sliding arm  530  moves within the slide channel  528  away from the hinge side of the door panel  16 , as the door panel is moved in the closing direction.  
         [0092]    It is noted that the user may resist and prevent movement of the door panel  16  against the force produced by the axial operator  100 , as the retrofit door operating system  500  attempts to move the door panel  16  toward the closed or open position. It is also noted that the user may manually effect movement of the door panel  16  while the retrofit door operating system is not in operation, since the axial operator  100  does significantly limit manually imparted rotatable motion of the door panel  16 . It may however be preferable to disengage the axial operator  100  to allow free movement of the door panel  16 . The handle structure  732  allows the user to manually move the clutch  700  to the disengaged position thereof. Shown in FIG. 1, by effecting a downwardly directed movement of handle grip portion  738  (or  738 ′) the second clutch member  704  may be uncoupled from the first clutch member  702  and as such any resistance of the axial operator  100  is bypassed.  
         [0093]    The preferred application of the illustrated system is installation on pre-existing manual swing door assemblies on residential structures. The term residential structures is not limited solely to residential homes or apartments, and is intended to include other structures that could be considered both commercial and residential in nature, such as individual hospital rooms, individual rooms at elderly care facilities or nursing homes, individual hotel/motel rooms and other such locations where it is advantageous to have power operated doors that are economical and relatively easy to install.  
         [0094]    One advantage of the illustrated embodiment is that it can be installed on both right and left-handed swing door assemblies without any modification. Specifically, the overall design can be considered as being functionally symmetrical or “non-handed” because its configuration when mounted on a right-handed assembly is functionally a mirror image of its configuration when mounted on a left-handed assembly. However, the invention may be practiced in a design without this advantage.  
         [0095]    In an alternative embodiment of the design, the operator  100  and control system could be mounted on the wall  14  or the door frame  12  instead of on the door panel  16 . 1  However, the combination of the axial operator  100  mounted on the door panel  16  as illustrated is preferred for aesthetic appearance purposes. Specifically, because the axial operator  100  has a relatively greater axial extent in comparison to its radial extent, and the door panel  16  has a relatively greater vertical extent than widthwise extent, the presence of the axial operator  100  on the door panel  16  appears less obtrusive and provides for an overall better appearance. By way of comparison, if the axial operator  100  were mounted, for example, above the door frame  12 , the vertical extent of the operator  100  provides for a poor aesthetic appearance. Specifically, the vertical axial operator  100  on the door panel  16  appears to fit within the overall shape of the door panel, whereas the vertical axial operator  100  above the door frame  12  appears to protrude from the frame  12 , giving the whole swing door assembly an awkward appearance.  
         [0096]    It can thus be appreciated the foregoing objectives of the invention have been fully and effectively accomplished. The foregoing illustrated embodiment has been provided to illustrate the structural and functional principles of the present invention and is not intended to be limiting. To the contrary, the present invention is intended to encompass all modifications, changes and alterations within the spirit and scope of the following claims.

Summary:
The present application discloses a retrofit power door assembly for installation on a manual door assembly. One aspect of the application related to a retrofit power door assembly having an axial operator. Another aspect of the application relates to a retrofit power door assembly having a clutch with a manually engageable release member.