Patent Publication Number: US-8540005-B2

Title: Apparatus and method for monitoring and controlling a covering for an architectural opening

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is the national stage application of PCT Patent Application No. PCT/US2009/061237 filed on Oct. 20, 2009 and entitled “Apparatus and Method For Monitoring and Controlling a Covering For an Architectural Opening,” which claims the priority under 35 U.S.C. §119(e) to U.S. provisional patent application No. 61/106,806 entitled “Apparatus and Method For Monitoring and Controlling a Covering For an Architectural Opening” filed on Oct. 20, 2008, which is applications are hereby incorporated by reference into the present application in its their entirety. 
     This application is also related to U.S. application Ser. No. 29/326,484 filed on Oct. 20, 2008 and entitled “Closure Panel For a Headrail For an Architectural Opening” and is hereby incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a method and apparatus for monitoring and controlling a covering for an architectural opening, and more particularly to detecting the position and movement status of a collapsible shade as it is being extended. 
     BACKGROUND OF THE INVENTION 
     Coverings for architectural openings such as windows, doors, archways and the like have assumed numerous forms for many years. Early forms of such coverings consisted primarily of fabric draped across the architectural opening, and in many instances the fabric was not movable between extended and retracted positions relative to the opening. 
     Retractable coverings for architectural openings, herein referred to as shades, have evolved into many different forms, which include roller shades in which a piece of flexible material can be extended from a wrapped condition on a roller to an extended position across the architectural opening, and vice versa. Other popular forms of retractable coverings for an architectural opening include Venetian blinds, vertical blinds, cellular shades and various variations on these basic designs. Cellular shades, as opposed to roller shades, generally collapse and stack up when retracted, and expand or extend when in the extended position. 
     Typically, shades of virtually any type may be manually retracted and extended by the user. More recently systems have been developed to automatically retract and extend shades. These automatic systems employ motors and various counter techniques to determine the position of the shade, and its direction of motion. 
     One issue with current automatic apparatus and methods for monitoring and controlling is that they may not accurately indicate the position of the window covering when being extended. Also, they also may not effectively indicate when the shade is obstructed during its downward motion. 
     It is to satisfy the above-recognized issues that the present invention has been developed. 
     BRIEF SUMMARY OF THE INVENTION 
     An apparatus and method associated with the extension of a covering for an architectural opening is described herein. The invention includes a mechanism for indicating a position of a shade member moving in an extending direction and includes a shade member movable between a retracted and an extended position, a motor drive, an actuation member operably associated with the shade member and responsive to the motor drive to cause the retraction and extension of the shade member, a control system operably associated with the motor drive, the control system monitoring at least one performance characteristic of the shade member and providing at least one control signal to the motor drive, a drive mechanism operably positioned between the motor drive and the actuation member, the control system monitoring the at least one performance characteristic during extension of the shade member, the performance characteristic having a first value when the shade member is extending, and the performance characteristic having a second value when the shade member is stationary, and the control system sending the at least one control signal to the motor drive when the second value of the at least one performance characteristic is received. 
     The invention further may include a mechanism wherein the at least one control signal is an instruction to turn off the motor drive. 
     Additionally, the invention may include a mechanism wherein the second value of the performance characteristic is an absence of a value. 
     Further, the invention may include a mechanism wherein the drive mechanism is a split drive mechanism. 
     In a further arrangement, the invention may be included in a method of detecting an obstruction or terminal position to the extension of a shade member. The method includes providing a drive mechanism having a first orientation during the extension and having a second orientation upon contacting the obstruction or reaching the terminal position. The method may also include the drive mechanism including a first engagement member and a second engagement member, the first engagement member and the second engagement member in the first relative orientation during extension; and the first engagement member and the second engagement member in the second relative orientation upon contacting the obstruction or reaching the terminal position. 
     In another aspect of one invention described herein, a mechanism for indicating the interruption of a shade member moving in an extending direction is disclosed. This mechanism includes a shade member movable between a retracted and an extended position, a motor drive, an actuation member operably associated with the shade member and responsive to the motor drive to cause the retraction and extension of the shade member, a control system operably associated with the motor drive and including a sensor, a drive mechanism operably positioned between the motor drive and the actuation member, the drive mechanism including a first engagement member engaged with the motor drive and a second engagement member engaged with the actuation member, the first and second engagement members rotatable relative to one another between a first and a second orientations. The sensor sensing the rotation of the drive mechanism when the first and second members are in the first orientation, and not sensing the rotation of the drive mechanism when the first and second members are in the second orientation. The control system, upon the sensor not sensing the rotation, sending at least one control signal to the motor drive to interrupt the motor drive. 
     Further to this one invention, the first engagement member is a drive member and the second engagement member is a driven member. 
