US4745785A | 1988-05-24 | |||
US20060001522A1 | 2006-01-05 | |||
US6212923B1 | 2001-04-10 |
WHAT IS CLAIMED IS:
1. A self adjusting lock system comprising: a lock cylinder having a direction of elongation defining an axial direction for the system and having a first and a second end; a rotatable first cylindrical plug in the lock cylinder, the first plug having an axially extending key slot from the first end of the lock cylinder; a rotatable second cylindrical plug in the lock cylinder, the second plug substantially coaxial to the first cylindrical plug; a bolt which is retractable substantially perpendicularly to the axial direction by rotation of each of the first plug and the second plug; and a control and rotation unit adapted to rotate the second plug, including: a power source, a processor; a motor; a current sensor adapted to sense motor current; and a clock adapted to measure time; wherein the control and rotation unit is adapted to sense motor current over time and to adjust operation of the lock system dependent on the sensed motor current over time.
2. A lock system according to claim 1 , wherein the control and rotation unit further includes a control module adapted to receive and to transmit signals and the processor is adapted to process and store data.
3. A lock system according to claim 2, wherein the control and rotation unit is adapted to store data indicative of sensed motor current versus time from operation of the lock system.
4. A lock system according to claim 3, wherein the control and rotation unit is adapted to perform an initial training operation to create a first current- versus-time profile, representing a plurality of events in the operation of the lock system, while performing at least one of: actuating the motor to rotate the second cylindrical plug from a bolted state to an unbolted state; and actuating the motor to rotate the second cylindrical plug from an unbolted state to a bolted state.
5. A lock system according to claim 4, wherein the control and rotation unit is adapted to perform at least one additional training operation to create at least one subsequent current-versus-time profile, representing a plurality of events in the operation of the lock system, while actuating the motor to rotate the second cylindrical plug from a bolted state to an unbolted state and actuating the motor to rotate the second cylindrical plug from an unbolted state to a bolted state.
6. A lock system according to claim 4 the initial current-versus-time profile is obtained from data.
7. A lock system according to claim 5, wherein the subsequent current-versus- time profile is obtained from data.
8. A lock system according to claim 7, wherein the control and rotational unit is adapted to mathematically operate upon the initial and the at least one subsequent current-versus-time profile to create and store a comparative current-versus-time profile.
9. A lock system according to claim 8, wherein the control and rotational unit is further adapted to calculate and store an electrical current threshold value and a time interval threshold value for respective events of the comparative current-versus-time profile based on data from corresponding respective events of the initial and subsequent current-versus-time profiles.
10. A lock system according to claim 9, wherein the electrical current threshold and time interval threshold values represent respective upper limit values corresponding to respective events.
11. A lock system according to claim 10, wherein the control and rotation unit is further adapted to compare sensed motor current and measured times of motor operation against the stored comparative current-versus-time profile and to determine whether instant sensed current and measured times do not exceed values of the comparative current-versus-time profile.
12. A lock system according to claim 11, wherein the control and rotation unit is adapted to set a warning flag when at least one of the instant sensed current and measured times exceed values of the comparative current- versus-time profile.
13. A lock system according to claim 11, wherein the control and rotation unit is further adapted to compare sensed motor current and measured times of motor operation against the stored respective threshold values and to set an error flag when at least one respective threshold value is exceeded.
14. A lock system according to claim 13, wherein the control and rotation unit is further adapted to self adjust the lock system when at least one threshold value is exceeded, the self-adjustment being at least one chosen from the list including: stopping motor operation; reversing motor operation; and recording the sensed motor current and time values.
15. A lock system according to claim 14, wherein the control and rotation unit is adapted to command rotation of the motor for a predetermined time to determine whether sensed current values are excessive and to stop motor operation for lock system servicing if sensed current values be excessive.
16. A lock system according to claim 15, wherein the control and rotation until is adapted to recalculate comparative current-versus-time profile and threshold values are recalculated as part of the self adjustment.
17. A lock system according to claim 1, wherein the lock system is retrofittable
in place of a conventional lock cylinder.
18. A lock system according to claim 1, wherein the control and rotation unit
further comprises a manual drive module adapted to disengage the motor
and to enable manual rotation of the second cylindrical plug.
