Patent Publication Number: US-7717155-B2

Title: Pivoting barrier operator system with integral cable storage drum and transfer assembly

Description:
TECHNICAL FIELD 
     The present invention relates generally to operators for barriers such as overhead doors. More particularly, the present invention relates to an operator system for moving a sectional or slab type overhead door between open and closed positions. More specifically, the present invention relates to a pivoting barrier operator system and a counterbalance system, wherein the counterbalance system supports a drive tube that carries an integral cable storage drum and transfer assembly that is coupled to a drive gear of the operator system. 
     BACKGROUND ART 
     Motorized devices for opening and closing sectional overhead doors have long been known in the art. These powered door operators were developed in part due to extremely large, heavy commercial doors for industrial buildings, warehouses, and the like where opening and closing of the doors essentially mandates power assistance. Later, homeowners&#39; demands for the convenience and safety of door operators resulted in an extremely large market for powered door operators for residential usage. 
     The vast majority of motorized operators for residential garage doors employ a trolley-type system that applies force to a section of the door or barrier for powering it between the open and closed positions. Another type of motorized operator is known as a “jack-shaft” operator, which is used virtually exclusively in commercial applications and is so named by virtue of similarities with transmission devices where the power or drive shaft is parallel to the driven shaft, with the transfer of power occurring mechanically, as by gears, belts, or chains between the drive shaft and a driven shaft, normally part of the door counterbalance system, controlling door position. While some efforts have been made to configure hydraulically or pneumatically-driven operators, such efforts have not achieved any substantial extent of commercial acceptance. 
     The well-known trolley-type door operators are attached to the ceiling and connected directly to a top section of a garage door and for universal application may be powered to operate doors of vastly different size and weight, even with little or no assistance from a counterbalance system for the door. Since the operating force capability of trolley-type operators is normally very high, force adjustments are normally necessary and provided to allow for varying conditions and to allow the operator to be adjusted for reversing force sensitivity, depending on the application. When a garage door and trolley-type operator are initially installed and both adjusted for optimum performance, the overhead door system can perform well as designed. However, as the system ages, additional friction develops in door and operator components due to loss of lubrication at rollers and hinges. Also, the door can absorb moisture and become heavier, and counterbalance springs can lose some of their original torsional force. These and similar factors can significantly alter the operating characteristics seen by the operator, which may produce erratic door operation such as stops and reversals of the door at unprogrammed locations in the operating cycle. 
     One system that addresses the aforementioned problems is disclosed in U.S. patent application Ser. No. 11/165,138 filed on Jun. 22, 2005, which is incorporated herein by reference. Such a system is referred to as a pivoting and barrier locking operator system. Briefly, such a system includes a motor with appropriate gearing that is linked to a counterbalance system that assists in moving a barrier, such as a sectional door, between defined limit positions. The motor either directly rotates a counterbalance drive tube or imparts rotational forces to a drive assembly which in turn rotates a counterbalance drive tube. Typically, the drive assembly is used when the operator system is installed for use with a pre-existing counterbalance system. In either version of operator system, the drive tube is connected at each end to a cable storage drum. Lift cables are secured at one end to each storage drum and at respective ends to at least a bottom section of the barrier. Accordingly, as the drive tube is rotated, the storage drums pay-out or reel in the respective cable. 
     With most cable storage drums, whether used in winches or in counterbalance systems for barriers, the drums positioned on shafts are rotatable about the axis of the shaft and are either fixed to the shaft such that the drum and shaft revolves together or the shaft is non-rotatable and serves as support and a bearing surface for the drum. Some prior art has drive gear systems where a drive gear, with input from a torque source, drives the driven gear ring attached or formed into the outer perimeter of the cable storage drum. In these prior art devices the rotation of the cable drum&#39;s driven gear is in the opposite direction of the drive gear. Where in most applications this opposite rotation is acceptable, in counterbalancing systems, such as disclosed in the &#39;138 application referenced above, it is not. Known designs that will allow the drive and driven gears to rotate the same direction require an idler gear that is driven by the drive gear and which then drives the driven gear. This arrangement requires additional room and bracketry to mount and contain the idler gear. 