     A further aspect of the invention contemplates that the first engagement member includes a magnet having a north and a south pole, the second engagement member includes a magnet having a north and a south pole, wherein in the first orientation the north poles of each of the first and second engagement members are in proximity to one another and the south poles of each of the first and second engagement members are in proximity to one another; and the sensor is a magnetic sensor. 
     The invention also includes a method of detecting an obstruction or terminal position to the extension of a shade member comprising sensing the downward motion of the shade member, the downward motion being interrupted by the obstruction or by reaching the terminal position, no longer sensing the downward motion of the shade member, and providing a control signal to a motor to arrest any further downward motion of the shade member. 
     Other aspects, features and details of the present invention can be more completely understood by reference to the following detailed description of the various embodiments, taken in conjunction with the appended claims and drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The features and advantages of the present invention will be more readily apparent from the following detailed description, illustrated by way of example in the drawing figures, wherein: 
         FIG. 1  shows a cellular shade system having a head rail, a collapsible shade attached to the head rail at its top portion, a bottom rail attached to the bottom portion of the shade, and a motor assembly for causing the retraction and extension of the shade. 
         FIG. 2  shows an enlarged partial view of the shade structure of  FIG. 1 , with the front panel opened up to uncover the battery tube and the motor assembly. 
         FIG. 3  is a partial view of  FIG. 2 , with the battery tube extracted from the head rail for clarity. 
         FIG. 4  is an exploded view of the head rail of the present invention. 
         FIG. 5  is an exploded view of the motor assembly shown in  FIG. 4  of the present invention. 
         FIG. 6  is a section view taken along line  6 - 6  of  FIG. 1 . 
         FIG. 7  is a partial view of the split drive mechanism, including the magnets shown in parallel alignment and having opposite poles adjacent one another. 
         FIG. 8  is a partial view of the driving engagement element, including the base portion, prongs, and magnet, and the slave engagement element, similar to that shown in  FIG. 7 . 
         FIG. 9  is a representative section taken along line  9 - 9  of  FIG. 4 , showing the driving and slave engagement members during an unloaded arrangement, with the magnets in axial side-by-side alignment. 
         FIGS. 10A  and B are representative sections similar to  FIG. 9 , with different amounts of rotation shown, wherein the magnets are oriented orthogonal to one another. 
         FIG. 11  is an exploded view of the end cap portion of the head rail for housing the motor drive circuit board and manual retraction and extension function. 
         FIG. 12  is a section taken along line  12 - 12  of  FIG. 1 , and shows the pin structure for the pivotal attachment of the panel on the head rail. 
         FIG. 13  is a section taken along line  13 - 13  of  FIG. 12  and shows the pivot pin for pivotally holding the panel on the head rail base. 
         FIG. 14  is an exploded view of the components of  FIGS. 12 and 13 . 
         FIG. 15  is a partial perspective view of the shade member moving downwardly and being obstructed by an object, causing the control system to turn off the electric motor and stop the downward motion. 
         FIG. 16  is a instruction flow diagram for a control system able to be utilized with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention described herein relates to the apparatus and method associated with the extension and retraction of a covering for an architectural opening. More particularly, the invention relates to the automatic retraction and extension of a collapsible shade structure positioned in a window, and may further apply to the extension of a window shade. It is contemplated that this invention may apply to other types of coverings for architectural openings. 
       FIG. 1  shows a shade structure  50  incorporating the present invention. The shade structure  50  includes a shade member  52  attached at or near its top edge  54  to a head rail  56 , and attached at or near its bottom edge  58  to a bottom rail  60 . The shade member  52  may be a collapsible cellular shade structure that effectively collapses against the bottom of the head rail  56  when retracted. When extended, the shade member  52  extends, in part, under the weight of the fabric and the bottom rail  60  as it moves downwardly away from the head rail  56 . 
     The movement of the shade member  52  between the retracted and extended positions is controlled by a cord system  62 . As is known, a cord  64  (see  FIG. 4 ) is strung through the shade  52  and the head rail  56  to control the up and down movement of the bottom rail  60  relative to the head rail  56 , which in turn causes the shade member  52  to retract or extend. The cord system  62  includes a cord  64  that attaches to the bottom rail  60  and extends through the shade member  52  up to the head rail  56 . More than one cord  64  may be positioned along the width of the shade member  52  if desired. Each cord  64  may engage a spool member  66  positioned in the head rail  56 , and winds onto the spool  66  when the shade  52  is retracted, and unwinds from the spool  66  when the shade  52  is extended. Each spool  66  is typically mounted on a rotating cord shaft  68  that extends along at least a portion of the head rail  56 . The rotating cord shaft  68  may be driven by an actuation means, such as an automated means  70 . One such automated means  70  is a motor assembly  72  operably engaging one end of the cord shaft  68 . The motor assembly  72  is powered by line voltage or battery power, and is controlled by direct user inputs made by remote control or manual actuation of a control switch. It is contemplated that other means, such as mechanical means (such as a control cord manually actuated by the user), may be utilized. 