19. A lock system according to claim 1, wherein the control and rotation unit is
supported from the second end of the lock cylinder.
20. A lock system according to claim 1, wherein a selector mechanism, located
between the first cylindrical plug and the second cylindrical plug, is adapted
to enable non-simultaneous rotation of the second and the first cylindrical
plug.
21. The lock system of claim 20, wherein the selector mechanism is configured
to primarily enable rotation of the second cylindrical plug.
22. The lock system of claim 21, wherein rotation of the first cylindrical plug
is enabled when a key is inserted into the key slot, the key acting to operate
the selector mechanism.
23. The lock system of claim 22, wherein rotation of the first cylindrical plug is
enabled by a mechanism internal to the lock system.
24. A method of operating a self-adjusting lock system comprising the steps of:
taking a lock cylinder having a direction of elongation defining an axial direction for the system and having a first and a second end; configuring a rotatable first cylindrical plug in the lock cylinder, the first plug having an axially extending key slot from the first end of the lock cylinder; positioning a rotatable second cylindrical plug in the lock cylinder, the second plug substantially coaxial to the first cylindrical plug; locating a bolt which is retractable substantially perpendicularly to the axial direction by rotation of each of the first plug and the second plug; and configuring a control and rotation unit to rotate the second plug, including: a processor; a motor; a current sensor to sense motor current; and a clock to measure time; wherein the control and rotation senses motor current over time and adjusts the lock system dependent on the sensed motor current over time. |
Self Adjusting Lock System and Method
FIELD AND BACKGROUND OF THE INVENTION
The present invention relates to a self adjusting lock system and, in
particular, it concerns a self adjusting retrofittable system that can be operated
to bolt and unbolt a lock, such as used in doors, and one which may also be
operated mechanically in case of power failure.
In a conventional mechanical cylinder lock, when an appropriate
matching key is inserted into the cylinder lock, the key serves to mechanically
align tumbler pins ("unlocked" or "opened" state), allowing the cylindrical plug
to be rotated freely to retract a bolt which is typically mechanically connected
the cylindrical plug and is driven by the rotated cylindrical plug.. Retraction of
the bolt is typically referred to as "unbolting" the lock. Conversely, when the
cylindrical plug is rotated (usually in a direction opposite that used for
unbolting) and the bolt is extended in such a way as to inhibit movement of a
door or window, etc. the action is referred to as "bolting" the lock. Following
bolting, the key is typically withdrawn from the key slot, the tumbler pins are
not aligned, which inhibits free rotation of the cylindrical plug, and the lock is
then in a "locked" or "closed" state.
In a conventional mechanical cylinder lock, when an appropriate
matching key is inserted into the cylinder lock, the key serves to mechanically
align tumbler pins, and thereby allowing the cylindrical plug to be rotated
freely to open the lock. Referring now to Figs. IA and IB, which are
representations of a prior art cylinder lock 10, with a key 12 inserted into the
cylinder lock, and a door lock 15. Door lock 15 includes, inter alia, a shaped
slot 16 for receiving cylinder lock 10 and a door lock hole 16 through which a
bolt (not shown) is inserted to secure the cylinder lock inside a door.
Typically, door lock 15 is inserted into a hollowed-out edge of the door (not
shown) and cylinder lock 10 is inserted through prepared holes in the door (not
shown in the figure) and perpendicularly into and through shaped slot 16,
substantially along axis 18. Door lock further comprises a bolt 19. Typically,
cylinder lock 10, when unlocked, serves to translate bolt 19 out of and back
into the cylinder lock, respectively bolting and unbolting the lock. Typically,
other cylinder locks having a cross-sectional profile and length substantially
matching cylinder lock 10 may be replaced or retrofitted instead of cylinder
lock 10. Typical names/manufacturers of such cylinder locks include, but are
not limited to: Euro Cylinders; Oval Cylinders; Asec 6-pin Euro profile; and
Chubb M3. Overall lengths of such cylinders typically vary from
approximately 70 - 95 mm.
