Patent Publication Number: US-11652268-B2

Title: Antenna rotator

Description:
TECHNICAL FIELD 
     The various embodiments disclosed herein relate to antenna rotators. More particularly, the various embodiments disclosed herein relate to antenna rotators having a motor drive with a selectively movable shaft to move an antenna. In particular, the various embodiments disclosed herein relate to antenna rotators having a removable position detection module to monitor a position of the selectively movable shaft, whereby the detection module is user-friendly to access and convenient to remove and replace. 
     BACKGROUND 
     Given the nature of antennas, including those utilized in the field of HAM radio (i.e. amateur radio), they are required to be mounted in an elevated manner so that the signals the antenna is intended to receive are not blocked by obstructions, such as buildings, trees, walls, and the like. Furthermore, antennas generally require that they be periodically rotated so that the antenna is oriented in a direction that optimizes the reception of the signal that is intended to be received. In order to conveniently rotate the antenna at its elevated position, an antenna rotator system is commonly used. 
     The antenna rotator system includes an antenna rotator or drive unit, which includes an electromechanical motor drive that is carried within a weather-resistant housing, and a remote user control unit that communicates with the rotator system to rotate the antenna in a direction determined by the end user. The antenna may be attached to a shaft provided by the electro-mechanical motor drive of the rotator system directly or through an elongated mast or mounting pole to which the antenna is mounted. Because the antenna and the antenna mounting poles are typically formed of metallic materials, and due to of the elevated position of the antenna, the rotator system is susceptible to being hit directly or indirectly by lightning strikes. Accordingly, the electronic components of the motor drive are exposed to damaging levels of electrical voltage and electrical currents. As a result, these electronic components contained within the housing of the antenna rotator are highly susceptible to failure and require frequent replacement. One particular electronic component that is especially susceptible to lightning damage and resultant failure is an antenna position encoder that is used to monitor the position of the antenna as it is rotated by the motor drive in the rotator housing. 
     Unfortunately, such replacement is difficult, cumbersome and time consuming given the often high, elevated position at which the antenna is mounted. As such, the antenna rotator must be removed from its elevated position, which entails the danger associated with working at heights, and then taken to a remote repair location. However, even if the rotator is successfully removed, it is exceedingly difficult to gain access to the electrical components therewithin due to the weather-proof design of the housing to conduct a repair. As a result, the antenna is taken out of service for an extended period of time to complete the repair, which is undesirable. In addition, it is extremely costly to remove the antenna rotator and have the damaged electrical components, which are often integrated on a single printed circuit board (PCB) repaired. In fact, in many instances, given the integrated PCB design of the electronics of the antenna rotator, the PCB cannot be repaired, particularly the position encoder electronics, and as a result a full, costly replacement of the entire PCB is required. 
     Therefore, it is desirable to provide a housing for an antenna rotator that includes one or more removable electronic components, such as a removable position detection module used to monitor an output shaft of a motor drive used to move an antenna, which is user-friendly to access and convenient to remove and replace. Furthermore, it is desirable to provide a housing for an antenna rotator that includes a removable position detection module that can be removed and replaced at the housing without removing the housing from its mounted location. 
     SUMMARY OF THE INVENTION 
     It is a first aspect of one or more embodiments disclosed herein to provide an antenna rotator including a housing having an access port; a motor drive assembly carried in the housing, the motor drive assembly adapted to be coupled to an antenna; an interface connector carried in the housing and positioned proximate to the access port, the interface connector coupled to a power supply line and a position detection line; and a detection module proximate to the access port and removably attached to the interface connector so as to communicate with the power supply line and the antenna position detection line, the detection module configured to detect a rotating position of a component of the motor drive assembly. 