     The head rail  56  includes a front panel  74  that may be pivotable between a closed position (shown in  FIG. 1 ) and an open position (shown in  FIG. 2 ). Mounting brackets  76  are shown for use in mounting the head rail  56  to a structure above or adjacent the head rail. Other orientations of the brackets  76 , or other brackets altogether, are contemplated to allow the head rail  56  to be attached to any suitable surface. The head rail  56  has end caps  78  to act as a cover to the internal workings of the head rail  56  and provide a finished appearance. 
       FIG. 2  shows the head rail  56  of  FIG. 1  with the front panel  74  in the open position. In the head rail  56 , behind the front panel  74 , the battery tube  80  is positioned to extend along at least a part of the length of the head rail  56 . The battery tube  80  is held at either end by brackets  82  that include electrical contacts for supplying power to the motor assembly  72 . In this configuration, the battery tube  80  extends along the head rail largely coextensively with, and towards the front panel  74  from, the rotating cord shaft  68 . The motor assembly  72  is positioned to one end of the head rail  56 , and is accessible through the front panel  74 . The motor assembly  72  is positioned in a housing structure  84 , which may be at least partially removed to expose the motor assembly  72 , explained in greater detail below. Retainer clips  86  positioned on the head rail  56  and at either end of the battery holder  80  help keep the battery holder  80  in position when the front panel  74  is opened. The battery holder  80 , in this embodiment, is a cylindrical hollow tube that holds standard cell batteries  81  end to end. 
       FIG. 3  is similar to  FIG. 2 , but shows the battery holder  80  removed from the head rail  56 . The two spools  66  mounted on the rotating cord shaft  68  extend along a portion of the length of the head rail  56 , and at one end engage the motor assembly  72 . The motor assembly  72  drives the rotating cord shaft  68  to turn the spools  66 , which in turn retract or extend the shade member  52 . 
       FIG. 4  shows the components of the shade structure  50 . The head rail  56  includes a head rail base  88  and two end caps  78  fastened thereto. Two spools  66  are received on the rotating cord shaft  68 . The spools  66  are positioned in brackets  92  that rotatably hold the spool  66  in the head rail  56  and allow the spools  66  to rotate with the rotating cord shaft  68 . One end of the rotating cord shaft  68  is supported by a spool bracket  92  near one end cap  78 . The other end of the rotating cord shaft  68  is operably engaged with the motor assembly  72 . The motor assembly  72  is positioned in the head rail  56 , adjacent the opposite end cap  78 . The opposite end cap  78  includes a recess  96  for housing a circuit board  98  that includes the manual actuation switch  100  for retracting and extending the shade member  52 , among other things. An end cover  102  is used to enclose the circuit board  98  in the recess  96 . A button  104  is positioned in this opposite end cap  90  to allow a user to actuate the manual actuation switches  100 . 
     The battery holder  80  is shown, with a mounting bracket  82  positioned at either end, including contacts  106 , to removably position the battery holder  80  in the head rail  56 . 
     The front panel  74  is pivotally mounted by two axle pins  108 , one on either end, positioned in drop-in notches  110  formed on the top surface of both end caps  78 . A slot  112 , also shown in  FIG. 6 , is formed on the bottom of the head rail base  88  to receive a mounting slat  114  used for attaching the top of the shade member  52  to the head rail  56 . 
     The bottom rail  60  includes a slot  116  formed on its top portion (also shown in  FIG. 6 ) to receive a bottom mounting slat  118  used for attaching the bottom of the shade member  52  to the bottom rail  60 . The cords  64  are attached to the bottom rail  60  using chord anchors  120 . The cord  64  extends through the bottom slat  118 , through the shade member  52 , through the top mounting slat  114 , into the head rail  56  and winds around a corresponding spool  66  therein. An end cap  122  may be positioned on either end of the bottom rail  60  to provide a finished appearance. 
       FIG. 5  shows the motor assembly  72  in an exploded view. The motor assembly  72  includes a housing  124  formed by a top cover  126  and a bottom cover  128 . The top cover  126  and bottom cover  128  at least partially enclose an electric motor drive  130  and a circuit board  132 , at least partially separated by a plate  134 . The electric motor drive  130  includes an electric motor  136  operably engaged with a gear reduction mechanism  138 . The electric motor  136  includes a motor output drive shaft  140  (not shown) extending from one end, which engages the gear reduction mechanism  138 . The gear reduction mechanism  138  includes a reduction output drive shaft  142 . The electric motor  136  also includes a second shaft  144  extending from the opposite end. 