Reference is now made to Figs. 2A and 2B, which are cross sectional
side views A-A of the cylinder lock shown in Fig. IA. The cylinder lock has a
body housing 20, which is bored from one end to the other end and a
cylindrical plug 22, which is fitted into the bore, and which may be rotated, as
described hereinbelow. A set hole 23 is located approximately in the middle of
cylinder lock 10 to typically receive a threaded bolt (not shown in the figure)
which is inserted into lock hole 16, to secure the cylinder lock within door lock
15, as described hereinabove in Fig. IB. Cylindrical plug 22 has a key slot 25
formed axially in cylindrical plug. Key 12 is inserted into slot 25. A pin-
tumbler set 30 is located in body housing 20 and in cylindrical plug 22 to serve
to lock and unlock rotational movement of cylindrical plug 22. Cylindrical
plug 22 and a second cylindrical plug 31 may be mechanically coupled and
uncoupled to a rotating tongue 35 by means of a selector mechanism (not
shown in the figure), which allows either of the two cylindrical plugs to rotate
the rotating tongue, which in turn serves to move the bolt of the door lock
(refer to Fig. IB). The cylinder lock shown in Figs. 2A and 2B is called a
"blind cylinder", in that a key can be inserted into only one side of the lock.
However, cylinder lock 10 may also comprise pin-tumbler sets in respective
cylindrical plugs at both ends.
Fig. 2B, which is a detailed view of Fig 2A, shows in greater detail pin-
tumbler set 30. Pin-tumbler set 30 includes tumbler pins 32 and driver pins 34,
both of which are constrained to move generally perpendicularly to key 12.
Springs 33 typically serve to preload the driver pins and the tumbler pins,
displacing them towards slot 25, thereby advancing part of one or more of
driver pins 34 into cylindrical plug 22 through openings in the plug (not shown
in the figure) and thereby locking rotation of cylindrical plug 22 when no key is
present in the slot. Typically, key 12 is formed to fit the pattern and respective
lengths of tumbler pins 32. When key 12 is fully inserted into slot 25, the key
presses tumbler pins 32 and driver pins 34 against springs 33, alignedly
inserting driver pins 34 into body housing 20, and thereby enables rotation of
the cylindrical plug. Whereas key 12 is shown inserted, with its wider traverse
edge contacting the tumbler pins, another inserted orientation of key 12 may
include its thinner traverse edge contacting the tumbler pins. Also, one or
more additional sets of collinearly arranged tumbler pins (not shown) may be
present, in the case of a master key, which is used to lock and unlock a number
of such specially configured cylinder locks.
A number of prior art electronic or combination electrical/mechanical
lock systems allow a user to open a locked cylinder in a number of ways. In
US Patent no. 3,889,501 by Fort, whose disclosure is incorporated herein by
reference, a combination electrical and mechanical system is described. The
system includes a lock having a fixed lock cylinder and a rotatable key slug. A
first solenoid is employed in the current system to drive a lock pin, which is
normally extended to lock the key slug. Upon insertion of an appropriately
aperture-encoded key, light sources and detectors mounted in the lock are used
in concert with appropriate circuitry to operate to the first solenoid to unlock
key slug. A second solenoid is operable, in response to an electrical power
failure, to extend a bolt pin. When the bolt pin is extended a proper mechanical
key is inserted and rotated, extension of the lock pin is prevented. A proper
mechanical key can be inserted to move a plurality of spring loaded pin
tumblers in the lock to enable rotation of the key slug during an electrical
power failure.
A conventional lock may be repeatedly bolted and unbolted over a
relatively long period of time with no noticeable degradation in operation.
When necessary, additional manual effort in moving elements of the lock, such
as the cylindrical plug and elements attached to the plug, is sufficient to
overcome any degradation due to mechanical wear, friction, thermal changes,
and dirt — among other causes of degradation. However, in an electrically
operated lock (especially one having a motor with limited torque or having a
limited power source, such as a battery-powered motor) degradation in lock
operation due to any of the causes noted hereinabove could yield a failure in
electrical lock operation. To avoid or deal with such cases, it is very useful for
an electrically operated lock to have the capability to self adjust and thereby
ensure smooth lock operation or to signal a condition where lock failure is
impending or occurs. In the description and claims hereinbelow, the term "self
adjust" refers to any method of exclusively using the characteristics of the
electrical motor or motors operating the lock to directly: effect changes in lock
operation; signal an impending lock failure condition; and signal a condition of
lock failure.
