Technology field

Present invention relates to a door operator system for an overhead door system and an overhead door system comprising such a door operator system.

Background

Overhead door systems such as roll up door systems and sectional door systems are commonly used to control access to parking garages, industrial buildings etc. Such systems commonly utilize a door operator with a motor, a cable driven by said motor and a drum around which the cable is wounded and unwounded to open and close the door or alternatively, a roll up shaft around which the door leaf is wounded and unwounded driven by the motor. The door leaf is guided in a door frame. In the case of a sectional door system, the cable is often connected to the bottommost section of the sectional door allowing for lifting of said sectional door within the doorframe. In the case of a roll up door, the roll up shaft is commonly attached to an upper edge of the door.

The motor is typically arranged on a motor shaft connecting to the drum or the roll up shaft. The shaft protrudes from the door frame such that the motor is arranged next to the opening in which the door system is arranged. In many applications, such as in parking garages, the space available for the door system is quite limited. In such cases, the extra space taken up by the motor is significant.

Present inventors have realized that there is room for improvement in this field.

Summary

According to an aspect, a door operator system for an overhead door system is provided. The door operator system is arranged to move a door leaf of the overhead door system between an opened and closed position.

The door operator system comprises a motor for driving the movement of the door leaf, a connecting member in driving connection with the motor and a hollow transmission element connected to the motor via the connecting member. The hollow transmission element is connected to the motor via the connecting member. The hollow transmission element is arranged to be connected to the door leaf for moving the door leaf between the opened and closed position.

The motor is at least partly arranged inside the hollow transmission element. According to an aspect, an overhead door system is provided. The overhead door system comprises a door operator system according to the above and a door leaf. The door operator system being arranged to move the door leaf between an opened and closed position.

Embodiments of the invention are defined by the appended dependent claims and are further explained in the detailed description section as well as in the drawings.

It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps, or components, but does not preclude the presence or addition of one or more other features, integers, steps, components, or groups thereof. All terms used in the claims are to be interpreted according to their ordinary meaning in the technical field, unless explicitly defined otherwise herein. All references to "a/an/the [element, device, component, means, step, etc.]" are to be interpreted openly as referring to at least one instance of the element, device, component, means, step, etc., unless explicitly stated otherwise. The steps of any method disclosed herein do not have to be performed in the exact order disclosed, unless explicitly stated.

Brief description of drawings

The present invention will be described further below by way of example and with reference to the enclosed drawings. In the drawings: Figure 1 shows an overhead door system according to an embodiment.

Figure 2 shows a perspective view of a door operator system according to an embodiment.

Figure 3 shows a schematic cross-section view of a door operator system according to an embodiment. Figure 4 shows a schematic cross-section view of a door operator system according to an embodiment. Figure 5a shows a schematic view of a connecting member according to an embodiment.

Figure 5b shows a schematic view of a connecting member according to an embodiment. Figure 6a shows schematic views of a hollow transmission element according to an embodiment.

Figure 6b shows schematic views of a hollow transmission element according to an embodiment.

Figure 6c shows schematic views of a hollow transmission element according to an embodiment.

Detailed description

Embodiments of the invention will now be described with reference to the accompanying drawings. The invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. The terminology used in the detailed description of the particular embodiments illustrated in the accompanying drawings is not intended to be limiting of the invention. In the drawings, like numbers refer to like elements.

Figure 1 discloses an overhead door system. The overhead door system 10 comprises a door operator system 100 and a door leaf 12, i.e. a door blade. The door operator 100 is arranged to move the door leaf 12 between an opened and closed position. The overhead door system comprises the door leaf 12. The door leaf 12 is mounted on a track system, i.e. mounted on tracks 31, 32. The door leaf 12 may be partitioned into interconnected sections 13.

The door operator system comprises a motor and a transmission connecting the motor and the door leaf 12, which will be described in further detail with reference to Figure 2. The depicted embodiment of the door system is a sectional door system. The door leaf 12 may in a preferred embodiment be a sectional door, and as the term implies, is thus partitioned into a number of sections 13. Each section 13 is hinged to the adjacent section(s) and the sections 13 generally extends horizontally /laterally from one side of the door leaf 12 to the other. The door leaf 12 can thus be shaped during the opening/closing by pivoting the sections 13 around the hinging between them. This allows the door leaf 12 to be guided and formed in its motion by a bent track, which transfers the door leaf 12 from an essentially vertical closed position to a horizontal or inclined open position. For the purpose of guiding the door leaf 12 along the track in a smooth and low-friction manner, each section 13 is preferably provided with laterally arranged rollers which are in engagement with the tracks. Alternatively, the tracks may be vertical whereby the door leaf 12 is guided between a vertical opened and closed position.