     An antenna rotator including a housing having an access port; a motor drive assembly carried in the housing, the motor drive assembly adapted to be coupled to an antenna; an interface connector carried in the housing and positioned proximate to the access port, the interface connector in electrical communication with one or more of a power supply line and a communication line; and a module positioned proximate to the access port and removably attached to the interface connector so as to communicate with one or more of the power supply line and the communication line, the module including an electronic component to control the operation of the motor drive assembly. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       These and other features and advantages of the various embodiments disclosed herein will become better understood with regard to the following description, appended claims, and accompanying drawings, wherein: 
         FIG.  1 A  is a perspective view of an antenna rotator in accordance with the concepts of the various embodiments disclosed herein; 
         FIG.  1 B  is an exploded view of the antenna rotator in accordance with the concepts of the various embodiments disclosed herein; 
         FIG.  2 A  is a perspective view of a base section of the antenna rotator housing having a detection module removed therefrom in accordance with the concepts of the various embodiments disclosed herein; 
         FIG.  2 B  is a perspective view of a base section of the antenna rotator housing having the detection module installed thereto in accordance with the concepts of the various embodiments disclosed herein; 
         FIG.  3 A  is an exploded view of the detection module in accordance with the concepts of the various embodiments disclosed herein; 
         FIG.  3 B  is perspective view of the detection module in accordance with the concepts of the various embodiments disclosed herein; and 
         FIG.  3 C  is another perspective view of the detection module in accordance with the concepts of the various embodiments disclosed herein. 
     
    
    
     DETAILED DESCRIPTION 
     An antenna rotator is generally referred to by numeral  100  as shown in  FIGS.  1 - 2    of the drawings. In particular, the antenna rotator  100  includes a housing  110  formed of a plurality of housing sections, such as base section  110 A and cap section  110 B each having respective cavities  111 A and  111 B. Disposed through a wall  200  of the base section  110 A is a module aperture or access port  250 , which opens into the cavity  111 A. The access port  250  allows the selective removal and attachment of a position detection module  300  that monitors an encoder  310  that is rotated by a motor drive  340  carried in the housing  110 . 
     The housing sections  110 A-B may be formed of any suitable material, such as metal or polymeric material for example. In addition, the housing sections  110 A-B may be joined together by any suitable fastener, such as screws, rivets, adhesive, and the like. In some embodiments, the sections  110 A and  110 B may be formed so that they take on any suitable complementary shape that allows them to be attached together. For example, one or more of the first and second sections  110 A-B may be formed to have generally triangular shapes, but is not required, as the sections  110 A-B may have a rectilinear shape, a curvilinear shape, or a shape that is a combination thereof. Furthermore, when the housing  100  is assembled, the sections  110 A and  110 B may be separated from each other by a separating member  360 , which will be discussed in detail below. However, in other embodiments, the separating member  360  may be fully confined within the housing so that it does not separate the sections  110 A and  110 B. 
     The cavity  111 A formed by the base section  110 A of the rotator housing  110  carries several components, as shown in  FIGS.  2 A-B . In particular, the base section  110 A includes the electric motor drive  340  mounted thereto, such as by suitable fasteners. The motor drive  340  includes a drive shaft  410  that is rotated by operation of the motor drive  340 . It should be appreciated that the motor drive  340  may be an AC (alternating current) motor or a DC (direct current) motor. The motor drive  340  is coupled by an electrical line  611  to a suitable power source, such as an AC (alternating current) or DC (direct current) power source. 
     Attached to the drive shaft  410  of the motor drive  340  is the encoder  310 . In some embodiments, the encoder  430  may include a disk or wheel that is mounted to the drive shaft  410 , and rotatably carried by the drive shaft  410  as it is driven under the operation of the motor drive  340 . In some embodiments, the encoder  310  may comprise a magnetic encoder, such as a magnetic encoder wheel or disk. However, the encoder  310  may comprise an optical encoder, which may be embodied as a wheel or disk. In still other embodiments, the encoder  430  may have any suitable detectable indicia. In addition, the encoder  310  may comprise any element in which a position of the drive shaft  410  can be determined through communication with the detection module  300  to be discussed. It should be appreciated that the encoder  310  shown in the FIGS. comprises a magnetic encoder disk. 
     A transmission  500  is also carried within the cavity  111 A of the base section  110 A and is in operative communication with the drive shaft  410  of the motor drive  340 . The transmission  500  includes a transmission output shaft  510 . The transmission  500  serves to alter the torque and rotational speed generated by the shaft  410  with a different rotational speed and torque that is supplied by the output shaft  510 . It should be appreciated that in some embodiments, the transmission  500  may not be used. 