A rotary locking mechanism is disclosed by Santamarta, in US Patent
Application Publication no. 2006/0048552A1, whose disclosure is incorporated
herein by reference. The locking mechanism is preferably intended for lock
cylinders and includes an electric motor, a locking bolt, an inertial rotating
mechanism which converts the rotation of the motor into a rectilinear
movement along the axis of the locking bolt, an elastic accumulator (such as a
spring) which is arranged in opposition to the backward retraction travel of the
locking bolt and a rectilinear guide mechanism for the working
extraction/retraction travel of the locking bolt. Interaction of the inertial
rotating mechanism and the elastic accumulator allow a motor to be used
having non critical mechanical characteristics, ensuing cost savings when
choosing the motor.
Fonea, in US Patent No. 6,147,622, whose disclosure is incorporated
herein by reference, discloses an electronic lock system which is also manually
operable to drive a lock cylinder to move a lock mechanism which includes at
least one bolt. The system includes a bidirectional motor engagable with the
lock cylinder At least one sensor in the lock system is used in conjunction with
an angular measurement device and/or stepper motor feedback to provide a
level of lock self diagnostics and self testing. The system may also be operated
in a mechanical manner. Additional features of the lock system, not related to
the capabilities noted hereinabove are also disclosed.
While the prior art includes an array of combination
electrical/mechanical lock systems of varying complexity and systems that
employ some adjustment based on mechanical feedback, there is a need for an
electronic or combination electrical/mechanical system that has the capability
to self adjust the lock over time, based on the characteristics of the electrical
motor or motors operating the lock and a system which can easily be retrofitted
to an existing lock installation. The system should be remotely operated to
unbolt and bolt the lock and to allow the same operations to be performed in a
conventional manual manner in case of an electrical power failure.
Furthermore, such a system could be integrated with the capabilities of electric
and manual locking and unlocking of the lock.
SUMMARY OF THE INVENTION
The present invention is a self adjusting lock system that can be
operated to bolt and unbolt a lock, which is retrofittable to a conventional lock
system and one which may be operated in a conventional manner upon power
failure. Furthermore, such a system may include capabilities of electrical and
manual locking and unlocking.
According to the teachings of the present invention there is provided a
self adjusting lock system including: a lock cylinder having a direction of
elongation defining an axial direction for the system and having a first and a
second end; a rotatable first cylindrical plug in the lock cylinder, the first plug
having an axially extending key slot from the first end of the lock cylinder; a
rotatable second cylindrical plug in the lock cylinder, the second plug
substantially coaxial to the first cylindrical plug; a bolt which is retractable
substantially perpendicularly to the axial direction by rotation of each of the
first plug and the second plug; and a control and rotation unit adapted to rotate
the second plug, including: a power source, a processor; a motor; a current
sensor adapted to sense motor current; and a clock adapted to measure time;
wherein the control and rotation unit is adapted to sense motor current over
time and to adjust operation of the lock system dependent on the sensed motor
current over time.
Preferably, the control and rotation unit further includes a control
module adapted to receive and to transmit signals and the processor is adapted
to process and store data. Most preferably, the control and rotation unit is
adapted to store data indicative of sensed motor current versus time from
operation of the lock system. Typically, the control and rotation unit is adapted
to perform an initial training operation to create a first current- versus -time
profile, representing a plurality of events in the operation of the lock system,
while performing at least one of: actuating the motor to rotate the second
cylindrical plug from a bolted state to an unbolted state; and actuating the
motor to rotate the second cylindrical plug from an unbolted state to a bolted
state. Most typically, the control and rotation unit is adapted to perform at least
one additional training operation to create at least one subsequent current-
versus-time profile, representing a plurality of events in the operation of the
lock system, while actuating the motor to rotate the second cylindrical plug
from a bolted state to an unbolted state and actuating the motor to rotate the
second cylindrical plug from an unbolted state to a bolted state. Most
preferably, the initial current-versus-time profile is obtained from data.
Typically, the subsequent current-versus-time profile is obtained from data.