     A portion of a split drive mechanism  146  may be operably mounted on the reduction output drive shaft  142 . The split drive mechanism  146  incorporates two similarly structured engagement members  148 , 150 . Regarding  FIGS. 7-10B , a drive engagement member  148  is mounted in rotational association with the reduction drive shaft  142 . The drive engagement member  148  has a base portion  152  that mounts onto the reduction output drive shaft  142  in a manner that rotates therewith. Axially extending prongs  154  extend from the base portion  152  at radially opposing positions. Each prong  154  extends beyond the end of the base portion  152 , and each has two longitudinally extending edges  156  that are angled in a radial plane. A cylindrical magnetic rod  158  may be positioned in the drive engagement member  148 , and may be positioned between the prongs  154  at or near the end of the base portion  152 . The cylindrical magnetic rod  158 , in one example, may be oriented to longitudinally extend at right angles to the diametrically opposed prongs  154 . One end of the magnetic rod has a north polarity (N), and the opposite end of the rod has a south polarity (S). 
     Referring still to  FIGS. 5 , and  7 - 10 B, the driven, or slave, engagement member  150  has a similar structure as the drive engagement member  148 . The base portion  160  of the slave engagement member  150  is rotationally associated with the cord shaft  68  (such as by a keyed engagement) that extends along at least a portion of the length of the head rail  56 . A second cylindrical magnetic rod  162  is positioned in the slave engagement member  150 , and extends at an angle to the diametrically opposed prongs  164  as is explained in more detail below. The split drive mechanism  146  is described in more detail below. 
     The electric motor drive  130  is supported in the housing  124  by a first end cap  166  positioned at the end of the electric motor  136 , and an opposite second end cap  168  positioned adjacent to and surrounding the split drive mechanism  146 . Each end portion  166 ,  168  includes latch posts  170  that pass through designated apertures  172  in the separation plate  134  and engage receptacle apertures  173  in the motor assembly circuit board  132 . The first end cap  166  may include an end aperture  174 . An optical sensor interrupter plate  176  is mounted on the second shaft  144 . The plate  176  has two lobes  178  that pass through an optical sensor  180  on the motor assembly circuit board  132  (when the electric motor drive  130  and circuit board  132  are assembled into the motor assembly  72 ) to allow a control system  182  at least partially on the circuit board  132  to detect, store, assess and/or act upon the rotational speed of the second shaft  144 , its revolutions per minute, and changes therein. This data may be used to control certain functions of the shade  52  retraction and extension, such as the shade position, speed of movement, location, and other information. The second shaft  144  may rotate at the same speed of the electric motor  136 , or alternatively may be gear-reduced to rotate at a different speed. The rotational speed of the second shaft as related to the rotational speed of the first shaft  140  is known, and without a gear reduction on the first shaft, is typically the same. 
     Continuing with  FIG. 5 , the second end cap  168  extends from the gear reduction mechanism  138  and surrounds the split drive mechanism  146 . The base portion  152  of the driven engagement member  148  is extends through and is journalled by an aperture  184  formed in the end of the second end cap  168 . 
     The electric motor drive  130  is powered by the batteries in the battery holder  80 . The battery supply is protected by an FET bridge rectifier, such as that shown in U.S. Pat. No. 4,139,880, which is incorporated herein in its entirety. This helps to lessen potential damage to the electronic components and allows the user to insert the battery tube in either direction regardless of polarity. It also avails a much lower voltage drop compared to more conventional diode protection. The battery power supply is in powered communication with the motor assembly circuit board  132 , and powers at least the components there on. A power input cable  186  extends from the electric motor drive  130  to a corresponding connector on the motor assembly circuit board  132 . 
       FIG. 6  shows a section of the head rail  56  and shade  52 , with the shade  52  in an extended position. The head rail base  88  supports the cord shaft  68  and the take-up spools  66 , as well as the battery holder  80 . The front panel  74  is pivotally attached at its top edge to pivot upwardly to allow access to the interior of the head rail  56 . The top mounting slat  114 , in this configuration, may be positioned through the top cell of the shade  52  and positioned in the slot  112  in the bottom of the head rail base  88 . The bottom mounting slat  118  may be positioned in the bottom cell of the shade member  52  and positioned in the slot  116  in the top of the bottom rail  60 . The cords  68  extend from the take-up spool  66  in the head rail  56  to the bottom rail  60 , through the shade  52 . The cord  68  may be affixed to the bottom rail  60  by cord anchors  120 . 
       FIGS. 7 and 8  show the split drive mechanism  146  in more detail, with some portions of the motor assembly  72  removed or cut away for clarity. The drive engagement member  148  and the driven or slave engagement member  150  are positioned adjacent to each other such that their base portions  152 ,  160  are aligned along a common axis  188 . The prongs  154 ,  164  of each of the drive  148  and slave  150  engagement members are spaced away from the common axis  188  by a fixed distance (radius), and in this example the same or similar fixed distance. As each of the drive  148  and slave  150  engagement members are rotated around the common axis  188 , the prongs move in a circumferential path. The space between the two prongs on each engagement member  148 ,  150  may then be considered a circumferential gap  190 . The prongs of each engagement member extend toward the other engagement member, with the prongs of one engagement member positioned in the circumferential gap  190  between the prongs of the other engagement member. 
