Abstract:
A barrier operator comprises a current limit portion and a barrier operator portion. The current limit portion is coupled to a mains supply and the barrier operator position is coupled to the mains supply and the current limit portion. The barrier operator portion actuates a movable barrier. The current limit portion regulates electrical current to at least one additional device.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application is a continuation-in-part of U.S. application Ser. No. 10/844,016, filed on May 12, 2004 and incorporated by reference in its entirety. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     Barrier movement operators generally include power and control systems for responding to operator inputs and sensed conditions to move a barrier between open and closed positions with respect to an opening. The barrier may be a door, a gate, a window, a window shade/protector or similar apparatus. Garage door operators are a common form of barrier movement operator.  
         [0003]     One type of garage door operator comprises a head end with control circuitry and a motor that extends and retracts a trolley connected to the door. The trolley moves along a rail connected between the head end and a support wall of a garage at a point above the garage opening. Such a trolley and rail type of garage door operator is generally supported from an overhead structure such as the ceiling joists of a garage. Support is often achieved by vertical metal support members from the housing of the head end to the ceiling joists which may result in a less than stylish connection.  
         [0004]     Ancillary equipment or accessories can be used to improve the functionality of the garage in which the garage door operator is mounted. For example, additional lighting is often placed in the garage, which in some instances, may be controlled by the controller of the head end. Also, a readily available extension cord and/or a mechanic&#39;s light is sometimes provided in the garage. The garage door operator itself may gain advantage to having an attached security camera, monitor, motion sensor and other sensing equipment. In previous systems, the inclusion of such additional equipment results in a mix of non-similar items affixed throughout the garage.  
         [0005]     In previous systems, the amount of current that an electrical outlet can supply to an operator and its accessories is limited by a circuit breaker. The current flows from the outlet to the operator and the accessories. When the barrier is moved, the movable barrier operator requires a large percentage of the current flowing from the outlet to operate. Both during the starting of the motor and situations where high force is required, the amount of current needed is at a peak. If during the starting of the motor, the sum of the operator current and the current supplied to the additional devices is above the threshold of the circuit breaker, the circuit breaker trips, current flow is halted, and the operator is unable to complete its operation. When the circuit breaker trips, the operation of the operator and the additional devices is impaired resulting in significant inconvenience to the user.  
         [0006]     Previous systems do not deal with this situation effectively. Also, in previous systems the power made available to the ancillary devices is the same regardless of whether the operator is active or inactive or which of the ancillary devices is in operation. This results in an inefficient use an allocation of system resources.  
       SUMMARY OF THE INVENTION  
       [0007]     A barrier operator includes a current limiting portion to limit the current supplied to additional or ancillary devices of a barrier operator system. The current limiting portion removes the possibility of tripping an external circuit breaker when a current surge occurs. The safety of the system is enhanced, and at the same time, the power available for the ancillary devices is customized depending upon whether the operator or one of the other ancillary devices is active.  
         [0008]     In many of these embodiments, a barrier operator includes a barrier operator portion and a current limit portion. The current limit portion is coupled to a mains supply. The barrier operator portion is coupled to the current limit portion and the mains supply. The current limit portion limits the electrical current made available to at least one ancillary device.  
         [0009]     The current limit portion of the operator may include a single current limit device or multiple current limit devices. In addition, the current limit portion may include a controller. The controller receives information indicative of the type of the at least one additional device.  
         [0010]     If a controller is used, the controller can make decisions concerning the activation of the additional devices based upon the type of device or other factors. For instance, if a first device is a compressor, a second device is a florescent light, and the third device is a heater, the controller can activate the compressor and heater when the operator is activated but leave the light deactivated. In addition, the controller can leave on the florescent light but not turn on the work light, if the approach would lower the current. The controller can be flexibly programmed to make these decisions based upon the specific needs of a user and the quantity of available current.  
         [0011]     The additional device may include a variety of different types of devices used in garages, for example, lights, heaters, sensors, security devices and compressors. The current limit device may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit, switch or fuse. Other examples current limiting devices are possible.  
         [0012]     Thus, a system and method is provided that prevents the tripping of a circuit breaker supplying current to an operator. This approach allows for a more convenient use experience during the operation of the operator and effectively manages current surges. Since current surges are effectively managed, operating conditions for a user are made more safe. Also, power is managed mote effectively because the state of the operator is considered on determining the amount of power supplied to ancillary devices. This results in the smoother and more efficient operation of the system. 