     An interface connector  600  is mounted within the cavity  111 A formed by the base  110 A. The interface connector  600  is coupled to various electrical and/or communication lines that are routed through the wall  200  of the housing  110  to a region that is external to the rotator  100 . The interface connector  600  is mounted within the cavity  111 A so that is it proximate to, and in some embodiments adjacent to, the module aperture  250  that is disposed through the wall  200  of the base housing  110 A. In further embodiments, a lock aperture  610  is disposed through the wall of the base  110 A. In some embodiments, the lock aperture  610  is positioned adjacent or proximate to the module aperture  250 . In further embodiments, the electrical lines that are coupled to the interface connector  600  include one or more of a power supply line  611  and an antenna position monitor or detection line  620 . In some embodiments, the interface connector  600  includes one or more terminals  630  to which the various electrical lines are connected, such as the power supply line  611  and the antenna position monitor line  620 . It should be appreciated, that in some embodiments, seven terminals  630  are used; however, the interface connector  600  may include any number of terminals  630 . In addition, the electrical lines  611  and  620  that are coupled to the interface connector  600  may be routed through a wire aperture (not shown) that is disposed through the wall  200  of the base  110 A. This wire aperture is in communication with another aperture  602  that is provided in a grommet or compression fitting  603  that is secured in the wall  200  of the housing  100 , such as by threaded fit for example. It should be appreciated that the free ends of the lines  611  and  620  may be respectfully attached to a suitable power source and a position controller device used to set a user defined position in which the antenna is to be rotated by the rotator  100  and/or to monitor a position of the antenna via the encoder  310  in a manner to be discussed. 
     The detection module  300 , shown particularly in  FIGS.  3 A-C , is configured to be inserted through the module aperture  250  in a manner to be discussed. In particular, the detection module  300  includes a bracket or support member  710 , which may be formed of any suitable material, such as metal, plastic, composite, polymeric material, and the like. The bracket  710  may be elongated and terminated by ends  712  and  714 . The bracket  710  carries a module connector  720  that is compatible with being electrically mated or coupled to the interface connector  600 . As such, the module connector  720  may include a plurality of terminals  730  that are configured to be electrically coupled to corresponding terminals  620  provided by the interface connector  600 . For example, the module connector  720  may include 7 terminals  730 . In other words, the interface connector  600  is configured to be compatibly coupled to the module connector  720  of the detection module  300  so that the power supply line  611  and the antenna position monitor line(s)  620  are electrically coupled to terminals  730  of the detection module  300 . 
     In addition, the detection module  300  includes a sensor  800 , such as a position sensor, which is positioned proximate to the end  712  of the bracket  710 . However, it should be appreciated that the sensor  800  may be attached at any position relative to the bracket  710 . The sensor  800  is attached to the bracket  710  via any suitable means of fixation, such as adhesive, rivets, a threaded connection, or the like, including by way of one or more threaded nuts. The sensor  800  is electrically coupled to the module connector  720  via a suitable coupling interface  810 , such as one or more wires or a printed circuit board (PCB) for example. In some embodiments, the sensor  800  may comprise a photodetector, a hall sensor, any magnetic or optic sensor, or the like that is capable of detecting or reading a rotational position of the encoder  430  that is carried by the shaft  410  of the motor drive  400 . In addition, the sensor  800  may be positioned relative to the longitudinal axis of the bracket  710  at a substantially right angle thereto. Thus, when the interface connector  600  is electrically coupled to the module connector  720 , the power supply line  611  and the antenna position monitor line  620  are placed in electrical communication with the sensor  800  to enable the sensor  800  to operate and monitor the rotational position of the encoder  310  as it is moved by the motor shaft  410 . 
     It should be appreciated that in some embodiments, when the detection module  300  is attached to the housing  110 , the sensor  800  having a face surface  802  may be positioned proximate to a radially-extending face surface of the encoder disk  430 , or alternatively, may be positioned so that the face surface  802  of the sensor  800  is positioned proximate to an outer circumferential or peripheral edge or surface  805  of the encoder disk  430 , as shown in  FIG.  2 B . 