     DISCLOSURE OF THE INVENTION 
     Therefore, one aspect of the present invention is to provide a pivoting barrier operator system with integral cable storage drum and transfer assembly. 
     It is another aspect of the present invention to provide an operator system for moving a barrier between limit positions, comprising an operator motor assembly mounted proximate to the barrier, at least a portion of the operator motor assembly movable depending upon an operating condition thereof; a counterbalance system adapted to be connected to the barrier, the counterbalance system coupled to the operator motor assembly to move the barrier; and an integral cable storage drum and transfer assembly connecting the operator motor assembly to the counterbalance system. 
     Yet another aspect of the present invention is to provide a cable storage drum and transfer assembly used in a barrier operator system which rotates a counterbalance tube that in turn moves a barrier between limit positions through at least one lifting cable, the assembly comprising a hub attachable to the counterbalance tube; a driven gear extending from the hub and engageable with the barrier operator system; and a cable storage area extending from the hub, the cable storage area attachable to the at least one lifting cable. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       For a complete understanding of the objects, techniques and structure of the invention, reference should be made to the following detailed description and accompanying drawings, wherein: 
         FIG. 1  is a rear perspective view of a sectional overhead garage door installation showing a motorized operator system according to the concepts of the present invention installed in operative relation thereto, with the operator system depicted in an operating position; 
         FIG. 2  is a perspective view of the motorized operator system shown in a locking position with a cover removed and associated with an integral cable storage drum and transfer assembly according to the concepts of the present invention; 
         FIG. 2A  is a perspective view of the motorized operator system, shown in an operating position with the cover installed and associated with the integral cable storage drum and transfer assembly according to the concepts of the present invention; 
         FIG. 3  is a left side exploded perspective view of the drum and transfer assembly of the present invention; 
         FIG. 4  is a right side exploded perspective view of the drum and transfer assembly of the present invention; and 
         FIG. 5  is a cross-sectional view of the operator system with the drum and transfer assembly. 
     
    
    
     BEST MODE FOR CARRYING OUT THE INVENTION 
     A motorized operator system according to the concepts of the present invention is generally indicated by the numeral  100  in  FIGS. 1-5 . The operator system  100  shown in  FIG. 1  is mounted in conjunction with a barrier such as a sectional door D of a type commonly employed in garages for residential housing. However, it will be appreciated that the concepts disclosed in relation to the operator system and its various embodiments can be employed with other barriers such as curtains, awnings, gates and the like. The opening in which the door D is positioned for opening and closing movements relative thereto is defined by a frame generally indicated by the numeral  102 , which consists of a pair of spaced jambs  104 ,  106  which are generally parallel and extend vertically upwardly from the floor (not shown). The jambs  104 ,  106  are spaced apart and may or may not be joined at their vertical upper extremity by a header or portions of a header  108  to thereby delineate a generally inverted u-shaped frame around the opening of the door D. The jambs and the header are normally constructed of lumber, as is well known to persons skilled in the art, for purposes of reinforcement and facilitating the attachment of elements supporting and controlling door D, including the operator system  100 . 
     Affixed to the jambs  104 , 106  proximate the upper extremities thereof and the lateral extremities of the header  108  to either side of the door D are flag angles  110  which are secured to the underlying jambs  104 , 106  respectively. Connected to and extending from the flag angles  110  are respective tracks T which are located on either side of the door D. The tracks provide a guide system for rollers attached to each side of the door as is well known in the art. The tracks T define the travel of the door D in moving upwardly from the closed to open position and downwardly from the open to closed position. The operator system  100  may be electrically interconnected with a peripheral device, such as a light kit, which may contain a power supply, a light, and a radio receiver with antenna. The receiver receives wireless signals—such as radio frequency or otherwise—for remote actuation of the peripheral device in a manner known in the art. The operator system  100  may be controlled by wired or wireless transmitter devices which provide user-functions associated therewith. The peripheral device may also be a network device which generates or transfers wireless signals to lights, locks or other operational peripherals. 