     
    
     BRIEF DESCRIPTION OF DRAWING  
       [0013]      FIG. 1  is a perspective view of a mounted prior art barrier movement operator;  
         [0014]      FIG. 2  is a perspective view of an improved barrier movement operator mounting according to the present invention;  
         [0015]      FIG. 3  is a front plan view of the mounting of  FIG. 2  according to the present invention;  
         [0016]      FIG. 4  is an end view of an elongate member and vertical support used in  FIG. 2  according to the present invention;  
         [0017]      FIG. 5  is an electrical block diagram illustrating power distribution according to the present invention;  
         [0018]      FIG. 6  is a top view of the barrier movement operator according to the present invention;  
         [0019]      FIG. 7  is a system for controlling in the distribution of current according to the present invention;  
         [0020]      FIG. 8  is a system for controlling in the distribution of current according to the present invention;  
         [0021]      FIG. 9  is a system for controlling in the distribution of current according to the present invention;  
         [0022]      FIG. 10  is a system for controlling in the distribution of current according to the present invention;  
         [0023]      FIG. 11  is a system for controlling in the distribution of current according to the present invention; and  
         [0024]      FIG. 12  is a system for controlling in the distribution of current according to the present invention. 
     
    
       [0025]     Skilled artisans will appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of various embodiments of the present invention. Also, common but well-understood elements that are useful in a commercially feasible embodiment are often not depicted in order to facilitate a less obstructed view of the various embodiments of the present invention.  
       DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0026]     Referring now to  FIG. 1 , a perspective view of the inside of a secure area such as a garage, having a known barrier movement operator is described. The area has a ceiling  16  and a front wall  14  with a doorway (not shown) therethrough which is opened and closed by a paneled garage door  24 . The position of the door  24  is controlled by a barrier movement operator head end  12  which moves a trolley  20  out and back along a rail  18 . The trolley  20  is connected to door  24  by a trolley/door arm  22 . The door  24  includes rollers at its edges which engage doorguides  26  and  28  and as the trolley  20  is drawn toward the head end  12  the door  24  is raised in the doorguides to a substantially horizontal position. The movement of the door may be controlled by user interaction with a wall control unit  31  which signals the head end of the user&#39;s requests. The head end  12 , which includes an electric motor, is powered from a maims voltage outlet  15  and is supported from the joists of the ceiling by support members  13 . Other sensors and signaling devices may be used to control barrier movement, but are not described because they are not necessary for an understanding of the present invention.  
         [0027]      FIG. 2  is an upward perspective view of a combined barrier movement operator support and power busing system. The trolley of the  FIG. 2  arrangement may be connected to a trolley/door arm  22  as shown in  FIG. 1  to raise and lower a door or other barrier.  FIG. 3  is a view of the same structure as  FIG. 2 , but the view is from the front of the garage, along the trolley rail  18 . The structure of  FIG. 2  includes an elongate member  33  which is supported by a plurality of vertical members  35  from an over head structure. The over head structure may be ceiling joists or another support member secured to the overhead structure of the garage. Elongate member  33 , which is shown in cross section in  FIG. 4 , comprises an open trough  34  which may be fabricating by roll forming  16  gauge sheet steel. The open trough  34  runs the length of the elongate member and may be used to provide power to accessories attached to the elongate member as discussed below.  
         [0028]     Vertical members  35  may comprise hollow tubes having a shoulder portion  37  at a bottom thereof Shoulder portion is affixed to the hollow tube vertical member  35  and includes female threads at the open end thereof. The elongate member  33  includes a plurality of mounting holes and the vertical members  35  are connected to the elongate member  33  by bolts  39  screwed into the female inner threads of shoulders  37  through the holes. The open ends of elongate member  33  may be closed by end caps  38 .  
         [0029]     The operator  12  includes a current limit portion  12   a.  The current limit portion  12   a  controls current to the additional devices  53 ,  54 ,  55 ,  56  and  57 . As described in greater detail below, the current limit portion  12   a  may include a single current limit device or multiple current limit devices. In addition, the current limit portion  12   a  additional may include a controller. In one example, the controller receives information indicative of the type of the at least one additional device.  
         [0030]      FIG. 6  is a top plan view of the barrier movement operator  12  portion of the elongate member  33  and portion of the trolley tail  18 . The barrier movement operator  12  is secured to the elongate member  33  by means of a plurality of bolts  41  which extend through the elongate member  33  into threaded holes in the barrier movement operator. Similarly, the trolley rail  18  is secured to the top of barrier movement operator  12  by means of a pair of bolts  43  through the rail and into barrier movement operator, Also shown in  FIG. 6  is a drive sprocket  45  which is rotated by a motor (not shown) to move a chain  47  which is attached to trolley  20 . Mains voltage may be provided to the barrier movement operator by a multi conductor power wire  49  which passed through one of the hollow vertical supports  35  and into the hollow trough  34  of elongate member  33 . Power wire  49  runs along the interior  34  of elongate member  33  and is passed to the barrier movement operator  12  via an opening  51  in the elongate member.  