     Continuing with  FIGS. 7 and 8 , this spatial arrangement of the prongs  154 ,  164  of the split drive mechanism  146  result in the engagement of the prongs of one engagement mechanism by the prongs of the other engagement mechanism when one engagement mechanism is rotated relative to the other engagement mechanism. When the prongs  154 ,  164  engage, such as in  FIG. 7 , they engage along the sides of the prongs. The side walls  156  of the prongs are radially angled so that they may engage in an abutment arrangement. Other suitable structures for adequate engagement between the prongs are contemplated. The arc length (generally, the width) of each prong  154 ,  164  is designed to control the amount of relative rotation between the drive  148  and slave  150  engagement members. The longer the arc length of the prong, the less relative rotation of the engagement members. The shorter the arc length, the more relative rotation of the engagement members  148 ,  150 . In one example of the structure disclosed herein, the prongs are designed with an arc length to allow the drive member prongs  154  and the slave member prongs  164  to rotate approximately 90 degrees relative to one another prior to engagement of the prongs  154 ,  164 . Other structures for engagement besides prongs are contemplated, such as tabs, collars, protrusion, gears, or other such structures. Other amounts of rotation prior to engagement between driven  148  and slave  150  engagement members is contemplated. 
     The rotation of the drive engagement member  148  is controlled by the rotation of the motor  136 , through the gear reduction mechanism  138 . The driven engagement member  148  and the slave engagement member  150  are operably associated with one another, in this arrangement, by contact between the prongs  154 ,  164 . The slave engagement member is rotatably associated with the shade member  52  through the cord shaft  68 , such that as the slave engagement member  150  rotates, the cord shaft  68  rotates, which causes the spool  66  to rotate and unwind the cord  64  or retract the cord  64  (depending on the direction of rotation of cord shaft  68 ). 
     In one instance, when the electric motor  136  is actuated, the output drive shaft  140  (not shown) is actuated, which in turn engages the reduction mechanism  138 , which in turn engages and rotates, through shaft  142 , the drive engagement mechanism  148  of the split drive mechanism  146 . The drive engagement mechanism  148  then rotates relative to the slave engagement mechanism  150  until the respective prongs  154 ,  164  engage (there may be only one prong on each engagement mechanism, or some other rotational engagement structure suitable for this purpose). When the prongs  154  of the drive engagement member  148  engage the prongs  164  of the slave engagement member  150 , the drive engagement member  148  may cause the slave engagement member  150  to rotate. This is the loaded position. As the slave engagement member  150  rotates, it causes the cord shaft  68  to rotate. This causes the cord spool  66  to let out or take in cord  64 , thus allowing the shade member  52  to extend or retract, as described in more detail below. 
     So, when the shade member is being extended, the drive engagement member  148  rotates one direction (i.e. for example clockwise in  FIGS. 10   a  and  b ) and engages the driven member  164  to cause it to rotate the cord shaft, which rotates the cord spool to unreel cord and allow the shade member to lower. When the shade member is being retracted, the drive engagement member  148  rotates the opposite direction and engages the driven member  164  to cause it to rotate the cord shaft, which rotates the cord spool to take-up cord on the spool, and thus pulls up the bottom rail of the shade member to retract the shade. Typically, the cord  64  on the spool  66  holds the bottom rail from extending the shade member until the cord shaft  68  rotates and cord  64  is rotated off the cord spool  66 , which allows the bottom rail to move downwardly. 
     In other instances, during extension of the shade member the shade member  52  may lower under its own weight, and the motor  136  may cause the drive member  148  to follow the rotation of the driven member  150  as the shade extends. 
     Still referring to  FIGS. 7 and 8 , the magnets  158 ,  162  are positioned in the driven  148  and slave  150  engagement members, respectively, such that they may move from being in parallel alignment with one another (when unloaded) to being in an orthogonal alignment (when loaded). The magnets  158 ,  162  are placed in the driven  148  and slave  150  engagement members such that when aligned in parallel ( FIG. 7 ), the opposite poles are adjacent each other. For instance, the north pole of the magnet  158  in the drive engagement member  148  is adjacent the south pole of the magnet  162  in the slave engagement member  150 , and the south pole of the magnet  158  in the drive engagement member  148  is adjacent the north pole of the magnet  162  in the slave engagement member  150 . With this magnet orientation placement, when the drive engagement member  148  and the slave engagement member  150  are able to rotate relatively freely (are “unloaded”), even from an orthogonal relative orientation, the magnetic attraction between the poles causes the magnets  158 ,  162  to attempt to align parallel to one another as shown in  FIGS. 7 ,  8 , and  9 , and cause the drive  148  and slave  150  engagement members to adapt the corresponding orientation also. 