     Referring now to  FIGS. 1 ,  2 , and  2 A of the drawings, the operator system  100  mechanically interrelates with the door D through a counterbalance system generally indicated by the numeral  114 . As shown, the counterbalance system  114  includes an elongated drive tube  116  having at one end a tensioning and cable drum assembly  118  positioned proximate one of the flag angles  110  away from the operator system. At an opposite end of the elongated drive tube  116  is another tensioning assembly specifically referred to herein as a cable storage drum and transfer assembly designated generally by the numeral  120  which is supported by a corresponding flag angle  110 . It will be appreciated by persons skilled in the art that operator system  100  could be employed with a variety of torsion-spring counterbalance systems. The assemblies  118  and  120  each have a cable received thereabout which is affixed to the door D preferably proximate the bottom, such that rotation of the assemblies  120  operate to open or close the door D in conventional fashion. Details of the assembly  120  will be discussed after a review of other operator components. 
     The operator system  100  is used mostly when a new operator is to be used with most of an existing counterbalance system. The operator system  100  employs a header bracket  128  which includes a header portion  150  from which extends a pair of header flanges  152 . Each flange has an aperture  154 , and a slot  156 . A support bracket may be provided to support the components of the operator system and the header bracket  128 . The major components of the operator system  100  include a bias assembly  132 , a motor assembly  136 , and a drive assembly  138 . The specific details of operation of the operator system  100  can be found in the aforementioned &#39;138 application. Briefly, however, it will be appreciated that the motor assembly  136  is pivotally supported by the bias assembly  132 . Both are carried by the header bracket  128 . In particular, the bias assembly  132  is at least partially carried by the slots  156 , and the drive assembly is rotatably received in the apertures  154 . A cover  160 , shown installed in  FIG. 2A , is detachably secured to the header flanges  152  and has an end  162  configured to match the shape of an end of the cable storage drum and transfer assembly  120 . The end  162  does not touch or interfere with movement or rotation of the assembly  120 , but is proximally positioned so as to prevent entry of foreign objects that might otherwise interfere with operation of the system  100  and/or the assembly  120 . 
     In  FIG. 2 , the motor assembly  136  is shown in a locking position with the door closed. When the motor assembly  136  is energized, it pivots upwardly away from the top section of the door, as best seen in  FIG. 2A . Next, a shaft driven by the motor assembly rotates and engages the drive assembly  138 , which in turn engages the cable storage drum and transfer assembly  120 . This in turn rotates the counter-balance tube  116  and the corresponding assembly  118 . One feature of the bias assembly  132  is that when an obstruction force is detected by the moving door, the bias force is overcome and causes the motor assembly to pivot downwardly which is detected by the operator system  100 . This partial pivoting of the motor assembly initiates corrective action so that the door is at least stopped or stopped and reversed. 
     As best seen in  FIGS. 3-5 , it can be seen that the cable storage drum and transfer assembly is designated generally by the numeral  120 . The assembly  120  includes a body  200  which provides an outwardly extending surface referred to herein as a rim  202 . The rim  202  provides a gear side  204  opposite a cable side  206 . Centrally located within the rim  202  is a hub  208  which is axially disposed and which provides a tube aperture  210  extending therethrough. The tube aperture  210  is sized so as to be slidably received on the counterbalance tube  116 . At least one and ideally a plurality of spokes  214  extend radially from the hub  208  to the rim  202 . Although four spokes are typically provided, it will be appreciated that the spokes could be of a unitary configuration or any multiple number appropriate to provide the necessary strength to the assembly  120 . 
     The rim  202  provides a rim internal surface  218  from which radially extends inwardly a plurality of rim teeth  220 . With appropriate modifications to the operator system, the rim teeth  220  could extend radially outward from the rim  202 . In any event, opposite the rim internal surface  218  is a rim external surface  224 . A portion of the external surface  224  is designated as a cable storage area  226  which is provided on a side of the body  200  away from the rim teeth  220 . However, it will be appreciated that the cable storage area  226  could be provided on the entire external surface of the body  200 . A cable lip  228  extends radially from an end of cable storage area  226  adjacent the cable side  206 . A plurality of cable grooves  230  are provided in the cable storage area  226  so as to retain at least one lift cable  231  in an organized fashion as the door to which the cables are attached is raised and lowered. Extending through the cable storage area  226  are a pair of cross apertures  232 . As shown in the drawings, these cross apertures  232  are spaced about 90 degrees apart from one another. However, the cross apertures may be equally spaced from one another and it will be further appreciated that although two cross apertures are shown, there could be only one cross aperture or, if desired, more than two cross apertures. 