         [0031]     The elongate member  33  also includes a number of points at which accessories can be attached to provide additional functionality. As shown in  FIG. 3 , light fixtures  53  and  54  are attached to a portion of the elongate member  33  to the left of the barrier movement operator  12  and light fixtures  55  and  56  are attached to the right. Further, a retractable cord, mechanic&#39;s light  58  is attached to the elongate member as is a retractable hose reel  59  for supplying compressed air from a compressor  52 . In other embodiments, other accessories such as a battery charger, security camera, CO monitor, motion detector etc., may be attached to the elongate member  33 .  
         [0032]      FIG. 5  is an electrical block diagram illustrating the connection and distribution of electrical power using the arrangement of  FIG. 2 . In  FIG. 5 a  portion of the elongate member  33  is shown to represent it&#39;s power distribution or power bus function and barrier movement operator  12  is shown in block diagram form. Barrier movement operator  12  comprises power distribution apparatus  71 , a controller  73 , barrier movement apparatus  75 , a light assembly  77 , and the current limit portion  12   a.  The current limit portion  12   a  limits current to the additional or ancillary devices. Barrier movement apparatus  75  may include a motor and sensors (not shown) which cooperate with control unit  73  to open and close a barrier. Power distribution unit  71  is equipped to receive mains voltage and to distribute mains voltage, or another created voltage, under the control of controller  73 . The light  77  is a common part of barrier movement operators and is used to provide one source of illumination under the control of controller  73 .  
         [0033]     Power wire  49  is connectable to a source of mains voltage and connects that voltage to power distribution unit  71 . Power distribution unit  71  distributes power within barrier movement operator  12  as is needed to provide barrier movement. Controller  73  is also responsible for controlling the application of mains voltage and other electrical power derived therefrom to accessories connected to barrier movement operator  12 .  
         [0034]     The following are examples of power distribution via elongate member  33 . The mains power on power conductor  49  may be distributed directly to attached accessories on elongate member  33  by connection to the power conductor. For example, one accessory may be a “night light” which is continuously powered, but which senses light levels and turns on the “night light” when light levels drop below a predetermined level. Further, the mechanics&#39; light and cord reel  58  and the compressor  52  may be permanently supplied with mains power by connection to power conductor  49 . A battery charger  61  may also be permanently connected to mains power. AC mains power may be selectively provided to accessories by the power distribution unit  71  under the control of controller  73 . For example, when a left hand garage door is being opened lights  54  and  53  may receive mains power from power distribution  71  via conductor  77 . Similarly, lights  55  and  54  may receive mains power from power distribution unit  71  via conductor  79  when a right hand garage door is being opened. Further, laser positioning devices  57  may receive power via conductor  81  or  82  to create a light spot only briefly when a vehicle is entering one side or the other of the garage. The power sent to a laser light  57  may be AC mains or DC created by power distribution  71  under control of controller  73 . In addition, conductors  91  may be employed by power distribution  71  to distribute low voltage power along elongate member  33  or potentially a lower mains voltage to dim the lighting.  
         [0035]     In the preceding embodiments, elongate member is shown as being open at the top. The elongate member may be closed on its top to provide protection against improper contact with household voltage. The barrier movement operator is shown in the preceding, attached to the underside of the elongate member. In other embodiments, the barrier movement operator may be attached to the top of the elongate member and rest thereon. Mains power was supplied to the apparatus by a power cord  49  passing through a hollow vertical support  35 . In other embodiments, the power cord may be connected to mains power without passing through a vertical support and such power may be supplied directly to barrier movement operator  12  via a power cord as shown in  FIG. 1 .  
         [0036]     Referring to  FIG. 7 , one example of an operator with a current limiting device is described. A power plug  710  is placed in a power outlet to supply power and current to the operator  702  via power lines  704  from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. A current limiting device  706  limits the current supply to additional or ancillary devices that are connected via an outlet  708 . The current limiting device  706  may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit or fuse. The current limitation for the additional devices is limited to the maximum current, which the operator  702  demands.  