In a sectional door system, the transmission may comprise a transmission element in the form of a drum 110 for transferring torque from the motor to the door leaf. The drum 110 is arranged to receive a cable wire 181. The cable wire 181 is connected to the door leaf 12 such that winding and unwinding of the cable wire 181 around the drum 110 causes movement of the door leaf 12 between the opened and closed position.

Again referencing Figure 1, the door operator system 100 may comprise a second drum 150 and a drum shaft 120. The drum shaft 120 connects the drum 110 and the second drum 150. The second drum 150 may be considered a driven drum or auxiliary drum. The drum 110 may be considered a first drum 110.

The second drum 150 is arranged to receive a second cable wire 182 connected to the door leaf 12 such that winding and unwinding of the second cable wire 182 moves the door leaf 12 between the opened and closed position. The first drum 110 is arranged to be mounted proximal to an axis extending along a first vertical edge of the door leaf 12. The second drum 160 is arranged to be mounted proximal to an axis extending along a second opposite vertical edge of the door leaf 12.

The drum 110 is connected to an output shaft of the motor of the door operator system, such that it upon rotation winds the cable wire 181 attached to the door leaf 12 onto the drum 110 and potentially winds the second cable wire 182 attached to the door leaf 12 onto the drum 150 and thus achieves an opening or closing motion of the door leaf 12.

In an alternative embodiment, the door operator system may comprise two motors, each driving a corresponding drum. In such a system, the shaft connecting the drums may be omitted.

As will be described later on with reference to Figure 4, the door system may be a roll up door system. In such a system the transmission comprises a transmission element in the form of a roll up shaft around which the door leaf 12 is winded in order to provide the opening and closing movement of the door leaf 12. Such a door leaf 12 may be in a flexible material and/or may comprise a plurality of interconnected sections. The door leaf 12 may be guided in a track system and be mounted to tracks according to the door system described above.

The door operator system may comprise a control unit for controlling the motor. The control unit is operatively connected to the motor. The control unit may be constituted by any suitable central processing unit CPU, microcontroller, Digital Signal Processor DSP, etc., capable of executing computer program code. The control unit may be implemented using instructions that enable hardware functionality, for example, by using executable computer program instructions in a general-purpose or special-purpose processor that may be stored on a computer readable storage medium (disk, memory etc.) to be executed by such a processor. The control unit may be implemented using any suitable, publically available processor or Programmable Logic Circuit (PLC).

Figure 2 depicts a perspective view of the door operator system according to an embodiment the present invention.

The door operator system 100 comprises the motor 210 for driving the movement of the door leaf 12. The motor 210 is preferably an electric motor, such as a brushless motor. The advantage with a brushless motor is that such a motor does not have the coal parts wearing down during use, which makes it more durable compared to other types of electric motors.

The door operator system further comprises a connecting member 170. The connecting member 170 is in driving connection with the motor 210. Thus, the connecting member 170 may be connected to the output shaft of the motor 210. Further, the door operator system 100, as described above, comprises a transmission element 110. The transmission element is a hollow transmission element 110. The hollow transmission element 110 is arranged to be connected to the door leaf 12 for moving the door leaf 12 between the opened and closed position. Notably, the motor 210 is at least partly arranged inside the hollow transmission element 110.

By having the motor arranged inside the hollow transmission element, the space taken up around the opening in which the door system is arranged may be substantially reduced. With the present design, multiple door systems may be arranged close to each other which is particularly advantageous in for example warehouses where there may be a need for multiple adjacent door systems.

The motor 210 is with the door operator system according to the present invention arranged such that it may act as a bearing for the hollow transmission element in the manual operation of the door. Thus, the complexity of the door operator system is reduced due to not having to utilize an additional bearing for the hollow transmission element. Further, the present door operator system allows for a balanced door system which may be operated without power.