Preferably, the control and rotational unit is adapted to mathematically
operate upon the initial and the at least one subsequent current-versus-time
profile to create and store a comparative current-versus-time profile. Most
preferably, the control and rotational unit is further adapted to calculate and
store an electrical current threshold value and a time interval threshold value
for respective events of the comparative current-versus-time profile based on
data from corresponding respective events of the initial and subsequent current-
versus-time profiles. Typically, the electrical current threshold and time
interval threshold values represent respective upper limit values corresponding
to respective events. Most typically, the control and rotation unit is further
adapted to compare sensed motor current and measured times of motor
operation against the stored comparative current- versus -time profile and to
determine whether instant sensed current and measured times do not exceed
values of the comparative current-versus-time profile.
Preferably, the control and rotation unit is adapted to set a warning flag
when at least one of the instant sensed current and measured times exceed
values of the comparative current-versus-time profile. Most preferably, the
control and rotation unit is further adapted to compare sensed motor current
and measured times of motor operation against the stored respective threshold
values and to set an error flag when at least one respective threshold value is
exceeded.
Preferably, the control and rotation unit is further adapted to self adjust
the lock system when at least one threshold value is exceeded, the self-
adjustment being at least one chosen from the list including: stopping motor
operation; reversing motor operation; and recording the sensed motor current
and time values. Most preferably, the control and rotation unit is adapted to
command rotation of the motor for a predetermined time to determine whether
sensed current values are excessive and to stop motor operation for lock system
servicing if sensed current values be excessive. Typically, the control and
rotation until is adapted to recalculate comparative current-versus-time profile
and threshold values are recalculated as part of the self adjustment.
Preferably, lock system is retrofittable in place of a conventional lock
cylinder. Most preferably, the control and rotation unit further comprises a
manual drive module adapted to disengage the motor and to enable manual
rotation of the second cylindrical plug.
Preferably, the control and rotation unit is supported from the second
end of the lock cylinder. Most preferably, a selector mechanism, located
between the first cylindrical plug and the second cylindrical plug, is adapted to
enable non-simultaneous rotation of the second and the first cylindrical plug.
Typically, the selector mechanism is configured to primarily enable rotation of
the second cylindrical plug. Most typically, rotation of the first cylindrical plug
is enabled when a key is inserted into the key slot, the key acting to operate the
selector mechanism. Typically, rotation of the first cylindrical plug is enabled
by a mechanism internal to the lock system.
According to the teachings of the present invention there is further
provided a method of operating a self-adjusting lock system comprising the
steps of: taking a lock cylinder having a direction of elongation defining an
axial direction for the system and having a first and a second end; configuring a
rotatable first cylindrical plug in the lock cylinder, the first plug having an
axially extending key slot from the first end of the lock cylinder; positioning a
rotatable second cylindrical plug in the lock cylinder, the second plug
substantially coaxial to the first cylindrical plug; locating a bolt which is
retractable substantially perpendicularly to the axial direction by rotation of
each of the first plug and the second plug; and configuring a control and
rotation unit to rotate the second plug, including: a processor; a motor; a
current sensor to sense motor current; and a clock to measure time; wherein
the control and rotation senses motor current over time and adjusts the lock
system dependent on the sensed motor current over time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is herein described, by way of example only, with
reference to the accompanying drawings, wherein:
FIGS. IA and IB are representations of a prior art cylinder lock and a
door lock, respectively;
FIGS. 2A and 2B are cross sectional side views of the cylinder lock
shown in Figs. IA and IB;
FIGS. 3 A and 3B are an illustrative diagram and a sectional diagram,
respectively, of a self-adjusting lock system in accordance with an embodiment
of the present invention;
FIG. 4 is an exemplary current-versus-time profile plot in accordance
with an embodiment of the current invention; and
FIG. 5 is the current-versus-time profile plot of FIG. 4 showing an
occurrence of the motor current value I 3 exceeding a current-threshold value
Th-I 3 .
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention includes a lock apparatus that can be operated to
bolt and unbolt a lock, such as used in doors, and one which may also be
operated mechanically in case of power failure.
Reference is now made to FIGS. 3A and 3B, which are, respectively, an
illustrative diagram and a sectional diagram of a self-adjusting lock system 110
in accordance with an embodiment of the present invention. Apart from
differences described below, self-adjusting lock system 110 is generally similar
to operation of cylinder lock 10 as shown in Figs. 2A and 2B, so that elements
indicated by the same reference numerals are generally identical in
configuration and operation. Embodiments of the current invention disclosed
hereinbelow are directed to be generally replaceable to cylinder lock 10 and/or
retrofittable to cylinder lock 10 in door lock 15 shown in Figs IA, IB, 2A, and
2B. Specifically, self-adjusting lock system 110 has a "blind cylinder", in that a
key can be inserted into only one side of the lock system.