         [0037]     Referring now to  FIG. 8 , another example of an operator with a current limiting device is described. A power plug  816  is placed in a power outlet to supply power and current to an operator  802  via power lines  803 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. Current limiting devices  804 ,  806 ,  808  supply and limit current to outlets  810 ,  812  and  814  respectively. The current limiting devices may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit or fuse. The outlets  810 ,  812  and  814  are connected to separate outside devices. The maximum current to each additional device is limited to the maximum current the operator  802  demands divided by the number of potential devices. The limit to the amount of current for each branch may be different and may be determined by a user.  
         [0038]     Referring now to  FIG. 9 , another example of an operator with a current limiting device is described. A power plug  910  is placed in a power outlet to supply an operator  902  with power and current. The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. The operator  902  includes a control circuit  904 , a current limiting device  906  and an outlet  908  to additional devices (not shown). The current limiting device  906  may be a secondary circuit breaker, positive temperature coefficient resistor, current detecting circuit or fuse. The control circuit  904  controls the operation of the barrier movement portion of the barrier operator.  
         [0039]     The current that a motor is allowed to absorb is limited by the limiting device  906 . The limiting device  906  slows down the rate at which a motor (not shown) accelerates but allows for a higher amount of current for the additional devices. This approach may be used alone or in combination with other approaches described herein.  
         [0040]     Referring now to  FIG. 10 , an example of an operator with another current limiting approach is described. A power plug  1008  is placed in a power outlet to supply an operator  1002 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. A power control element  1004  controls the amount of current supplied to outlet  1006 . The outlet  1006  is connected to additional devices (not shown). In this approach, the power control element  1004  turns off the additional devices whenever the operator  1002  is required to move a barrier. This allows the barrier to have a full current supply, but at the same time, power the additional devices.  
         [0041]     Referring now to  FIG. 11 , another example of an operator with current limiting devices is described. A power plug  1112  is placed in a power outlet to supply power and current to an operator  1102  via power lines  1103 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. The operator  1102  includes switches S 1 , S 2  and S 3  that are connected to outlets  1108 ,  1106  and  1104  respectively. The outlets  1104 ,  1106  and  1108  and switches S 1 , S 2  and S 3  are connected to control logic  1110 . The control logic  1110 , in one example, may be in the form of a microprocessor. As an example, the switches S 1 , S 2 , and S 3  can be relays, triacs, other solid state relays or combinations of these devices.  
         [0042]     The switches S 1 , S 2  and S 3  are operated by the control logic  1110 . The control logic  1110  causes the switches S 1 , S 2  and S 3  to be opened and closed depending upon how the control logic has been programmed.  
         [0043]     The control logic  1110  may also be responsible for phasing-in the operation of the additional devices. For example, the control logic  1110  may determine to activate a first additional device at time t 1 , a second additional device a certain length of time later, and a third additional device another length of time later. Phasing-in the additional devices avoids current spikes that might be created at start-up if all the additional devices were activated at the same time. The additional devices may be any that have been described previously. In addition, the additional devices may include other barrier operators.  
         [0044]     In this approach, information indicating the types of devices that are attached to the operator is supplied to the control logic  1110 . By knowing, for instance, that the first device is a compressor, the second device is a florescent light and the third device is a heater, the control logic  1110  can make an intelligent decision as to which devices to activate based upon certain predefined circumstances. For instance, the control logic  1110  can activate the compressor and heater when the operator is activated but leave the light deactivated. The control logic  1110  can leave on the florescent light but not turn on the heater, if the approach would lower the current. Those skilled in the art will realized that the control logic  1110  can be configured in any number of ways to act upon the additional devices depending upon the desires of a user.  
         [0045]     Referring now to  FIG. 12 , an example of an operator where information concerning additional devices is received by the operator is described. A power plug  1214  is connected to a power and current outlet and power and current is supplied to the operator via lines  1203 . The power outlet receives power and current from a mains supply. In one example, the mains supply may be the standard 110V residential supply in the United States. However, other examples of mains supplies are possible. Outlets  1204 ,  1206 ,  1208  and  1212  are connected to additional devices.  
         [0046]     The knowledge of the type of device can be given either through a third connection (information, power and ground) or through a specific connection to the additional device. The specific connection can be specific plugs or a specific wire connection for switched and unswitched power. The third connection (information) can be performed by a number of methods. Serial communication is one example as is having an impedance connected to that terminal to allow the impedance measurement to give the magnitude of current demanded by the products connected to the terminal.  
         [0047]     While there has been illustrated and described particular embodiments of the present invention, it will be appreciated that numerous changes and modifications will occur to those skilled in the art, and it is intended in the appended claims to cover all those changes and modifications which fall within the true scope of the present invention.