The motor 210 being at least partly arranged inside the hollow transmission element 110 herein refers to the hollow transmission element 110 at least partly encapsulating the motor 210. The hollow transmission element 110 may be preferably by annular such that the motor 210 extends inside the opening of the annular hollow transmission element 110.

Preferably, the connecting member 170, the hollow transmission element 110 and the motor are coaxially arranged. Preferably, the motor 210 at least partly extends directly above the door leaf 12.

This allows for a more compact door system. Thus, the motor 210 may be arranged such that it intersects the axis extending along the vertical edge of the door leaf.

Alternatively, or additionally, the motor 210 extends horizontally at least partly between a first vertical axis extending along a first vertical edge of the door leaf and a second vertical axis extending along a second, opposite, vertical edge of the door leaf. The motor 210 may be mounted to a bracket 191. The bracket 191 may be attached to the track system, i.e. the track 31, or directly to wall adjacent to the door operator system. The door operator system may be mounted to said bracket 191, whereby the hollow transmission element 120, connecting member 170 and the motor 210 are all suspended by means of the bracket 191. Alternatively, the motor 210 may be mounted to a wall adjacent to the door system.

In one embodiment, the hollow transmission element 120 and/or the connecting member 170 are supported by the motor 210. In one embodiment, the hollow transmission element 120 and/or the connecting member 170 are supported solely by said motor 210. This allows for a less complex door operator system which is less cumbersome to install.

Figure 3 and 4 schematically depicts embodiments of the door operator system 10. Figure 3 depicts an embodiment suitable for a sectional door system and an embodiment suitable for a roll up door system. Referencing said figures, the connecting member 170, 370 may be at least partly arranged inside the hollow transmission element 110, 310.

The connecting member 170, 370 may be mounted to the output shaft 212 of the motor 210.

In order to control torque transfer and allow for easy manual operation of the door system, the door operator system 100 may comprise a coupling 219. The coupling 219 is arranged between the connecting member 170 and the motor 210. The coupling 219 is arranged to selectively decouple the motor 210 from the hollow transmission element 110, 310.

The coupling may be any type of coupling available to the skilled person, such as for example a spline coupling, lamella coupling, dog clutch etc. The coupling 219 may be operatively connected to the control unit, whereby the control unit is configured to control the coupling 219. Additionally, or alternatively, the coupling may be manually operable.

The door operator system 100 may comprise at least one torque transferring interface 173, 373. The at least one torque transferring interface 173, 373 is associated with the connecting member 170, 370. The at least one torque transferring interface 173, 373, each torque transferring interface 173, 373 being arranged to transfer torque to a torque receiving interface 113, 313. The torque receiving interface 113, 313 is associated with the hollow transmission element 170, 370. Thus, the torque receiving interface 113, 313 is arranged to receive torque from the connecting member for driving the hollow transmission element 110, 310.

In one embodiment, the torque receiving interface 113, 313 is in engagement with the torque receiving interface 113, 313.

Further, the connecting member 170, 370 comprises at least one torque transferring interface 173, 373. Each torque transferring interface 173, 373 is associated with the connecting member 173, 373. Each torque transferring interface 173, 373 is arranged to transfer torque to a torque receiving interface 113, 313 from the connecting member 170, 370. The torque receiving interface 113, 313 is associated with the hollow transmission element 110. Associated herein refers to that the torque receiving/transferring interfaces are directly or indirectly coupled to the connecting member and the hollow transmission element respectively.

In one embodiment, the torque receiving interface 113, 313 may be provided with the hollow transmission element 110, 310 and/or the connecting member 170, 370 may be provided with the torque transferring interface 173, 373. This allows for a more compact door operator system. In one embodiment, the torque receiving interface 113, 313 may be connected to, e.g. forms a separate component, the hollow transmission element 110, 310. In one embodiment, the torque transferring interface 173, 373 may be connected to, e.g. forms a separate component, the connecting member 170, 370. This allows for a more robust door operator system capable of providing a higher torque. Preferably, the torque transferring interface and the torque receiving interface may form a planetary gearing for transferring torque between the connecting member and the hollow transmission element.