In one embodiment of the current invention, the side of the lock system
in which a key is inserted is outside a door and/or towards an unsecured area,
whereas the blind side of the lock system is inside a door and/or towards a
secured area. This orientation of the lock system would typically allow a
person in the secured area and/or inside the door to unbolt the door without a
key, whereas a key and/or a remote control unit would be necessary to open
and unbolt the lock system from outside the door and/or in the unsecured area.
Operation of the lock system 110 is further described hereinbelow.
Lock system 110 has a blind plug rotation module 135, which includes a
motor and power module 140, gearing module 150, and manual drive module
170. Blind plug rotation module 135 is configured substantially coaxially with
the axis of rotation of blind plug 31 and motor and power module 140 is
configured substantially normal to axis of rotation of blind plug 31.
Furthermore, motor and power module 140 is configured substantially parallel
and flush with the door surface (not shown in the figure). Motor and power
module 140, is configured to provide rotation displacement to the gearing
module to unbolt the lock system, as describe hereinbelow. In an embodiment
of the current invention, the motor and power module includes electronic
components (not shown in the figures) to enable command and telemetry
information to be exchanged with it and a remote controller which may be
wired and/or which may be in the form of a cellular telephone, key fob,
computer, or any device that affording wireless control.. Manual drive module
170 is also configured to provide rotation to unbolt the lock system, as
described hereinbelow.
Motor and power module 140 includes an electric or electronic
rotational drive motor 142 which drives a motor beveled gear 144. A power
source 146, which may be in the form of batteries or an electrical mains
connection, may be located between motor 142 and the door surface, or the
power source may be located to either side of the motor or, alternatively, with
the motor between the power source and the door surface. When commanded
to drive, the drive motor turns motor beveled gear 144, which is engaged
substantially normally with a bolting beveled gear 154. Drive shaft 156 is
configured substantially coaxially with blind plug 31 and the drive shaft runs
through the center of bolting beveled gear 154. The bolting beveled gear is
fixed to the drive shaft by means of pin 158, as shown. Blind plug 31 is shaped
to fit into drive shaft 156 as shown, and a pin-in-slot configuration 160 enables
drive shaft 156 to rotate the blind while enabling the drive shaft to be translated
away from the blind plug. The motor and power module also includes (not
indicated in the figures): a processor which can store data, a current sensor to
sense motor current; and a clock to measure time. The processor, current
sensor, and clock are further discussed hereinbelow.
Manual drive module 170 includes drive knob 172 which fits over and is
mechanically connected to the end of drive shaft 156 by linkage 174. Linkage
174 is configured to allow the drive shaft to be translated away from the blind
plug by pressing drive knob 172 towards the blind plug. When the drive shaft is
translated away from the blind plug sufficiently, bolting beveled gear 154 is
disengaged from motor beveled gear 144, thereby enabling manual rotation of
the blind plug by drive shaft 156 by rotation of drive knob 172. Linkage 174
may have a bias mechanism, such as a spring (not shown in the figure) to bias
the drive shaft so that bolting beveled gear 154 is normally engaged with motor
beveled gear. Such a bias mechanism allows the lock system to be in a state
where the motor normally operates to bolt and unbolt the lock system even if
the drive knob were recently used.
A selector mechanism 180 is positioned between the blind plug and
cylindrical plug 22. The selector mechanism is further described hereinbelow.
The inventor of the current patent application, in US Patent Application
no, 11/469865, referred hereinbelow as '865 and whose disclosure is
incorporated herein by reference, discloses various features, configurations,
and methods of opening a lock cylinder with and without a key, including inter
alia: electronic, remote, and manual operation of the lock cylinder. A
cylindrical plug rotational handle is further disclosed in '865, which enables a
cylindrical plug located at the key slot side of the lock cylinder to be manually
rotated when the lock cylinder is unlocked without a key.