     The magnetic fields around the magnets are affected by the relative orientation of the magnets. Referring to  FIG. 9 , when the magnets  158  (behind  162 ),  162  are aligned parallel to each other in the unloaded position, with adjacent north and south poles as described above, the magnetic fields  192  around each end of the magnets  158 ,  162  are somewhat cancelled out and have limited extension. Referring to  FIG. 10A , when the magnets  158 ,  162  are oriented orthogonally (in the loaded position), the magnetic field  194  around the now more adjacent South-South poles and magnetic field  196  around the North-North poles (each offset by 90 degrees in this arrangement) expands. 
       FIGS. 10   a ,  10   b , and  11  show a magnetically actuated switch  198 , such as a reed switch  200 , positioned near the split drive mechanism  146 . The reed switch  200  is in sufficiently close proximity to be actuated when the magnets  158 ,  162  are in the orthogonal position, and to not be actuated when the magnets  158 ,  162  are in the parallel position. The reed switch is operably associated with the control system  182 . This is illustrated in more detail below. 
       FIG. 9  shows a representational cross section of the head rail  56  through the motor assembly  72 , taken along line  9 - 9  of  FIG. 4 , with the shade member in its fully-extended position at the end of its cord length. In this arrangement, the split drive mechanism  146  is shown with the drive engagement member  148  and the slave engagement member  150  in an unloaded state, so the drive magnet  158  and the slave magnet  162  align parallel to one another. The reed switch  200  is shown mounted on the motor assembly circuit board  132  adjacent to the split drive mechanism  146 . In this orientation, the resulting magnetic fields  192  are relatively small, and the magnetic fields  192  of the parallel aligned magnets do not actuate the reed switch  200 . When the control system  182  no longer receives an activation signal from the reed switch, it shuts off power to the motor. Since the split drive mechanism  146  is in the unloaded state when the shade member is at its lowest, fully extended position (i.e. where the end of the cord length is reached), or when the shade member  52  is obstructed when being extended and moving downwardly, as is described elsewhere herein, the lack of actuation signal from the reed switch triggers a power shut off to the motor to stop further downward motion of the shade. 
     Still referring to  FIG. 9 , the split drive mechanism  146  is shown in the unloaded position with the magnets  158 ,  162  in parallel alignment with each other, given the position of the engagement member  148 ,  150  with each other. The optical sensor  180  associated with the second shaft  144  at the other end of the electric motor  136 , however, may continue to sense the speed and possibly direction of rotation, among other data, to provide information to the control system  182  about the shade member  52 , such as the position of the shade  52  when moving upwardly, and the direction of movement. This data from the optical sensor may help the control system determine whether, and at what position, the shade motion was stopped due to full extension or due to interrupted motion. 
       FIGS. 10A and 10B  are sections views similar to  FIG. 9 , except the split drive mechanism  146  is shown in the loaded state (with magnets  158  and  162  being orthogonal), such as where the shade member  52  is being extended (or lowered) from the head rail  56 . With reference to  FIG. 10A  and B, the shade member  52  is lowered when the split drive mechanism  146  is rotated in the clock-wise direction (in other configurations it may be rotated counter clock-wise). Compared to  FIG. 9 , the drive  148  and slave  150  engagement mechanisms are re-oriented so the drive  158  and slave magnets  162  are orthogonal to one another, which in turn enlarges the magnetic field  194  surrounding the S-S poles and the magnetic field  196  surrounding the N-N poles of the magnets  158  and  162 . The enlarged magnetic fields  194 ,  196  are sized sufficiently to actuate the reed switch  200  as the split drive mechanism  146  rotates. The magnetic fields  194 ,  196  are characterized by the dashed lines in  FIG. 10A , and are meant only as representations of the relative magnetic fields. In the orientation of  FIG. 10A , the reed switch  200  is actuated due to the relative locations of the magnetic fields  194  and  196 . In this configuration, the reed switch  200  may be actuated 2 times for every revolution of the split drive mechanism  146 . Other sensor types that are capable of sensing rotation may be implemented. 
       FIG. 10B  shows the split drive mechanism rotated 90 degrees clockwise, where the magnetic fields  194  and  196  do not appropriately engage the reed switch to cause actuation, and thus the reed switch  200  opens. As the magnetic fields  194 ,  196  pass by the reed switch  200 , the reed switch changes state, which data is monitored by the control system  182  for possible use thereby. 
     The loaded position or state of the split drive mechanism  146 , which creates the orthogonal position of the magnets  158 ,  162 , is experienced most times other than when the shade is positioned at its lowest, or most extended, position (at the end of the cord length when extended from the spool) and when obstructed in its downward extension to that lowest, or most extended, position. When the shade member  52  as described herein extends, it extends under the weight of the bottom rail  60  and the fabric of the shade member  52 , which unwinds the cord  64  from the spools  66  as the electric motor  136  turns the cord shaft  68  the appropriate direction (clockwise in  FIGS. 10A ,  10 B). 