     Attached to the end  714  of the bracket  710 , and in some embodiments at a position that is opposite the sensor  800 , is a cover  900 . The cover  900  has an opposed inner surface  910  and outer surface  920 . As such, the inner surface  910  may be attached to the bracket  710  using any suitable means of attachment, such as rivets, screws, adhesive or the like. The cover  900  is dimensioned to close or cover the module aperture  250 . In some embodiments, a seal or gasket  950  may be placed adjacent to the inner surface  910  of the cover  900  to prevent the intrusion of environmental elements, such as rain, snow and the like through the module aperture  250  and into the housing  100  when the detection module  300  is attached thereto. The cover  900  also includes a lock mechanism  912  that is configured to be selectively locked to the lock aperture  610  that is disposed in the housing section  110 A. Accordingly, the lock mechanism  912  may be selectively locked and unlocked by a user in a convenient and user-friendly manner. In particular, the lock mechanism  912  may include a shaft  914 , which includes one or more barbs  916  at one end, while a keyed depression  917 , such as a slot, is provided at another end. As such, the when the shaft  914  is received within the lock aperture  610  and rotated, the barb  916  is selectively captured by an inner surface of the housing section  110 A so as to retain or release the detection module  300  relative to the housing section  110 A. However, the lock mechanism  912  may include any suitable structure for selectively retaining the detection module  300  to the housing section  110 A. It should be appreciated that in some embodiments, the lock mechanism  912  may be carried by other portions of the detection module  300  other than the cover  900 . In some embodiments, the lock mechanism may comprise magnets in the cover  900 , which are magnetically attached to the housing section  110 A, so as to secure the module  300  thereto. 
     In addition, when the sections  110 A and  110 B of the rotator  100  are assembled together, the plate  360  is positioned therebetween, as shown in  FIG.  1 B . The plate  360  includes opposed inner and outer surfaces  970  and  972 . The plate  360  may be generally shaped to conform to the shape of the sections  110 A and  110 B, and may be formed of any suitable material, such as metal or polymeric material for example. A gear assembly  980  is positioned proximate to the outer surface  927  of the plate  360  and includes an aperture  982  through which the shaft  510  is received. As such, the gear assembly  980  is configured to be rotatably driven by the shaft  510  of the transmission  500 . In addition, the gear assembly  980  is configured to rotatably move a primary output shaft  990  to which an antenna, antenna mast, or other attachment bracket  992  is attached. As such, the motor drive  340 , the transmission  500  and the gear assembly  980  form a motor drive assembly. It should be appreciated that through the use of know techniques, the motor drive  340  may be configured to effectuate the movement of the rotating the shaft  990  with or without one or more of the transmission  500  and gear assembly  980 . In other words, the rotator  100  may be configured as a direct drive system in which the shaft  410  of the motor drive  340  is directly attached to an antenna. Thus, a motor drive assembly includes at least the motor drive  340 , and optionally in some embodiments, as shown in the FIGS., the transmission  500  and the gear assembly  980 . 
     Thus, to place the rotator  100  into operation, the detection module  300  is inserted into the module aperture  250  so that the sensor  800  and the connector  720  are within the cavity  111 A. As a result, the module connector  720  is enabled to be operatively mated with the interface connector  600  within the housing  110 A. The lock mechanism  912  is then set by the user to secure the detection module  300  to the housing  110 . Thus, when the module connector  720  and the interface connector  600  are mated, the electrical lines  611  and  620  are connected to the coupling interface  810  of the sensor  800 . As such, the sensor  800  is made operable. 
     As such, when the detection module  300  is damaged during operation of the antenna rotator  100 , such as through lightning, or through any other event internal or external to the rotator  100 , the detection module  300  may be easily and conveniently removed and replaced with a new, operable detection module  300 . Such a configuration, results in a savings in time and cost, by allowing a user to easily remove and replace the position detection module  300 , while leaving the rotator housing  110  mounted in position. In other words, the rotator housing  110  allows the user to remove only the detection module  300 , whereas in conventional rotators, an individual would have to expend substantial time and effort removing the conventional rotator from its existing mount, disassembling it, and then repairing the components embodying the detection module  300  therewithin. 
     It is also contemplated that in other embodiments the detection module  300  may comprise a module that does not include the sensor  800 , but which contains any other desired electrical component(s) for enabling or controlling the operation of the antenna rotator, or providing an additional operating feature for the antenna rotator  100 . For example, the module may include the module connector  600 , which is configured to communicate with one or more of the lines  611 , 620 . 
     Therefore, it can be seen that the objects of the various embodiments disclosed herein have been satisfied by the structure and its method for use presented above. While in accordance with the Patent Statutes, only the best mode and preferred embodiments have been presented and described in detail, with it being understood that the embodiments disclosed herein are not limited thereto or thereby. Accordingly, for an appreciation of the true scope and breadth of the embodiments, reference should be made to the following claims.