In one embodiment, the torque transferring interface 173, 373 is engaging with a corresponding torque receiving interface 113, 313. As depicted in Figure 3 and 4, the hollow transmission element 110, 310 may be annular and the inner surface of the hollow transmission element is provided with the torque receiving interface 113, 313. In the depicted embodiments the torque receiving interface 113, 313 directly engages with the torque transferring interface 173, 373.

With reference to Figure 3, the hollow transmission element is a drum 110. The drum 110 is arranged to receive the cable wire connected to the door leaf such that winding and unwinding of the cable wire around the drum causes movement of the door leaf between the opened and closed position.

The drum shaft 120 connects the drum 110 and the second drum 150. The second drum is arranged to receive a wire cable connected to the door leaf such that winding and unwinding of the second cable wire around the second drum 150 causes movement of the door leaf between the opened and closed position.

The drum 110 may be provided with a torque receiving interface 113. As depicted, the inner surface of drum 110 may be provided with said torque receiving interface 113. The connecting member 170 is at least partly arranged within said drum 110, whereby the torque transferring interface 173 engages with the torque receiving interface 113 for transferring torque from the motor 210 via the connecting member 170 to the drum 110.

The connecting member 170 is connected to the output shaft 212 of the motor 210. The inner surface of the drum 110 thus surrounds the motor 210, the output shaft 212 of the motor 210 and the connecting member 170. With reference to Figure 4, the hollow transmission element is a roll up shaft 310.

The roll up shaft 310 is arranged to be connected to the door leaf for moving the door leaf between the opened and closed position by means of winding and unwinding of the door leaf around the roll up shaft 310.

The roll up shaft 310 may be annular. The inner surface of the roll up shaft 310 may be provided with the torque receiving interface 313. The connecting member 370 is at least partly arranged within the roll up shaft 310, whereby the torque transferring interface 373 for transferring torque from the motor 210 via the connecting member 370 to the roll up shaft 310.

The door operator system 100 may further comprise a supporting member 360 rotatably coupled to the roll up shaft 310. Thus, one axial end of the roll up shaft 210 may engage the supporting member 360 and an opposite axial end of the roll up shaft 210 may be engage the torque transferring interface 373 either directly or indirectly.

As depicted in Figure 4, the connecting member may comprise a plurality of torque transferring interfaces 373a, 373b, 373c. This will be further described with reference to Figure 5a-b.

Turning to Figure 5a and Figure 5b embodiments of the connecting member are depicted.

As most clearly shown in Figure 5a, the connecting member 170 may comprise a shaft connection 175 arranged to receive the output shaft of the motor. The shaft connection 175 may comprise an aperture for receiving said output shaft. In one embodiment, the shaft connection 175 may have a plurality of interfaces for receiving corresponding interfaces of the output shaft, whereby the shaft connection 175 may be arranged to receive a plurality of output shafts with different types of corresponding interfaces. This allows for fitting of the connecting member to multiple types of motors and output shafts, which increases the flexibility of the door operator system.

In one embodiment, the connecting member 170, 370 may be a molded component. In one embodiment, the connecting member 170, 370 may be in Zink, whereby a lighter and more cost-efficient door operator system is achieved. In embodiments where the connecting member 170, 370 is provided with the torque transferring interface, the torque transferring interface may be in steel.

The door operator system may comprise a plurality of torque transferring interfaces 173, 373. Each torque transferring interface 173, 373 is associated with the connecting member 170, 370. Each torque transferring interface is arranged to engage with a corresponding torque receiving interface associated with a separate hollow transmission element such that the hollow transmission element is interchangeable with a different hollow transmission element associated with a torque receiving interface corresponding to a different torque transferring interface. Thus, the hollow transmission element may be interchanged with a different hollow transmission element which is accommodated by a different torque transferring interface. This allows for a modular door operator system wherein the transmission element can be replaced depending on the intended use of the door system. As depicted in Figure 5a-b, The connecting member 170, 370 may be provided with a plurality of torque transferring interfaces 173, 373.

In one embodiment, each torque transferring interface is arranged to engage with a corresponding torque receiving interface of a separate hollow transmission element such that the hollow transmission element is interchangeable with a different hollow transmission element with a torque receiving interface 173, 373 provided on the connecting member 170, 370.