     Referring now specifically to  FIG. 4 , which primarily shows the cable side  206  of the assembly  120 , it can be seen that the rim internal surface  218  provides a plurality of ribs  236  extending toward and attached to the hub  208 . The ribs  236  may be aligned or integral with the spokes which are best seen in  FIG. 3 , however such alignment is not required. A boss  240  extends from the hub and is aligned with each respective cross aperture  232 . Specifically, each boss  240  provides internal threads  242  which are aligned with the cross apertures and extend all the way through the hub  208 . A cable notch  244  is provided in the cable lip  228  along the cable side  206 . It will be appreciated that an end of the lift cable not attached to the upper or lower section of the door is received and secured within the cable notch  244  so as to facilitate raising and lowering of the door. A transition channel  245  is provided proximal the cable side  206  so as to allow the lift cable  231  to transition from the cable notch  244  to the cable grooves  230 . The channel  245  includes a channel wall  246  that together with the cable lip  228  forms a transition groove  247  which receives the cable  231 . The channel wall  246  changes in radial height from the notch  244  to the grooves  230 . This ensures retention of the cable as the assembly  120  is rotated. 
     The assembly  120  is slidably received on to the counterbalance tube  116  and positioned in a desired location so as to be properly aligned with the flag angle  110 . Once properly positioned, and before installing the lift cable to the assembly  120 , the installer inserts fasteners  248 , which are preferably in the form of set screws, through the cross apertures  232  and into the internal threads  242 . These fasteners are appropriately tightened such that rotation of the counterbalance tube  116  results in a corresponding rotation of the assembly  120 . Although threaded fasteners  248  are shown in the drawing, those skilled in the art will appreciate that other types of fastening mechanisms could be employed to secure the assembly  120  to the counterbalance tube  116 . The cross apertures  232  allow for the fasteners to be installed substantially perpendicularly with respect to the counterbalance tube  116 . This allows for a more secure attachment of the assembly  120  to the tube  116 . Indeed, such a configuration reduces the amount of stress imparted to the assembly  120  and, as such, reduces cracking thereof normally encountered during installation. 
     Once the assembly  120  is properly positioned on the counterbalance tube  116 , the operator system is positioned and aligned such that the drive assembly  138  is engageable with the assembly  120 . In particular, the drive assembly  138  includes a drive gear  250  with drive gear teeth  252  which mesh with and engage the rim teeth  220 . As more fully described in the &#39;138 application, the drive gear  250  is axially movable so as to engage and disengage the assembly  120 . As best seen in  FIG. 5 , the drive gear teeth  252  are shown in the engaged position. Accordingly, as the motor assembly initiates movement of the drive gear assembly  138 , the body  200  rotates in a corresponding fashion. As the body rotates, the counterbalance tube  116  rotates so as to reel in or pay out the lift cables so as to raise or lower the door. 
     The advantages of the present configuration are readily apparent to those skilled in the art. In particular, the present construction provides for ease of installation by providing apertures through the cable storage drum area which allows for insertion and servicing of the set screws in the received threaded areas. Moreover, the cable storage area is mostly empty when the lift cable is payed out and the barrier or door is in a closed position to allow for such access. Still other advantages of the present invention are provided inasmuch as the assembly  120  eliminates the need for multiple parts to provide the driven gear and cable storage functions. The assembly also allows for installation of set screws to be substantially perpendicular to the drive shaft so as to prevent cracking of the assembly  120 . Another advantage is that the drive gear and the driven gear are allowed to rotate in the same direction. Yet another advantage of the present invention is that no additional room is required for the drive gear and the drive gear fits within the boundaries defined by the driven gear. As such, less room is required along the drive shaft and both the driven gear and the cable storage drum now require only one attachment point. Still other advantages are realized since there are less parts so as to reduce the cost of the overall assembly. 
     Thus, it can be seen that the objects of the invention 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 embodiment has been presented and described in detail, it is to be understood that the invention is not limited thereto and thereby. Accordingly, for an appreciation of the true scope and breadth of the invention, reference should be made to the following claims.