In addition, '865 discloses the incorporation of a selector mechanism
generally identical in configuration and operation to selector mechanism 180 in
the current figure 3B. The selector mechanism taught in '865 enables selective
opening and rotation of the lock cylinder with a key or rotation of the cylinder
from the blind side of the cylinder when no key is present, as shown in Figs
9A-C and 1OA and B in '865 and described therein. Embodiments of the current
invention may include features, configurations, and methods noted hereinabove
as well as others disclosed in '865 to enhance the lock system operation,
specifically in opening and closing the lock and in rotating cylindrical plug 22
and blind plug 31, in conjunction with bolting and unbolting the lock system,
as described hereinabove.
Reference is now made to FIG. 4, which is an exemplary current- versus-
time (I versus t) profile plot 200, in accordance with an embodiment of the
current invention. Although numerical values of I and t are not indicated in the
current-versus-time (I versus t) profile plot 200 due to the very wide variation
of motor and lock system characteristics, approximate typical representative
ranges of current and time values could be on the order of milliamps to
thousands of milliamps for current and on the order of tens to thousands of
milliseconds for time. Embodiments of the current invention employing
smaller and larger scaled lock systems would have different current and time
characteristics, mutatis mutandis.
When rotational drive motor 142 (refer to FIG. 3B) is commanded to
bolt or unbolt the lock system, the current sensor and the clock interact with the
processor to create a current-versus-time profile plot 200. The current-versus-
time profile represents a series of events in the operation of the lock system, as
described hereinbelow. In considering the motor operation for unbolting the
lock system from a completely bolted position, the motor is commanded at
time t = 0 and current = 0. As is characteristic for most electric motors, the
current increases rapidly even before the motor begins to turn. A maximum
current value I 1 is obtained at time t l5 for example, as the motor turns, backlash
in the gears and friction of the blind plug 31 are overcome, and retraction of the
bolt (see FIG. IB) is initiated. The motor current typically continues to drop as
the bolt continues to move. After a time interval designated At 1 , an initial
portion of the lock system unbolting process is complete, as motor current
ceases to drop quickly. Another time interval, designated δt 2 , follows wherein
motor current is nearly constant over time, below a local maximum value of I 2 .
Time interval δt 2 could correspond, for example, to smooth movement of the
bolt, as retraction proceeds. Another time interval δt 3 , follows wherein motor
current begins to rise rapidly to a value of I 3 at time t 3 . Time interval δt 3 could
correspond, for example, to the bolt being presently fully retracted and an
increase in gearing backlash. At the end of time interval δt 3 , the lock system is
in a fully unbolted state and the motor is commanded to stop.
Knowing electromechanical characteristics of the rotational drive motor
and mechanical characteristics of the gears and other mechanical components
of the lock system, the current-versus-time profile may be used to give an
indication of system performance and to furthermore enable adjustments to the
lock system, as described hereinbelow. One way to develop such knowledge,
for example, is to initially command the motor to unbolt the bolted lock
system. Initial unbolting of the lock system may be performed, for example,
after the lock system is initially installed or following some maintenance
operation which could impact the lock system operation. An initial current-
versus-time profile, similar to the current-versus-time profile shown in FIG. 4
is then recorded. Additional, subsequent unbolting current-versus-time profiles
may be generated and stored, in a similar manner. Statistical techniques may be
used as know in the art to operate upon the initial and subsequent current-
versus-time profiles to determine typical mean current values for I 1 , I 2 , and I 3
and other current values and for determining corresponding mean time values
and mean δt values of a comparative current-versus-time profile — which has an
appearance similar to current-versus-time profile plot 200. Other ways to
obtain the comparative current-versus-time profile include: mathematically
modeling system performance to calculate the profile; and combining both
mathematical models with one or more physically run unbolting operations.
The comparative current-versus-time profile is stored and it is used to compare
against instantaneously-measured current-versus-time profile information from
subsequent operation of the lock system.
Because the comparative current-versus-time profile represents a
statistical sample and because the sample reflects a level of uncertainty,
tolerance or threshold values for current values, time, and δt values (as
described above) are calculated or are set to reflect the level of uncertainty.