     In short, the split drive mechanism  146  orients the magnets  158 ,  162  in a manner (loaded state) to actuate the reed switch  200 , in the present arrangement, at least when the shade member  52  is being extended downwardly. This is intended to facilitate the monitoring and control of the shade structure  50 , and specifically the electric motor  136 , to react when the downward motion is stalled, such as when the bottom rail  60  reaches its lowermost position (i.e., the shade member is fully extended to the end of its cord length) or where the downward motion is obstructed for some reason, such as by an unexpected object. In one basic implementation, when the shade member  52  is moving downwardly, the reed switch  200  is periodically actuated by the movement of the magnetic fields  194 ,  196  as the split drive mechanism  146  rotates. 
     The actuations of the reed switch  200  is monitored by the control system  182 , which includes sufficient capability (such as by a microprocessor with various inputs and outputs, associated software and the like) to collect, analyze, and/or provide feedback and control signals based on the various inputs from the shade structure  50 , the motor assembly  72 , and/or the user via wired, wireless (RF or IR or the like) or other types of communication of instructions. Other aspects of the performance of the shade structure  50  may be monitored and used to control or provide feedback to the control system  182  or shade structure  50 . For instance, the optical sensor  180  on the second shaft  144  of the electric motor  136  senses the rpm, and other features of the rotation of the electric motor  136 . The rotational rate or speed of the second shaft  144  may be indicative of the rotational rate or speed of the motor  136 , while the rotational rate of the split drive mechanism  146  (and thus the cord shaft  68 ) may be different due to the gear reduction mechanism  138 . The translation between the two is defined (such as the motor  136  running at a 4000 rpm, and the gear reduction mechanism  138  having a 69:1 reduction ratio) so the resulting data may be correlated by the control system  182  for use. The control system  182 , with these varied inputs, may then be able to detect the fully retracted and fully extended position of the shade member  52 , and use the rotation of the loaded split drive mechanism  146  as a means to determine where in the downward, extending, path the bottom rail  60  is positioned with some accuracy. 
     In operation, in one arrangement, when the shade member  52  is extended downwardly, the reed switch  200  is actuated by the rotating loaded split drive mechanism  146 . When the shade  52  becomes fully extended, the cord  64  is substantially all removed from the cord spool  66  on the cord shaft  68 , and the cord  64  transfers the load from the front of the spool  66  to the rear of the spool  66  as the spool rotates and the attachment points between the cord  64  and the spool  66  rotates from the front (right side) of  FIG. 6  to the rear (left side) of  FIG. 6  before the motor is shut off. This unloads the split drive mechanism  146 , and may rotate the engagement mechanisms of the split drive mechanism to allow parallel alignment of the magnets. In the unloaded condition, the magnets  158 ,  162  move to a parallel alignment (under the inherent magnetic attraction between the north and south poles of each magnet  158 ,  162 ) and the magnetic fields  192  are reduced in size. The reed switch  200  is then no longer actuated. The control system  182  may interpret the absence of signal from the reed switch  200  as meaning the bottom rail  60  is at its lowest-most position and may instruct the electric motor  136  to shut off. 
     Alternatively, with reference to  FIG. 15 , as the shade member  52  is being extended with the split drive mechanism  146  in a loaded status (thus actuating the reed switch  200 ), the motion of the bottom rail  60  may be obstructed by an object  202  in or near the architectural opening  204 . This obstruction may cause the transition of the split drive mechanism  146  from a loaded to an unloaded status, thus allowing the magnets  158  to align and reduce the size of the magnetic field  192 . The reed switch  200  would thus no longer be actuated. The lack of signal from the reed switch may be interpreted by the control system  182  as an obstruction, and thus instruct the electric motor  130  to shut down to mitigate any damage to the shade structure  50  until the obstructing object  202  may be removed. Upon removal of the obstruction  202 , the user may instruct the control system  182  to direct the shade member to continue moving downwardly (or upwardly). As noted above, it is contemplated that the control system  182  may allow either manual control by a user, or remote control  206  via RF, IR or other such wireless technology. 
     In the current configuration, the split drive mechanism  146  actuates the reed switch while extending and retracting since it may be in the loaded configuration during both motions. The control system  182 , in one configuration, ignores the signal from the reed switch  200  during retraction since as described regarding  FIG. 15 , the control system is monitoring primarily for the obstruction of the extending shade member  52 , and the occurrence of the fully extended position. However, the control system  182  may be programmed to monitor the actuation of the reed switch  200  during both extension and retraction to provide various data related thereto. The split drive mechanism may also be designed such that when retracting the magnets may be aligned and thus not cause the reed switch to activate. The motor  130 , in one embodiment, is a two-way motor so that it rotates in one direction when the shade is extending, and rotates the opposite direction when the shade is retracted. 