In one embodiment, the torque transferring interface 173, 373 or the torque receiving interface comprises one or more splines 119. Thus, the other of the torque transferring interface 173, 373 or the torque receiving interface comprises corresponding recesses 173 for receiving said one or more splines for transferring torque from the connecting member to the hollow transmission element.

As seen in Figure 5a, the connecting member may be provided with the corresponding recesses. The recess may extend radially from the periphery of the connecting member towards the center of the connecting member.

The plurality of torque transferring interfaces may thus be formed by a plurality of different shaped splines or recesses.

In one embodiment, the torque transferring interface 373 and the torque receiving interface may each comprise geared surfaces for transferring torque from the connecting member 370 to the hollow transmission element.

In one embodiment, the torque transferring interface 373 and the torque receiving interface may each comprise geared surfaces meshing with each other for transferring torque from the connecting member 370 to the hollow transmission element.

As depicted in Figure 5b, the connecting member may be provided with a plurality of geared surfaces.

In one embodiment, the geared surfaces may be in the form of coaxially arranged geared wheels. The geared wheels are fix relative a carrier, thus forming the connecting member 370. The geared wheels provide different interfaces for accommodating corresponding torque receiving interfaces. The torque receiving interfaces may comprise geared wheels suitable for meshing with the corresponding gear wheel of the torque transferring interface. Figures 6a-c depicts hollow transmission elements according to embodiments of the present invention.

The drum and the second drum may be in a polymeric material with the torque receiving interface being in a metal material such as aluminum or steel. As depicted in said figures, the hollow transmission element may comprise splines

119 for interfacing with corresponding recesses in the in the torque transferring interface. The splines 119 may extend radially and inwardly from the annular wall of the hollow transmission element.

The advantage with the connecting member comprising multiple interfaces for receiving different hollow transmission elements is that the door operator system may be modified to different applications in a simple manner. This may be particularly advantageous in the field of sectional door systems.

Figures 6a-c depicts a set of hollow transmission elements in the form of drums. Depending on the intended movement of the door leaf, i.e. the design of the track of the door system, the drum may be adapted accordingly.

Referencing Figure 6a, the drum 110 may be essentially cylindrical. This is particularly advantageous for door systems in which the track solely comprises vertical sections, i.e. door systems in which the door leaf is only moved vertically between a vertical opened position and a vertical closed position. The cylindrical shape allows for an even torque transfer between motor and door leaf corresponding to the straight and even vertical movement of the door leaf.

Referencing Figure 6b, the drum 110 may be essentially conical. This is particularly advantageous for door systems in which the track comprises both horizontal and vertical sections and an interconnecting section, i.e. door systems in which the door leaf is moved between a horizontal or inclined opened position and a vertical closed position. The conical shape allows for adaptation of the torque during the movement of the door leaf. Initially in the opening movement of the door leaf a large torque is required which is provided by the larger diameter of the drum. The conical shape handles the force from the balancing spring of the door system. When the door is in the closed position, the spring is at its highest tension, the tension is then decreased as the door moves upwards towards the opened position. The conical shape thus allows for an even lifting force during movement of the door leaf such that the biggest diameter of the drum moves the door while the spring is having the most tension and the smallest diameter of the drum moves the door while the spring has the least tension.

Referencing Figure 6c, the drum may comprise a cylindrical section and a conical section. This is particularly advantageous for door systems in which the door leaf is intended to move between an inclined opened position and a vertical closed position.

According to an aspect an overhead door system is provided. The overhead door system comprises a door operator system according to any one of the above embodiments and a door leaf. The door operator system is arranged to move the door leaf between an opened and closed position.

In one embodiment, the motor at least partly extends directly above the door leaf

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It should be mentioned that the inventive concept is by no means limited to the embodiments described herein, and several modifications are feasible without departing from the scope of the appended claims. In the claims, the term “comprises/comprising” does not exclude the presence of other elements or steps. Additionally, although individual features may be included in different claims, these may possibly advantageously be combined, and the inclusion in different claims does not imply that a combination of features is not feasible and/or advantageous. In addition, singular references do not exclude a plurality. The terms “a”, “an”, “first”, “second” etc. do not preclude a plurality. Reference signs in the claims are provided merely as a clarifying example and shall not be construed as limiting the scope of the claims in any way.