Threshold values can serve as "upper limit" values in a similar fashion as
"upper control limits" are applied in statistical process control in many
manufacturing industries. This means, for example, that when the lock system
is operated and when instant current-versus-time performance is monitored
against the comparative current-versus-time profile, operation of the lock
system continues even though a desired mean value is exceeded, so long as the
corresponding threshold value is not exceeded. In the case of the comparative
current-versus-time profile, values indicated in FIG. 4, such as Th-I 1 , TH-I 2 ,
TH-I 3 etc, represent thresholds of current values and Th-At 1 , Th-At 2 , and Th-
δt 3 represent thresholds for corresponding time interval values. Thresholds may
be determined in a number of ways, including: calculating statistical variations
of representative means of current and time values; applying a mathematical
function (the simplest of which would be to add a constant relative value, such
as adding 10%, to the mean value); or a combination of statistical and
mathematical function techniques.
The current-versus-time profiles described hereinabove relate to an
unbolting operation; however one skilled in the art will understand that a
current-versus-time profile, a comparative current-versus-time profile, and
corresponding threshold values can similarly be developed for an unbolting
operation. In this way, bolting and unbolting operations for the lock system can
be completely characterized with stored comparative current-versus-time
profiles.
Reference is now made to FIG. 5, which is a comparative current-
versus-time profile plot 220 for an unbolting operation showing an occurrence
of the motor current value Iy exceeding a current-threshold value Th-I 3 in
accordance with and embodiment of the present invention. Apart from
differences described below, current-versus-time profile plot 220 is generally
similar to current-versus-time profile plot 200 as shown in FIG. 4, so that
elements indicated by the notations in the figures are generally identical in
meaning and operation. As noted hereinabove, comparative current-versus-
time profiles and thresholds may be developed for bolting and unbolting
operations, so that the following discussion applies for a bolting as well an
unbolting operation, mutatis mutandis.
In an embodiment of the current invention, as the lock system is
unbolted, motor current is monitored versus time and monitored current and
time values are compared with the unbolted comparative current-versus-time
profile stored in the system, as described hereinabove. When it is sensed that an
instant current or time value exceeds the corresponding comparative current-
versus-time profile, a warning flag or warning condition may be set, but no
other action is taken by the system. Such an occurrence could be representative,
for example, of a momentary increase in friction or some other spurious, short¬
lived problem of the lock system.
However, when it is determined, for example, that an instant current
value exceeds the corresponding threshold value of the comparative current-
versus-time profile, an occurrence which could represent a serious problem or
failure of the lock system, the system will signal an error condition (i.e. setting
an error flag), which may be local to the lock system itself and/or to a remote
location. In addition, the system may take one or more of the following
exemplary actions:
1. Stop the drive motor;
2. Reverse the direction of the drive motor; and
3. Record I 3' and its corresponding time value t 3' .
In addition to the actions listed above, embodiments of the current
invention can include the processor automatically commanding the drive motor
to rotate for a predetermined short time to determine if current values are again
excessive. If current values are determined to be not excessive, then the system
is allowed to continue operation. The processor may then recalculate the
comparative current-versus-time profile and threshold Th-I 3 , as well as
threshold Th-At 3 (not indicated in the current figure). Additionally or
alternatively, the lock system may automatically perform or be commanded to
perform a complete unbolting operation and/or additional operations, such as
downloading current-versus-time profile data, to retrain and/or to recalculate
the comparative current-versus-time profile and respective threshold values.
If current values are still excessive, then the motor is stopped and an
error condition is signaled. At this point, the lock system may be partially or
completely inoperative until, for example, an obstruction is removed or a repair
is made to the system, which may be followed by operations to recalculate the
comparative current-versus-time profile and thresholds as described
hereinabove.
The process of employing the processor, current sensor, and clock and
controlling the drive motor and recalculating the comparative current-versus-
time profile and one or more respective thresholds is a self-adjustment of the
lock system operation. Other similar adjustments of the lock system may be
initiated, for example, by data being transferred to the lock system, serving to
change the comparative current-versus-time profile and one or more respective
thresholds. As noted hereinabove, operation and calculation of current-versus-
time profiles applies for bolting and for unbolting operations.
Whereas the embodiments of the current invention are described herein
using a rotational drive motor and gearing, the principle of operating and
adjusting operation of the lock system according to current-versus-time
behavior of any drive system, such as but not limited to a linear motor, or any
other type of motor, with our without gearing.
It will be appreciated that the above descriptions are intended only to
serve as examples, and that many other embodiments are possible within the
scope of the present invention as defined in the appended claims.