     Additionally, for instance, the particular structure of the split drive mechanism could be modified structurally but still operate in a similar manner. For instance, in one example, orientation of the magnets in  FIG. 9 , given the orientation of the drive member  148  and the driven member  150  therein, may be orthogonal; and correspondingly the orientation of the magnets in  FIGS. 10   a  and  10   b , given the orientation of the drive member  148  and the driven member  150  therein, may be parallel. If so modified, the layout of the spool, shaft, line and motor direction during extension and retraction would need to be modified such that in the downward, loaded motion of the shade the magnets were in an orthogonal orientation, and upon interruption or reaching terminal position when the engagement members would become unloaded and the magnets would align in parallel. This change in alignment of the magnets would thus cause the sensor to not sense any rotation, at which time the control system would send a stop signal to the motor  130 . 
       FIGS. 11 ,  12 ,  13 , and  14  show various views of the head rail  56 , and specifically the pivotal connection between one end of the front panel  74  and the end cap  78 . The drop-in notch  110  is formed in the top surface of both one end cap  78  and the opposite end cap  78 . The notch  110  receives an axle pin  108  that is positioned to extend from each of both of the ends of the top edge of the front panel  74 . In one arrangement, the pin  108  includes a circumferential groove  208  that engages the walls of the drop-in notch  110 , to help position the pin  108  securely in the notch  110 . With the pin  108  on either end of the front panel  74  positioned in the corresponding notch  110 , the front panel  74  may pivot between an open position and a closed position. In an open position as shown in  FIG. 2 , the battery holder  80  may be accessed and removed to allow replacement of the battery. The spools  66 , cord  64 , and rotating cord shaft  68  in the head rail  56  may be accessed if needed, and the motor assembly  72  may be accessed. When the front panel  74  is closed, the head rail  56  has a finished appearance. The button  104  shown in  FIG. 11  may be actuated by a user to manually raise and lower the shade member  52 . The button  210  engages the switch  100  on the circuit board  98 , which switch  100  controls the motor assembly  72  to cause the actuation of the shade member  52 .  FIG. 14  shows an exploded view of the opposite end cap  90 , pivot axle pin  108 , front panel  74 , circuit board  98  and button  104 . 
       FIG. 16  shows one example of a instruction flow diagram for the control system  182 . 
     It is contemplated that the invention disclosed and described herein may be used with other types of shade members than a collapsible shade member. For instance, the invention may be implemented with a roller-type shade where the shade member retracts by rolling up into a wind-up roller positioned in the head rail, as well as other types of shade structures where the shade member is moved between extracted and extended positions. The instant invention may also be used with shade structures where the shade retracts and extends vertically, or retracts and extends horizontally (such as vertical blinds). The shade structure may include slats or vanes made out of rigid or flexible materials and rolled or collapsed between an extended and retracted position. The electric motor described herein may be a two-way motor. 
     It is contemplated that the benefits described herein may be obtained by utilizing different structure and/or function. Other mechanisms that change the magnitude of a magnetic field, and thus the pattern of actuation of a sensor for collecting data and controlling the shade structure may also be employed. Different types of sensors may be employed, and different types of actuation means other than magnetic fields may be utilized to actuate the sensor. 
     While the methods disclosed herein have been described and shown with reference to particular steps performed in a particular order, it will be understood that these steps may be combined, subdivided, or re-ordered to form an equivalent method without departing from the teachings of the present invention. Accordingly, unless specifically indicated herein, the order and grouping of the steps are not generally intended to be a limitation of the present invention. 
     A variety of embodiments and variations of structures and methods are disclosed herein. Where appropriate, common reference numbers were used for common structural and method features. However, unique reference numbers were sometimes used for similar or the same structural or method elements for descriptive purposes. As such, the use of common or different reference numbers for similar or the same structural or method elements is not intended to imply a similarity or difference beyond that described herein. 
     The references herein to “up” or “top”, “bottom” or “down”, “lateral” or “side”, and “horizontal” and “vertical”, as well as any other relative position descriptor are given by way of example for the particular embodiment described and not as a requirement or limitation of the shade or the apparatus and method for assembling the shade. Reference herein to “is”, “are”, “should”, “would”, or other words implying a directive or positive requirement are intended to be inclusive of the permissive use, such as “may”, “might”, “could” unless specifically indicated otherwise. 
     The apparatus and associated method in accordance with the present invention has been described with reference to particular embodiments thereof. Therefore, the above description is by way of illustration and not by way of limitation. Accordingly, it is intended that all such alterations and variations and modifications of the embodiments are within the scope of the present invention as defined by the appended claims.